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In this paper, the multiaxial formulation of a mechanism-based model for fatigue life prediction is presented whichcan be applied to low-cycle fatigue (LCF) and thermomechanical fatigue (TMF) problems in which high-cycle fa-tigue loadings are superimposed. The model assumes that crack growth is the lifetime limiting mechanism and thatthe crack advance in a loading cycleda/dNcorrelates with the cyclic crack-tip opening displacement ΔCTOD.The multiaxial formulation makes use of fracture mechanics solutions and thus, does not need additional modelparameters quantifying the effect of the multiaxiality. Furthermore, the model includes contributions of HCF on ΔCTODand assesses the effect of the direction of the HCF loadings with respect to LCF or TMF loadings inthe life prediction. The model is implemented into the finite-element program ABAQUS. It is applied to predictthe fatigue life of a thermomechanically loaded notched specimen that should represent the situation between theinlet and outlet bore holes of cylinder heads. A good correlation of the predicted and the measured fatigue lives isobtained.
This paper focuses on the microstructure-dependent inelastic behavior of lamellar gray cast iron. It comprises the reconstruction of three dimensional volume elements by use of the serial sectioning method for the materials GJL-150, GJL-250 and GJL-350. The obtained volume elements are prepared for the numerical analyses by means of finite-element method. In the finite-element analysis, the metallic matrix is modeled with an elastic–plastic deformation law. The graphite inclusions are modeled nonlinear elastic with a decreasing value of Young’s modulus for increasing tensile loading. Thus, the typical tension–compression asymmetry of this material class can be described. The stress–strain curves obtained with the microstructure-based finite-element models agree well with experimental curves of tension and compression tests. Besides the analysis of the whole volume element, the scatter of the stress–strain response in smaller statistical volume elements is investigated. Furthermore, numerical studies are performed to reduce computational costs.
In this paper the yield surface of a recently presented microstructure-based volume element of the gray cast iron material GJL-250 is assessed after different plastic loading histories. The evolution of the yield surface is investigated for different volumetric, deviatoric and uniaxial loadings. The micromechanical material properties of the metallic matrix and the graphite inclusions are validated by means experimental stress-strain hysteresis loops. The metallic matrix is modeled as elastic-plastic with a non-linear kinematic hardening law. The graphite inclusions are described by means of a volumetric strain state dependent Young’s modulus. The results show that the shape of the yield surface does not change significantly in comparison to the initial yield surface after pure deviatoric loadings. After volumetric loadings, the dependence of the material on the Lode angle is significantly reduced. Uniaxial tensile preloadings result in a deformed yield surface, whereby the magnitude of the deformation depends on the applied load. Uniaxial preloadings to compression do not change the shape of the initial yield surface.
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.
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.
The following contribution deals with the growth of cracks in low-cycle fatigue (LCF) and thermomechanical fatigue (TMF) tested specimens of Inconel 718 measured by using the replica method. The specimens are loaded with different strain rates. The material shows a significantly higher crack growth rate if the strain rate is decreased. Electron backscatter diffraction (EBSD) is adopted to identify the failure mechanism and the misorientation relationship of failed grain boundaries in secondary cracks. The analyzed cracks propagated mainly transgranular but also intergranular failure can be observed in some areas. It is found that grain boundaries with coincidence site lattice (CSL) boundary structure are generally less susceptible for intergranular failure than grain boundaries with random misorientation. For modeling the experimentally identified crack behavior an existing model for fatigue crack growth based on the mechanism of time dependent elastic–plastic crack tip blunting is enhanced to describe environmental effects based on the mechanism of oxygen diffusion at the crack tip. For the diffusion process the temperature dependent parabolic diffusion law is assumed. As a result, the time dependent cyclic crack tip opening displacement (DCTOD) is used as representative value to describe both mechanisms. Thus, most
of the included model parameters characterize the deformation behavior of the material and can be determined by independent material tests. With the determined material properties, the proposed model describes the experimentally measured crack growth curves very well. The model is validated based on predictions of the number of cycles to failure of LCF as well as in-phase and out-of-phase TMF tests in the temperature range between room temperature and 650 °C.
Cast iron materials are used as materials for cylinder heads for heavy duty internal combustion engines. These components must withstand severe cyclic mechanical and thermal loads throughout their service life. While high-cycle fatigue (HCF) is dominant for the material in the water jacket region, the combination of thermal transients with mechanical load cycles results in thermomechanical fatigue (TMF) of the material in the fire deck region, even including superimposed TMF and HCF loads. Increasing the efficiency of the engines directly leads to increasing combustion pressure and temperature and, thus, lower safety margins for the currently used cast iron materials or alternatively the need for superior cast iron materials. In this paper (Part I), the TMF properties of the lamellar graphite cast iron GJL250 and the vermicular graphite cast iron GJV450 are characterized in uniaxial tests and a mechanism-based model for TMF life prediction is developed for both materials. The model can be used to estimate the fatigue life of components by means of finite-element calculations (Part II of the paper) and supports engineers in finding the appropriate material and design. Furthermore, the effect of the elastic, plastic and creep properties of the materials on the fatigue life can be evaluated with the model. However, for a material selection also the thermophysical properties, controlling to a high level the thermal stresses in the component, must be considered. Hence, the need for integral concepts for material characterization and selection from a multitude of existing and soon-to-be developed cast iron materials is discussed.
A complete thermomechanical fatigue (TMF) life prediction methodology is developed for predicting the TMF life of cast iron cylinder heads for efficient heavy duty internal combustion engines. The methodology uses transient temperature fields as thermal loads for the non-linear structural finite-element analysis (FEA). To obtain reliable stress and strain histories in the FEA for cast iron materials, a time and temperature dependent plasticity model which accounts for viscous effects, non-linear kinematic hardening and tensioncompression asymmetry is required. For this purpose a unified elasto-viscoplastic Chaboche model coupled with damage is developed and implemented as a user material model (USERMAT) in the general purpose FEA program ANSYS. In addition, the mechanismbased DTMF model for TMF life prediction developed in Part I of the paper is extended to three-dimensional stress states under transient non-proportional loading conditions. The material properties of the plasticity model are determined for lamellar graphite cast iron GJL250 and vermicular graphite cast iron GJV450 from isothermal and non-isothermal uniaxial tests. The methodology is applied to obtain a TMF life prediction on two cast iron cylinder heads for heavy duty diesel engine applications made from both cast iron materials. It is shown that the life predictions using the developed methodology correlate very well with observed lives from two bench tests in terms of location as well as number of cycles to failure.