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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.
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).
In this work, time-independent and time-dependent plasticity models are presented that are well suited for the calculation of stresses and strains with the finite-element method to assess the low-cycle and thermomechanical fatigue life of engineering components. The focus are plasticity models that are available in finite-element programs nowadays as standard material models and describe isotropic and kinematic hardening, strain-rate dependency as well as static recovery of hardening. For the presented models, aspects relevant for the application of the models are addressed as the determination of the material properties and the numerical implementation. Nevertheless, the plasticity models are also embedded in the thermodynamic framework used for the derivation of thermodynamically consistent plasticity models. Only uniaxial formulations are used to achieve a good readability and preventing the use of tensors.
In this paper, the J-integral is derived for temperature-dependent elastic–plastic materials described by incremental plasticity. It is implemented using the equivalent domain integral method for assessment of three-dimensional cracks based on results of finite-element calculations. The J-integral considers contributions from inhomogeneous temperature fields and temperature-dependent elastic and plastic material properties as well as from gradients in the plastic strains and the hardening variables. Different energy densities are considered, the Helmholtz free energy and the stress-working density, providing a physical meaning of the J-integral as a fracture criteria for crack growth. Results obtained for a plate with two different crack configurations each loaded by a cool-down thermal shock show domain-independence of the incremental J-integral for different energy densities even for high temperature gradients and significant temperature-dependence of the yield stress and the hardening exponent in the presence of large scale yielding. Hence, the derived J-integral is an appropriate parameter for the assessment of cracks in thermomechanically loaded components.
Turbocharger housings in internal combustion engines are subjected to severe mechanical and thermal cyclic loads throughout their life-time or during engine testing. The combination of thermal transients and mechanical load cycling results in a complex evolution of damage, leading to thermo-mechanical fatigue (TMF) of the material. For the computational TMF life assessment of high temperature components, the DTMF model can provide reliable TMF life predictions. The model is based on a short fatigue crack growth law and uses local finite-element (FE) results to predict the number of cycles to failure for a technical crack. In engine applications, it is nowadays often acceptable to have short cracks as long as they do not propagate and cause loss of function of the component. Thus, it is necessary to predict not only potential crack locations and the corresponding number of cycles for a technical crack, but also to determine subsequent crack growth or even a possible crack arrest. In this work, a method is proposed that allows the simulation of TMF crack growth in high temperature components using FE simulations and non-linear fracture mechanics (NLFM).
A NLFM based crack growth simulation method is described. This method starts with the FE analysis of a component. In this paper, the method is demonstrated for an automotive turbocharger housing subjected to TMF loading. A transient elastic-viscoplastic FE analysis is used to simulate four heating and cooling cycles of an engine test. The stresses, inelastic strains, and temperature histories from the FEA are then used to perform TMF life predictions using the standard DTMF model. The crack position and the crack plane of critical hotspots are then identified. Simulated cracks are inserted at the hotspots. For the model demonstrated, cracks were inserted at two hotspot locations. The ΔJ integral is computed as a fracture mechanics parameter at each point along the crack-front, and the crack extension of each point is then evaluated, allowing the crack to grow iteratively. The paper concludes with a comparison of the crack growth curves for both hotspots with experimental results.
In order to make material design processes more efficient in the future, the underlying multidimensional process parameter spaces must be systematically explored using digitalisation techniques such as machine learning (ML) and digital simulation. In this paper we shortly review essential concepts for the digitalisation of electrodeposition processes with a special focus on chromium plating from trivalent electrolytes.
In this paper, the temperature dependent cyclic mechanical properties of the martensitic hot work tool steel 1.2367 after tempering are investigated. To this end, hardness measurements as well as monotonic and cyclic tests at temperatures in the range from room temperature to 650 °C are performed on material tempered for different tempering times and temperatures. To describe the observed time and temperature dependent softening during tempering a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is developed. Furthermore, mechanism-based as well as phenomenological relations for the cyclic mechanical properties of the Ramberg-Osgood model depending on carbide size and temperature are introduced. A good overall agreement of the measured and the calculated stress-strain hysteresis loops for different temperatures and heat treatments is obtained using the determined material properties of the kinetic and mechanical model.