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- sonotrodes (2)
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- cyclic load (1)
- dislocation arrangements (1)
- hydrogen embrittlement (1)
- hydrogen enhanced localized plasticity (HELP) (1)
- loss coefficient (1)
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As additive manufacturing offers only low surface quality, a subsequent machining of functional and highly loaded areas is required. Thus, a sound knowledge of the interrelation between the additive and subtractive manufacturing process as well as the resulting mechanical properties is indispensable. In this work, specimens were manufactured by using laser-based powder bed fusion (L-PBF) with substantially different sets of process parameters as well as subsequent grinding (G) or milling (M). Despite the substantially different surface topographies, the fatigue tests revealed only a slight influence of the subtractive manufacturing on the fatigue behavior, whereas the different laser-based powder bed fusion process parameters led to pronounced changes in fatigue strength. In contrast, a significant influence of subtractive finishing on the fatigue properties of the defect-free continuously cast (CC) reference specimens was observed. This can be explained by a dominating influence of process-induced defects in laser-based powder bed fusion material, which overruled the influence of surface machining. However, although both laser-based powder bed fusion parameter sets resulted in substantial defects, one set yielded similar fatigue strength compared to continuously cast specimens.
Metastable austenitic CrNi steels undergo phase transformation when loaded or deformed plastically. In the current work a macroscopic and phenomenological constitutive model is presented to model the strain induced transformation of austenite to martensite. The approach is based on the previous works of Olsen and Cohen [1] & Stringfellow et al. [2]. The kinetics of the phase transformation is modelled based on the assumption that the intersections of the shear bands in the austenitic phase, act as potential martensite nucleation locations. Evolution of the shear band density and their intersections are modelled using the plastic strain in the austenitic phase. The probability of the intersection creating martensite is given by a Gaussian cumulative distribution, which in turn depends on the temperature and stress triaxiality. The resulting stress- strain behavior considers the volume fraction, plastic strains and the strain hardening parameters of the individual phases as internal variables. An explicit formulation of the material model is implemented as a user subroutine in a bi-linear element formulation of FEM. Some of the required material parameters are estimated by fitting experimental stress-strain and martensite volume evolution curves. For the purpose of illustrating the model's behavior, boundary value problems of components with structured surfaces are presented.
Finishing processes result in changes of near-surface morphology, which strongly influences the fatigue behavior of components. Especially, roller bearings show a high dependency of the lifetime on surface roughness and the residual stress state in the subsurface volume. To analyze the influence of different finishing processes on the near-surface morphology, including the residual stress state, roller bearing rings made of AISI 52100 are finished in this work using hard turning, rough grinding, and fine grinding. In addition, fatigue specimens made of AISI 52100 and finished by cryogenic hard turning are investigated. For each condition, the residual stresses are determined at different distances from the surface, showing pronounced compressive stresses for all conditions. While the ground roller bearing rings show highest compressive residual stresses at the surface, the hard turned bearing ring and the cryogenic hard turned fatigue specimens reveal maximum compressive stresses in the subsurface volume. Moreover, cyclic indentation tests (CITs) are conducted in the different subsurface volumes, showing a higher cyclic plasticity in relation to the respective initial state, which is assumed to be caused by finishing-induced compressive residual stresses. Thus, the presented results indicate a high potential of CITs to efficiently characterize the residual stress state.
Defects change the phonon spectrum and also the magnetic properties of bcc-Fe. Using molecular dynamics simulation, the influence of defects – vacancies, dislocations, and grain boundaries – on the phonon spectra and magnetic properties of bcc-Fe is determined. It is found that the main influence of defects consists in a decrease of the amplitude of the longitudinal peak, PL, at around 37 meV. While the change in phonon spectra shows only little dependence on the defect type, the quantitative decrease of PL is proportional to the defect concentration. Local magnetic moments can be determined from the local atomic volumes. Again, the changes in the magnetic moments of a defective crystal are linear in the defect concentrations. In addition, the change of the phonon density of states and the magnetic moments under homogeneous uniaxial strain are investigated.
Nuclear inelastic scattering of synchrotron radiation is used to study the changes induced by external tensile strain on the
phonon density of states (pDOS) of polycrystalline Fe samples. The data are interpreted with the help of dedicated atomistic
simulations. The longitudinal phonon peak at around 37 meV and also the second transverse peak at 27 meV are decreased
under strain. This is caused by the production of defects under strain. Also the thermodynamic properties of the pDOS demonstrate
a weakening of the force constants and of the mean phonon energy under strain. Remaining differences between
experiment and simulation are discussed.
The fatigue life of metals manufactured via laser-based powder bed fusion (L-PBF) highly
depends on process-induced defects. In this context, not only the size and geometry of the defect, but
also the properties and the microstructure of the surrounding material volume must be considered.
In the presented work, the microstructural changes in the vicinity of a crack-initiating defect in a
fatigue specimen produced via L-PBF and made of AISI 316L were analyzed in detail. Xenon plasma
focused ion beam (Xe-FIB) technique, scanning electron microscopy (SEM), and electron backscatter
diffraction (EBSD) were used to investigate the phase distribution, local misorientations, and grain
structure, including the crystallographic orientations. These analyses revealed a fine grain structure
in the vicinity of the defect, which is arranged in accordance with the melt pool geometry. Besides
pronounced cyclic plastic deformation, a deformation-induced transformation of the initial austenitic
phase into α’-martensite was observed. The plastic deformation as well as the phase transformation
were more pronounced near the border between the defect and the surrounding material volume.
However, the extent of the plastic deformation and the deformation-induced phase transformation
varies locally in this border region. Although a beneficial effect of certain grain orientations on the
phase transformation and plastic deformability was observed, the microstructural changes found
cannot solely be explained by the respective crystallographic orientation. These changes are assumed
to further depend on the inhomogeneous distribution of the multiaxial stresses beneath the defect as
well as the grain morphology
Ultrasonic processes such as ultrasonic welding or ultrasonic fatigue testing use power
ultrasound to stimulate materials with amplitudes in the range of 1–100 µm. The ultrasonic welding
process is sensitive to any changes in the system or even the environment that may result in lower
joint quality. The welding tools, so called sonotrodes, have to be accurately designed to endure high
mechanical and thermal loads while inducing a sufficient amount of welding energy into the joining
zone by oscillation with the Eigenfrequency of the whole system. Such sonotrodes are often made of
thermally treated metals where the heat treatment is accompanied by microstructural changes. During
ultrasonic stimulation, the material may further change its properties and microstructure due to cyclic
loading. Both are expected to be recognized and identified by loss coefficients. Therefore, the loss
coefficient was determined by modal analysis of rods and fatigue specimen made of different materials
to correlate microstructural changes to attenuation. The determined loss coefficients indicated
microstructural changes in all materials investigated, confirming results from previous investigations
that showed an increasing attenuation due to cyclic loading for AISI 347. For the sonotrode materials
Z-M4 PM and Ferrotitanit WFN, the loss coefficients decreased due to thermal treatments. Technically
most relevant, changes in elastic modulus due to thermal treatments were quantitatively related to
frequency changes, which can significantly simplify future sonotrode development.
Two different material batches made of random and textured orientated polycrystalline nickel-base superalloy René80 were investigated under isothermal low cycle fatigue tests at 850 °C for a notched specimen geometry. In contrast to a smooth specimen geometry, no significant improvement in fatigue behaviour of the notched specimen could be observed for the textured material. Finite element simulations reveal an area along the notch where high stiffness evolves for the textured material, which lead to nearly similar shear stresses in the slip systems compared to a random orientation distribution and therefore to no distinct differences in the lifetime.
The locally occurring mechanisms of hydrogen embrittlement significantly influence
the fatigue behavior of a material, which was shown in previous research on two different AISI
300-series austenitic stainless steels with different austenite stabilities. In this preliminary work, an
enhanced fatigue crack growth as well as changes in crack initiation sites and morphology caused
by hydrogen were observed. To further analyze the results obtained in this previous research, in
the present work the local cyclic deformation behavior of the material volume was analyzed by
using cyclic indentation testing. Moreover, these results were correlated to the local dislocation
structures obtained with transmission electron microscopy (TEM) in the vicinity of fatigue cracks.
The cyclic indentation tests show a decreased cyclic hardening potential as well as an increased
dislocation mobility for the conditions precharged with hydrogen, which correlates to the TEM
analysis, revealing courser dislocation cells in the vicinity of the fatigue crack tip. Consequently,
the presented results indicate that the hydrogen enhanced localized plasticity (HELP) mechanism
leads to accelerated crack growth and change in crack morphology for the materials investigated. In
summary, the cyclic indentation tests show a high potential for an analysis of the effects of hydrogen
on the local cyclic deformation behavior.
Ultrasonic welding of titanium alloy Ti6Al4V to carbon fibre reinforced polymer (CFRP) at 20 kHz frequency requires suitable welding tools, so called sonotrodes. The basic function of ultrasonic welding sonotrodes is to oscillate with displacement amplitudes typically up to 50 µm at frequencies close to the eigenfrequency of the oscillation unit. Material properties, the geometry of the sonotrode, and the sonotrode tip topography together determine the longevity of the sonotrode. Durable sonotrodes for ultrasonic welding of high-strength joining partners, e.g., titanium alloys, have not been investigated so far. In this paper, finite element simulations were used to establish a suitable design assuring the oscillation of a longitudinal eigenmode at the operation frequency of the welding machine and to calculate local mechanical stresses. The primary aim of this work is to design a sonotrode that can be used to join high-strength materials such as Ti6Al4V by ultrasonic welding considering the longevity of the welding tools and high-strength joints. Material, sonotrode geometry, and sonotrode tip topography were designed and investigated experimentally to identify the most promising sonotrode design for continuous ultrasonic welding of Ti6AlV4 and CFRP. Eigenfrequency and modal shape were measured in order to examine the reliability of the calculations and to compare the performance of all investigated sonotrodes.