Ingenieurwissenschaften und zugeordnete Tätigkeiten
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- Additive Manufacturing (97)
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- 6 Materialchemie (496)
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- 9.4 Integrität von Schweißverbindungen (152)
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The advent of the Industrial Revolution was accompanied by several accidents of dramatic dimensions. The analysis of these events was the fundament for the continuous improvement in the reliability of technical systems. In the year 1871 the Prussian state created a technical institution dedicated for this task – the origin of BAM. Failure analysis and prevention is until today a central objective of our institute; due to its complex nature an interdisciplinary task. In our talk we will present an overview of the activities of BAM in the area of failure analysis; especial attention will be given to the corrosion aspects in the analysis of these cases.
Experimental and analytical investigation of the TMF-HCF lifetime behavior of two cast iron alloys
(2016)
The superposition of small amplitude, high frequent loading cycles (HCF) to the slow, large amplitude, TMF loading cycles can significantly reduce the TMF life, i.e. the number of TMF blocks until failure. In this work, the combined TMF-HCF loading has been experimentally investigated for two cast iron alloys. Both alloys contain globular graphite nodules but the first one has a ferritic while the second one has an austenitic crystal structure. In particular, the influence of the HCF frequency, of the HCF loading amplitude and of the location of the superposed HCF cycles has been investigated. It was observed that the HCF frequency has a limited impact on the TMF fatigue life. In other words, the number of superposed HCF-cycles has only a slight influence on the TMF fatigue life, which contradicts the linear damage accumulation rule concept. On the other side, the HCF-strain amplitude has a highly non-linear influence on the TMF fatigue life.
The experimental results can be understood in terms of a fracture mechanics based damage mechanism [1]: Cracks readily initiate due to the TMF loading and the duration of the growth of the cracks up to a few mm controls the fatigue life. If HCF-loading cycles are superposed, cyclic crack propagation dramatically accelerates at some stage. This stage is related to the existence of a threshold for crack growth under pure HCF-conditions and largely controls the fatigue life of the combined loading.
The previous ideas have been expressed in a model that can be very simply applied to provide the fatigue life reduction factor due to the superposed HCF cycles. It only contains two additional adjustable parameters and can be combined with any TMF model.
Amongst various other NDT methods, within the EMRP-project ‘VITCEA’ active thermography is validated for testing of CFRP and GFRP structures constructed for energy application. In this contribution, the optical and thermal properties of CFRP and GFRP reference defect artefact (RDA) and natural defects artefact (NDA) test specimens are characterized. Different excitation techniques and techniques for data analysis are compared for optimizing the number of detected defects.
The increased use of fibre-reinforced plastic (FRP) composites for improved efficiency and reliability in energy related applications e.g. wind and marine turbine blades, nacelles, oil and gas flexible risers, also increases the demand for innovative non-destructive testing technologies. Thus, in order to achieve increased acceptance of suited and optimized non-destructive testing (NDT) methods in industry, the European Metrology Research Programme (EMRP) project ENG57 Validated Inspection Techniques for Composites in Energy Applications (VITCEA) deals with the development and validation of innovative NDT technologies. In this contribution, results concerning thermographic investigations at test specimens during tensile loading and active thermography testing after tensile loading are presented. Additionally, the determination of the optical properties (relative transmittance and directional spectral emissivity) of CFRP and GFRP test specimens is described.
We report on the development of ultra-small core-shell silver nanoparticles synthesized by an up-scaled modification of the polyol process. It is foreseen to use these thoroughly characterized particles as reference material to compare the catalytic and biological properties of functionalized silver nanoparticles. Small-angle X-ray scattering (SAXS) analysis reveal a narrow size distribution of the silver cores with a mean radius of RC = 3.0 nm and a distribution width of 0.6 nm. Dynamic light scattering (DLS) provides a hydrodynamic radius of RH = 10.0 nm and a PDI of 0.09. The particles’ surface is covered with poly(acrylic acid) (PAA) forming a shell with a thickness of 7.0 nm, which provides colloidal stability lasting for more than six months at ambient conditions. The PAA can be easily exchanged by biomolecules to modify the surface functionality. Replacements of PAA with glutathione (GSH) and bovine serum albumin (BSA) have been performed as examples. We demonstrate that the particles effectively catalyze the reduction of 4-nitrophenol to 4-aminophenol with sodium borohydride. The tunable catalytic activity of (436 ± 24) L g-1 s-1 is the highest reported in literature for silver nanoparticles.
Multilayer Graphene (MLG), a nanoparticle with a specific surface of BET = 250 m2/g and thus made of only approximately 10 graphene sheets, is proposed as a nanofiller for rubbers. When homogenously dispersed, it works at low loadings enabling the replacement of carbon black (CB), increase in efficiency, or reduction in filler concentration. Actually the appropriate preparation yielded nanocomposites in which just 3 phr are sufficient to significantly improve the rheological, curing and mechanical properties of different rubbers, as shown for Chlorine-Isobutylene-Isoprene Rubber (CIIR), Nitrile-Butadiene Rubber (NBR), Natural Rubber (NR), and Styrene-Butadiene Rubber (SBR). A mere 3 phr of MLG tripled the Young’s modulus of CIIR, an effect equivalent to 20 phr of carbon black. Similar equivalents are observed for MLG/CB mixtures. MLG reduces gas permeability, increases thermal and electrical conductivities, and retards fire behavior. The later shown by the reduction in heat release rate in the cone calorimeter. The higher the nanofiller concentration is (3 phr, 5 phr, and 10 phr was investigated), the greater the improvement in the properties of the nanocomposites. Moreover, the MLG nanocomposites improve stability of mechanical properties against weathering. An increase in UV-absorption as well as a pronounced radical scavenging are proposed and were proved experimentally. To sum up, MLG is interesting as a multifunctional nanofiller and seems to be quite ready for rubber development.
Investigations on the tensile testing procedure conducted within the European project TENSTAND
(2015)
The current presentation shows the intention of the former European TENSTAND project on computer controlled tensile testing of metals. The history of the tensile testing standards is explained. Some test results of the TENSTAND project are shown. The presentation is focused on criticism of Chinese delegates in ISO TC 164 SC1 WG4 who stated that the TENSTAND project which was finished about 10 years ago came to wrong conclusions and were misleading. This presentation points out misunderstandings of the Chinese delegation in the test program and the results of the TENSTAND project and the former development of the tensile testing standard ISO 6892-1. Some tests of the TENSTAND project were newly evaluated using the original test data. The evaluation showed again that the conclusions of the TENSTAND project are correct.
As subcritical crack growth (SCCG) can reduce tensile strength of glasses by many orders of magni-tude, the potential for improvement of fatigue behaviour is most intriguing in developing ultra-strong glasses. An essential bottleneck is the basic understanding of the numerous interplaying pressure-, temperature- and water-affected relaxation phenomena at the crack tip and related toughening strat-egies. Therefore, the present project aims to advance the basic understanding of structural relaxa-tion effects and local properties caused by increased water concentration and tensile stresses at the crack tip as they are a key for structural toughening designs to develop SCCG-free glasses and glass surfaces.
Our first studies give clear evidence that glass structure and dynamics is strongly modified upon hy-dration of glasses. These changes are highly related to the nature of network formers but are affect-ed as well by the counter ions (network modifier). Results of the 1st project part suggest that struc-tural relaxation below glass transition temperature, i.e. overlapping of short-range (beta) and long-range (alpha) interactions can contribute to SCCG in water-free environments and that structurally dissolved water in the glasses can have decisive impact on this effect.
In the 2nd project stage specific glasses compositions will be investigated to gain an improved un-derstanding on the relation of sub-Tg relaxation and inert SCCG as well as to shed light to the relat-ed effects of dissolved water and its speciation. These glasses cover a broader range of different glass topologies and binding partners, whereby the coupling of alpha and beta relaxations is varied systematically by alkali-, alkaline earth ions and water species concentrations. Preparation of hy-drous glasses (up to 8 wt% water) will be performed by high pressure syntheses. Structure will be resolved by NMR, Raman and IR spectroscopy while structural relaxation is accessed in the temper-ature and frequency domain using dynamic mechanical spectroscopy and ultrasonic damping. We will focus on measurements of inert SCCG (region III) conducting experiments in vacuum and dry gas atmospheres using indentation techniques and stressing of glass specimens in DCB geometry.
Experimental data on SCCG will be provided to SPP groups, which deals with fatigue in metallic glasses and vice versa we will test theoretical predictions of ab-initio simulations of partner within SPP 1594 in order to quantify the effect of water on the crack tip. In summa topological factors con-trolling the subcritical crack growth with respect to water will be identified from which structural toughening designs for highly fatigue resistant-glasses can be derived.
Laser-GMA-hybrid welding of longitudinally welded large-diameter pipes of grades API- X80/ X120
(2015)
Potentials of the hybrid laser arc welding processes were investigated regarding reliable production of longitudinal welds of high strength pipe steels X80 and X120
Hybrid laser arc welding of the root pass:
Significant reduction in the weld cross section – savings of filler material
Lower heat input into the base material - improvement of mechanical properties of the weld joint
The arc type does not have any influence on the character of dilution in the laser part of the hybrid weld
14 mm deep root face was considered as optimum. No penetration of the filler material could be detected beyond this depth limit
Metal powder filler wires, micro alloyed with Ni and partly with Cr and Mo, guaranteed sufficient Charpy impact toughness at low temperature for the both investigated materials:
Hybrid laser arc welding is a very efficient process for the root pass in multi-pass welding and opens a large technical and economic potential for the manufacture of large pipes
Experimental study and numerical simulation of hot crack formation for novel laser weldability test
(2015)
Hot cracking susceptibility in laser beam welding was assessed for several stainless steels by means of the CTW test
The strain rate has a significant influence on the formation of the hot crack
It was possible to determine the critical strain and strain rate that led to shot crack formation
A material ranking of hot cracking resistance could be made.A three-dimensional FEM using the contact element technique to simulate hot cracking during LBW under external load conditions was developed.
Good agreement between the strain field measured using the DIC technique and the simulation results
Susceptibility to hot cracking can be predicted by using FEM with the correct mechanical and thermo-physical material properties
Test procedure to characterize the cracking susceptibility of RSW-steels has been developed
During externally loaded test procedure all investigated steels (HDT780CD+Z100, HDT780C+ZE75/75, HX340LAD+Z100, HCT690TD+Z100) showed a cracking behavior
With increased specimen load, the crack length grows for the micro-alloyed-steel and TRIP-steel
Complex phase steels behavior during test procedure:
Crack length growth with increasing force could not be determined
The cracking susceptibility of electro-galvanized steels is less than hot-dip galvanized steels (in this case)
30
The damage process of short glass fibre (30% weight) reinforced polyamide caused by mechanical loading was investigated from the beginning on micro cracking level to the incipient crack of mm-dimension. Based on high resolution computer tomography and the X-ray-refraction technique the inner surface due to micro-cracking at the short fibre ends and the fibre matrix debonding of the skin surface of the filament was determined quantitatively. With the knowledge of the fatigue crack propagation rate and fracture toughness of the material from former research projects, it was derived that the total inner surface due to micro cracks measured by X-ray refraction is much higher than the specimen could have withstand the load, supposed the surface is in a localized crack. Hence, the damage process could be described from micro to macro level. Accompanying fractographic investigations endorse the modelling based on the NDT-techniques.
The combination of tomographic, microstructural data with other experimental techniques and with modeling is paramount, if we want to extract the maximum amount of information on material and component properties. In particular, quantitative image analysis, statistical approaches, direct discretization of tomographic reconstructions represent concrete possibilities to extend the power of the tomographic 3D representation to insights into the material and component performance. This logic thread holds equally for industrial and academic research, and valorizes expensive experiments such as those carried out at synchrotron sources, which cannot be daily repeated.
I will show a few examples of possible use of X-ray tomographic data for quantitative assessment of damage evolution and microstructural properties, as well as for non-destructive testing. Examples of micro-structured inhomogeneous materials will be given, such as Composites, Ceramics, Concrete, and Additively manufactured parts. I will also show how X-ray refraction computed tomography (CT) can be highly complementary to classic absorption CT, being sensitive to internal interfaces.
Computational Advances
(2014)
The influence of two different weld imperfections (gap/crack) on the fatigue behaviour of spot welded joints was tested
Surface cracks havenoinfluenceon thefatiguelife
Samples with cracks in the electrode indentation /HAZ where tested
Stiffness curves are not significantly influenced by surface cracks
3D FE-Simulation demonstrate no changes of stress due to surface imperfections
Drop-out of molten material was avoided by EM pressure
Compensation of the hydrostatic pressure of up to 20 mm thick
aluminum and stainless steel (experiment and FEM)
Mitigation of the weld bead dynamics
Significant changes in the velocity distributions in the weld pool
Weld pool geometry shape changes due to Hartmann effect
Significant porosity reduction
Surface quality improvements
Drop-out of molten material was avoided by EM pressure
Compensation of the hydrostatic pressure of up to 20 mm thick
aluminum and stainless steel (experiment and FEM)
Mitigation of the weld bead dynamics
Significant changes in the velocity distributions in the weld pool
Weld pool geometry shape changes due to Hartmann effect
Significant porosity reduction
Surface quality improvements
Epoxy/Carbon nanotube (CNT) composites are interesting materials that could be used in a wide variety of applications. In this study, CNT contents of 0.25, 0.5, 1 and 2 wt% were used for reinforcing epoxy. A nanoindentation device and a temperature regulating system were developed in order to investigate the effect of CNTs on the time-dependent properties of epoxy using relaxations and creep tests on the nano scale. The relaxation tests showed a significant shift for the relaxation spectrum towards shorter times with introducing a low CNT content of 0.25 wt%. Additionally, creep tests showed that both the holding time at a constant load and the unloading velocity have a major effect on the contact stiffness. However, there was no effect for the CNTs on the creep behavior with contents lower than 1 wt%, which was related to the presence of a percolation threshold around this value.
The load partition in Mg-Y-Zn system is studied by means of synchrotron diffraction. in-situ tensile tests disclose LPSO phases were for the first time proved to behave as an efficient reinforcement in Mg-Y-Zn alloys, therefore they could be treated as “short-fibre composite” for the modeling of mechanical behaviour.
The radiation-induced degradation of PMMA is known to be inhibited by low-molecular-weight substances, mainly of aromatic structure. In the case of linear and angular condensated aromatic compounds a protection of 80 % was attained. The efficiency is proportional to the concentration up to beginning saturation. Its dependence from resonance energy and from the first excited singulet state allows the conclusion that the additives act by means of excitation transfer and radical scavenging. The yield of chain-scissions is noticed to be constant up to high doses. This suggests that the additives are not destroyed by reason of the considerable radiation resistance of aromatic compounds. The fact that the mixtures are more intensively coloured than the pure polymer in spite of lower degradation is in contradiction to this assumption. This colouration, not noticed at the pure additives at corresponding doses, is a sign of a significant decomposition of the additives combined with the protection of the polymer against degradation. The object of our investigation was to study this connection in detail with special regard to energy transfer.