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Für die Werkstoffe EN GJS700, EN GJV450 und EN GJL250 werden die Lebensdauern unter kombinierter thermomechanischer und hochfrequenter Belastung vorhergesagt. Hierzu wird ein mechanismenbasiertes Lebensdauermodell verwendet, das auf dem Wachstum von Mikrorissen beruht. Das Modell berücksichtigt das Wachstum von Rissen durch nieder- und überlagerte hochfrequente Belastungszyklen. Anhand von einachsigen Ermüdungsversuchen wurden die Parameter des Lebensdauermodells angepasst, sodass eine bestmögliche Lebensdauervorhersage erzielt wird. Dabei stimmen die vorhergesagten Lebensdauern gut mit den experimentell ermittelten Zyklenzahlen zum Versagen überein.
Bauteile in Dampfturbinen, stationäre Gasturbinen und Fluggasturbinen sind hohen Beanspruchungen ausgesetzt. Wenn die Turbinen gestartet werden, erwärmen sich die Bauteile im „heißen Bereich“ der Turbine auf über 1000 °C. Damit die Bauteile bei diesen Temperaturen nicht einfach dahinschmelzen, werden spezielle hochtemperaturfeste Legierungen verwendet, wie beispielsweise Nickelbasis-Superlegierungen. Die hohen Temperaturschwankungen die beim Starten und beim Abschalten der Turbine auftreten, machen aber auch diese Werkstoffe auf Dauer nicht mit. Beim Aufheizen dehnt sich das Material aus, beim Abkühlen zieht es sich wieder zusammen. Dieses Hin- und Her-Verformen führt dazu, dass der eingesetzte Werkstoff unter „Stress“ kommt und Spannungen im Werkstoff auftreten. Diese Spannungen können dazu führen, dass sich Risse im Material bilden, die unter der zyklischen Belastung (wiederholtes Starten und Abschalten) wachsen, bis das Bauteil kaputt ist. Der Fachmann spricht dabei von der thermo-mechanischen Ermüdung (Thermomechanical Fatigue, TMF) des Werkstoffs.
HiSiMo cast irons are frequently used as material for high temperature components in engines as e.g. exhaust manifolds and turbo chargers. These components must withstand severe cyclic mechanical and thermal loads throughout their service life. The combination of thermal transients with mechanical load cycles results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material and, after a certain number of loading cycles, to failure of the component. In this paper (Part I), the low-cycle fatigue (LCF) and TMF properties of HiSiMo are investigated in uniaxial tests and the damage mechanisms are addressed. On the basis of the experimental results a fatigue life model is developed which is based on elastic, plastic and creep fracture mechanics results of short cracks, so that time and temperature dependent effects on damage are taken into account. The model can be used to estimate the fatigue life of components by means of finite-element calculations (Part II of the paper).
HiSiMo cast irons are frequently used as material for high temperature components in engines as e.g. exhaust manifolds and turbo chargers. These components must withstand severe cyclic mechanical and thermal loads throughout their life cycle. The combination of thermal transients with mechanical load cycles results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material and, after a certain number of loading cycles, to failure of the component. In Part I of the paper, a fracture mechanics model for TMF life prediction was developed based on results of uniaxial tests. In this paper (Part II), the model is formulated for three-dimensional stress states, so that it can be applied in a post-processing step of a finite-element analysis. To obtain reliable stresses and (time dependent plastic) strains in the finite-element calculation, a time and temperature dependent plasticity model is applied which takes non-linear kinematic hardening into account. The material properties of the model are identified from the results of the uniaxial test. The plasticity model and the TMF life model are applied to assess the lifetime of an exhaust manifold.
In this paper the fatigue life of three cast iron materials, namely EN-GJS-700, EN-GJV-450 and EN-GJL-250, is predicted for combined thermomechanical fatigue and high cycle fatigue loading. To this end, a mechanism-based model is used, which is based on microcrack growth. The model considers crack growth due to low frequency loading (thermomechanical and low cycle fatigue) and due to high cycle fatigue. To determine the model parameters for the cast iron materials, fatigue tests are performed under combined loading and crack growth is measured at room temperature using the replica technique. Superimposed high cycle fatigue leads to an accelerated crack growth as soon as a critical crack length and thus the threshold stress intensity factor is exceeded. The model takes this effect into account and predicts the fatigue lives of all cast iron materials investigated under combined loadings very well.
In this paper, an unconditionally stable algorithm for the numerical integration and finite-element implementation of a class of pressure dependent plasticity models with nonlinear isotropic and kinematic hardening is presented. Existing algorithms are improved in the sense that the number of equations to be solved iteratively is significantly reduced. This is achieved by exploitation of the structure of Armstrong-Frederik-type kinematic hardening laws. The consistent material tangent is derived analytically and compared to the numerically computed tangent in order to validate the implementation. The performance of the new algorithm is compared to an existing one that does not consider the possibility of reducing the number of unknowns to be iterated. The algorithm is used to implement a time and temperature dependent cast iron plasticity model, which is based on the pressure dependent Gurson model, in the finite-element program ABAQUS. The implementation is applied to compute stresses and strains in a large-scale finite-element model of a three cylinder engine block. This computation proofs the applicability of the algorithm in industrial practice that is of interest in applied sciences.
In this paper, the initial multiaxial yield behavior of three different gray cast iron materials with lamellar shaped graphite inclusions is numerically investigated by means of the finite-element method. Therefore, volume elements including the real microstructure of the materials are loaded bi- and triaxially beyond macroscopic yield. The shape of the obtained yield surfaces are compared to the surfaces of four continuum models which, amongst others, are proposed in literature to describe the inelastic behavior of gray cast iron with lamellar shaped graphite inclusions. It is found that the presented continuum models and the macroscopic yield surfaces obtained with microstructure-based finite-element models deviate. Furthermore, the initial inelastic flow direction is computed at the onset of macroscopic yielding. The analysis show that the inelastic flow is normal to the yield surface.
A new yield function for lamellar gray cast iron materials is proposed. The new model is able to describe the results of recently performed microstructure-based finite-element computations that resolve the three dimensional yield surface of three different gray cast irons. The yield function requires only the yield stress in tension and compression of the respective material as model parameters. Furthermore, the algorithmic formulation of the new model is assessed for numerical robustness and efficiency.