This study aims to develop mathematical models to improve multi-performance metrics, such as relative density and operating costs, in laser powder bed fusion (LPBF), also known as selective laser melting, a metallic additive manufacturing technique, by optimizing the printing process parameters. The work develops a data-driven model for relative density based on measurements and an analytical model for operating costs related to the process parameters. Optimization models are formulated to maximize relative density or minimize operating costs by determining the optimal set of process parameters, while meeting a target level of the other performance metrics (i.e., relative density or operating costs). Furthermore, new metrics are devised to test the sensitivity of the optimization solutions, which are used in a novel robust optimization model to acquire less sensitive process parameters. The sensitivity analysis examines the effect of varying some parameters on the relative density of the fabricated specimens. Samples with a relative density greater than 99% and a machine operating cost of USD 1.00 per sample can be produced, utilizing a combination of low laser power (100 W), high scan speed (444 mm/s), moderate layer thickness (0.11 mm), and large hatch distance (0.4 mm). This is the first work to investigate the relationship between the quality of the fabricated samples and operating cost in the LPBF process. The formulated robust optimization model achieved less sensitive parameter values that may be more suitable for real operations. The equations used in the models are verified via 10-fold cross-validation, and the predicted results are further verified by comparing them with the experimental data in the literature. The multi-performance optimization models and framework presented in this study can pave the way for other additive manufacturing techniques and material grades for successful industrial-level implementation.
Stainless steel 316L has been an extensively investigated metallic material for laser powder bed fusion (L-PBF) in the past few decades due to its high corrosion resistance. However, there are challenges related to producing LPBF parts with minimal defects, attaining mechanical properties comparable with traditional process and dependency on time consuming post process treatments. The selection of L-PBF process parameters is crucial to overcome these challenges. This paper reviews the research carried out on L-PBF process parameter optimization for fabrication of 316L steel components for maximizing part densifications and attaining desired microstructure morphologies in parts. A brief work on numerical simulation approach for process parameter optimization for high densifications is also included in this paper.
Metamaterials are architected cellular materials, also known as lattice materials, that are inspired by nature or human engineering intuition, and provide multifunctional attributes that cannot be achieved by conventional polymeric materials and composites. There has been an increasing interest in the design, fabrication, and testing of polymeric metamaterials due to the recent advances in digital design methods, additive manufacturing techniques, and machine learning algorithms. To this end, the present review assembles a collection of recent research on the design, fabrication and testing of polymeric metamaterials, and it can act as a reference for future engineering applications as it categorizes the mechanical properties of existing polymeric metamaterials from literature. The research within this study reveals there is a need to develop more expedient and straightforward methods for designing metamaterials, similar to the implicitly created TPMS lattices. Additionally, more research on polymeric metamaterials under more complex loading scenarios is required to better understand their behavior. Using the right machine learning algorithms in the additive manufacturing process of metamaterials can alleviate many of the current difficulties, enabling more precise and effective production with product quality.
High density polyethylene (HDPE) can show viscoelastic-viscoplastic behaviors under monotonic loads and a stress softening after reloading under cyclic ones. This sets a challenge in simultaneously representing such response in material constitutive models. In addition, due to the adoption of novel accelerated tests at higher temperatures, e.g., 95 degrees C, the need for a higher temperature calibration is motivated. Therefore, the objective of this study is threefold: (i) to investigate the capability of the three network viscoplastic (TNV) model in capturing HDPE thermo-viscoplasticity under monotonic and cyclic loads, (ii) to report observations on HDPE at various strain-rates and temperatures from 23 degrees C to 95 degrees C including the alpha-relaxation region (iii) to explore the ratcheting behavior of HDPE, i.e., cyclic creep. The FEA analysis based on the calibrated TNV model was successfully able to predict the HDPE behavior under static, quasi-static and dynamic loads. The predicted strain range Delta epsilon and midrange strain epsilon s of the cyclic creep showed good agreements. This implies that the TNV model can be a reliable candidate for HDPE engineering assessments. Findings of this work will have many industrial applications, e.g., products manufacturers or resin producers, in which HDPE is used under complex loads. Similar procedures can be followed for other thermoplastics which lays the basis for establishing a standard calibration guideline.
Architected cellular structures are increasingly receiving attention in numerous applications due to advances in additive manufacturing and their promising multi-functional properties. Herein, 30 architected strut-based lattices of cubic crystal symmetry are developed and their stiffness and strength are investigated computationally and experimentally. Finite element simulations are conducted to compute the effective stiffness, yield strength, and buckling strength under uniaxial, shear, and hydrostatic loadings. Also, elastic anisotropy is assessed and bifurcation analysis is performed to estimate the threshold relative density for each lattice. Selected lattices of various relative densities are 3D printed from a polymeric material using selective laser sintering (SLS). The numerical results show that the modes of deformation whether stretching-dominated, bending-dominated, or mixed differ for the various loading conditions. It is observed that by combining different lattice structures in a hybrid approach, a decrease in the anisotropic behavior is obtained, and an overall enhancement of the mechanical properties is achieved. The numerical results show rather good agreement with the experimental findings. The current study can be crucial for using the investigated lattices for enhancing the multi-functional properties of structural systems.
Triply periodic minimal surfaces (TPMS), which are a class of architected cellular materials, have attracted significant attention lately, due to their prevailing mechanical, electrical and chemical properties, to name a few, and due to the advancements in additive manufacturing technologies that make it possible to print such mate-rials. However, simulating the elastic-plastic mechanical behavior of structural systems (e.g., beams, plates, cores of sandwich panels, structural systems with various levels of geometric complexity) that are latticed with thousands of TPMS lattices are computationally expensive to model explicitly, and hence the need to develop accurate yield surfaces in order to capture their plastic behavior in a homogenized approach. In this work, a generalized initial yield criterion is proposed for sheet-based TPMS lattices, which incorporates the Lode parameter L. The initial yielding of five different sheet-based TPMS lattices are investigated in five different loading conditions. These lattices are Schoen's I-WP (IWP-s), Gyroid (GYR-s), Diamond (DIA-s), F-RD (FRD-s) and Primitive (PRIM-s). The proposed yield criterion accurately predicts the initial yielding of all these lattices in all the loading conditions considered, outperforming other yield criteria currently proposed in literature.
Owing to the advancements in additive manufacturing and increased applications of additively manufactured structures, it is essential to fully understand both the elastic and plastic behavior of cellular materials, which include the mathematically-driven sheet lattices based on triply periodic minimal surface (TPMS) that have received significant attention recently. The compressive elastic and plastic behaviors have been well established for many TPMS latticed structures, but not under multiaxial loading. Furthermore, TPMS lattices are compu-tationally expensive to model explicitly when used in latticing various structures for enhanced multi -functionality, and hence the need to develop accurate yield surfaces in order to capture their plastic behavior in a homogenized approach. The majority of previous yield surfaces developed for cellular materials originate from cellular foams, and limited attempts has been made to develop yield surfaces for TPMS lattices. In this study, a numerical modeling framework is proposed for developing the initial yield surface for cellular materials and is used to develop the initial yield surface for Schoen's IWP sheet-based TPMS cellular lattices. The effect of different loading conditions on the effective yield strength of the IWP sheet-based (IWP-s) TPMS lattice is numerically investigated, based on a single unit cell of IWP-s under fully periodic boundary conditions, assuming an elastic-perfectly plastic behavior of the base material, for relative densities (rho) ranging from 7% to 28%. In order to account for different loading conditions, the stress state is characterized in a generalized fashion through the Lode parameter (L). The effect of L is studied over a range of mean stress values (sigma m) to understand the effect of both L and sigma m on the effective yield strength. An initial yield surface is developed incorporating the effect of L, sigma m and rho, and is validated numerically showing rather good agreement. In the 3D principal stress space, the shape of the yield surface for the IWP-s lattice resembles the shape of a cocoa pod.
Determining the tangential mechanical properties of a tube is essential for simulation of various manufacturing processes that involve the use of a tubular geometry. The aim of this study is to develop a procedure to determine the tangential true stress-strain behavior of pipes. For this purpose a modified ring test setup is proposed consisting of a ring specimen loaded with two separate D-blocks. Using a finite element model, an optimized ring specimen geometry is obtained. The optimized ring specimen exhibits uniform tangential distribution in the gauge region of the specimen and necking occurs consistently at the center of the gauge length. It is found that friction has a substantial effect on the mechanical response of the ring test for which two different setups to reduce friction are proposed. One using lubricated D-blocks (DB) and one using lubricated D-blocks with needle roller bearing (RB). Assisted by the FE model, the friction during the experiment is account for and a data analysis procedure to determine the tangential stress-strain curve of the pipe is proposed. It is found that the results using this procedure show very good agreement with previously published results.
This licentiate thesis is generally concerned with the ductile failure and rupture mechanisms encountered under combined tension and torsion loading. In the first part entitled Paper A, an experimental investigation of the rupture mechanisms in a mid-strength and a high strength steel was conducted employing a novel test configuration. The specimen used was a double notched tube specimen loaded in combined tension and torsion at a fixed ratio. The effective plastic strain, the stress triaxiality and the Lode parameter was determined in the centre of the notch at failure. Scanning electron microscopy of the fractured surfaces revealed two distinctively different ductile rupture mechanisms depending on the stress state. At high stress triaxiality the fractured surfaces were covered with large and deep dimples, suggesting that growth and internal necking of voids being the governing rupture mechanism. At low triaxiality it was found that the fractured surfaces were covered with elongated small shear dimples, suggesting internal void shearing being the governing rupture mechanism. In the fractured surfaces of the high-strength steel, regions with quasi-cleavage were also observed. The transition from the internal necking mechanism to the internal shearing mechanism was accompanied by a significant drop in ductility.
In the second part entitled Paper B, a micromechanics model based on the theoretical framework of plastic localization into a band introduced by Rice is developed. The model employed consists of a planar band with a square array of equally sized cells, with a spherical void located in the centre of each cell. The periodic arrangement of the cells allows the study of a single unit cell for which fully periodic boundary conditions are applied. The micromechanics model is applied to analyze failure by ductile rupture in experiments on double notched tube specimens subjected to combined tension and torsion carried out by the present authors. The stress state is characterized in terms of the stress triaxiality and the Lode parameter. Two rupture mechanisms can be identified, void coalescence by internal necking at high triaxiality and void coalescence by internal shearing at low triaxiality. For the internal necking mechanism, failure is assumed to occur when the deformation localizes into a planar band and is closely associated with extensive void growth. For the internal shearing mechanism, a simple criterion based on the attainment of a critical value of shear deformation is utilized. The two failure criteria capture the transition between the two rupture mechanisms successfully and are in good agreement with the experimental result.
The industrial application of high strength steels in structural components has increased the demand on understanding the ductile failure behavior of this type of materials. In practical situations the loading experienced on components made out of these materials can be very complex, which may affect the failure behavior.
The objective of this work is to study the effect of stress state on ductile failure and the mechanisms leading to rupture in high strength steels. The stress state is characterized by the stress triaxiality T and the Lode parameter L, which is a deviatoric stress state parameter that discriminates between axisymmetric or shear dominated stress states. For this purpose experiments on two different specimen configurations are performed; a double notched tube (DNT) specimen tested in combined tension and shear and a round notched bar (RNB) specimen tested in uniaxial tension. The two specimens give rise to different stress states at failure in terms of T and L. The failure loci for the DNT specimen show an abrupt change in ductility, indicating a transition between the rupture mechanisms necking of intervoid ligaments and shearing of intervoid ligaments. A clear difference in ductility between the two specimen configurations is also observed, which is closely associated with the difference in stress state at failure.
A micromechanical model is developed, which assumes that ductile material failure occurs when the deformation becomes highly non-linear and localizes into a band. The model, which is applied to analyze the experiments, consists of a band with a square array of equally sized cells, with a spherical void located in the center of each cell. The model, extended with a shear criterion, captures the experimental trend rather well. The model also shows that the effect of the deviatoric stress state (L) on void growth, void shape evolution and coalescence is significant, especially at low levels of T and shear dominated stress state.
An experimental investigation of the rupture mechanisms in a mid-strength and a high-strength steel were conducted employing a novel test configuration. The specimen used was a double notched tube specimen loaded in combined tension and torsion at a fixed ratio. The effective plastic strain, the stress triaxiality and the Lode parameter were determined in the centre of the notch at failure. Scanning electron microscopy of the fractured surfaces revealed two distinctively different ductile rupture mechanisms depending on the stress state. At high stress triaxiality the fractured surfaces were covered with large and deep dimples, suggesting that growth and internal necking of voids being the governing rupture mechanism. At low triaxiality it was found that the fractured surfaces were covered with elongated small shear dimples, suggesting internal void shearing being the governing rupture mechanism. In the fractured surfaces of the high-strength steel, regions with quasi-cleavage were also observed. The transition from the internal necking mechanism to the internal shearing mechanism was accompanied by a significant drop in ductility.
A micromechanics model based on the theoretical framework of plastic localization into a band introduced by Rice is developed. The model consists of a planar band with a square array of equally sized cells, with a spherical void located in the centre of each cell. The periodic arrangement of the cells allows the study of a single unit cell for which fully periodic boundary conditions are applied. The micromechanics model is applied to analyze failure by ductile rupture in experiments on double notched tube specimens subjected to combined tension and torsion carried out by the present authors. The stress state is characterized in terms of the stress triaxiality and the Lode parameter. Two rupture mechanisms can be identified, void coalescence by internal necking at high triaxiality and void coalescence by internal shearing at low triaxiality. For the internal necking mechanism, failure is assumed to occur when the deformation localizes into a planar band and is closely associated with extensive void growth until impingement of voids. For the internal shearing mechanism, a simple criterion based on the attainment of a critical value of shear deformation is utilized. The two failure criteria capture the transition between the two rupture mechanisms successfully and are in good agreement with the experimental result.
Polypropylene (PP) plastic pipes have recently gained widespread application in non-pressurized gravity pipes used for seawater intake lines in the petrochemical industry. These pipes consist of a solid wall base pipe, on which an outer reinforcement called the omega-profile is spirally winded and hot fusion bonded. The omega-profile is usually filled with grout to provide on-bottom stability for subsea installation. It is of high importance that the bond between the omega-profile and the base pipe has sufficient strength to provide resistance against buckling of the pipeline system. The objective of this study is to investigate the collapse behaviour of such large-diameter PP pipes subjected to a negative internal pressure. The bond is modelled with cohesive zone modelling technique with the aim to determine the failure mode that governs the collapse behaviour of the pipe, e.g. buckling or delamination. Experiments where conducted on single cantilever beam (SCB) specimens cut from the pipe to determine the cohesive bond strength between the omega-profile and base pipe. The findings from the experiments are implemented in a full pipe model, where the surface between the omega-profile and base pipe is assigned bond strength characteristics in accordance with the experimental results. The FEA results of the nonlinear collapse analysis of the full pipe model show that for the range of grout stiffness values considered (0 <= E- (g) <= 30 GPa), the governing failure mode of the pipe is initiated by buckling and proceeded by delamination. For delamination to govern the failure mode, a grout stiffness greater than 36 GPa in combination with a weaker bond strength than the experimentally measured would be required. The methodology presented in this study gives a rather accurate tool for the design and analysis of this type of structures, and can reliably assess the bond strength level required in view of the governing failure modes, e.g. buckling and delamination.
In this paper a welding simulation procedure is developed using the FE software ANSYS in order to predict residual stresses. The procedure was verified with temperature and residual stress measurements found in the literature on multi-pass butt welded plates and T-fillet welds. The predictions show qualitative good agreement with experiments. The welding simulation procedure was then employed on a welded ship engine frame box at MAN B&W. A subroutine for LEFM analysis was developed in 2D in order to predict the crack path of propagating fatigue cracks. The objective was to investigate fatigue test results from special designed test bars from the frame box where all test failed from the non-penetrated weld root. A subroutine was developed in order to incorporate the predicted residual stresses and their relaxation during crack propagation by isoparametric stress mapping between meshes without and with cracks, respectively. The LEFM fatigue life predictions shows good agreement with the fatigue test result when the residual stresses are taken into account in the crack growth analysis.
The present study investigates the influence of thermo-mechanical material properties of different steel grades (S355-S960) on welding residual stresses and angular distortion in T-fillet joints. Different cases in which temperature dependent thermo-mechanical material properties are considered as constant, linear, and as a function of temperature are simulated by using finite element (FE) method. Experiments are carried out to evaluate temperature dependent yield stress and Young's modulus for S700 and S960 steel grades. Furthermore, JMat Pro software is used to obtain the remaining thermo-mechanical material properties. The numerical predictions of angular distortion and transverse residual stresses are validated with experimental measurements. It is observed that for assessment of residual stresses, except yield stress, all of the thermo-mechanical properties can be considered as constant. For the prediction of angular distortions with acceptable accuracy, heat capacity, yield stress and thermal expansion should be employed as temperature dependent in the welding simulations.
Due to the recent boom in digital design for additive manufacturing and 3D printing, there has been a significantly growing interest in latticed structures for light design and improved mechanical properties. However, the focus in the literature has mostly been on compressive mechanical properties of uniformly latticed structures with little emphasis on flexural properties of latticed-beams that are functionally graded and hybridized with different lattice topologies. Therefore, this paper aims to explore the effect of lattice relative density gradation and hybridization on the specific flexural properties of prominent sheet-based triply periodic minimal surfaces (TPMS) cellular four-point loaded beams. First, the effective elastic properties of the cubic porous topologies are evaluated computationally to converge to certain sheet-based TPMS cellular structures capable of providing high flexural properties. Schwartz primitive (P) revealed high stiffness to shear loading, meanwhile, the F-Rhombic Dodecahedron (FRD) showed better resistance to uniaxial loading, and the Diamond (D) showed well-combined uniaxial and shear moduli. The selected four-point bend (4 PB) latticed-beams are functionally graded following a bilinear pattern and hybridized through the span of their length inspired by the shearing force and bending moment diagrams arising in the 4 PB beam, in view of the effective elastic properties of the TPMS topologies. The additively manufactured AlSi10Mg uniform, functionally-graded, and hybridized latticed-beams are tested in four-point bending and the results are compared with the finite element results. Both the experimental and numerical outcomes show good agreement within the elastic-plastic regime. From experimental results, it is found that functional grading and hybridization can considerably enhance the specific flexural modulus of sheetbased TPMS latticed-beams. Also, relative density gradation within the four-point bend specimens proved very essential in deflecting crack growth thereby retarding the final failure, meanwhile hybridization is conveyed to mitigate shear-band failure. Combination of functional gradation and hybridization on the latticed-beams resulted in a significant increase in the specific flexural stiffness. Therefore, this study provides guidelines on how to enhance the flexural properties of lightweight beams through lattice functional grading and hybridization.
To create a human-like skin for a robotic application, current touch sensor technologies have a few drawbacks. Electrical Impedance Tomography (EIT) is a candidate for this application due to its applicability over complex geometries; nevertheless, it has accuracy concerns. This study employs artificial neural networks (ANNs) to investigate the accuracy and capability of EIT-based touch sensors. A finite element (FE) model is utilized to solve the forward EIT problem while simultaneously determining the system's comprehensive mechanical response. The FE model is comprised of a polyurethane (PU) foam domain, a conductive spray layer and a set of sixteen electrodes. To replicate the process of touching the sensor body, a punch of varying diameters and touch forces is utilized. The mechanical response of the sensor body is modeled using the hyperfoam material model calibrated through experimental uniaxial and shear test data, while the electric conductivity of the sprayed skin surface is obtained experimentally as function of applied strain. The viscoelastic behavior of the PU foam material is also obtained experimentally. These experimental data were implemented in the FE model through user subroutines to model the mechanical and electrical properties of the sensor in the EIT forward problem. The traditional EIT inverse problem image reconstruction was replaced utilizing ANNs as an alternative to extract mechanics based parameters. The ANNs were created to predict the spatial coordinates of the touch point, and they were proven to be extremely accurate. Using the EIT voltage readings as input, the ANNs were utilized to forecast the system's mechanical behavior such as contact pressure, contact area, indentation depth, and touching force.
Sulfide stress cracking (SSC) presents a complex hydrogen-assisted cracking problem in oil and gas (O&G) production, primarily due to the presence of a wet hydrogen sulfide (H2S) environment. Recognized as a form of hydrogen embrittlement, SSC profoundly impacts the performance and durability of oil country tubular goods (OCTG), with potential adverse financial and environmental consequences. For instance, casings play a crucial role as mechanical barriers throughout drilling, completion, and production operations. However, their exposure to sour service conditions renders them susceptible to SSC and premature failures. The O&G industry currently faces multiple challenges in material selection and designing for sour service conditions to effectively mitigate SSC-related failures. This article aims to provide an in-depth review encompassing design practices, material qualification standards, and experimental testing methodologies used to assess the susceptibility of OCTG to SSC under sour service conditions. This work also examines recent advancements in fracture mechanics-based modeling approaches, which offer accurate simulation capabilities for hydrogen-assisted failures of practical engineering significance.
A micromechanics model based on the theoretical framework of plastic localization into a band introduced by Rice [1] is developed. The model employed consists of a planar band with a square array of equally sized cells, with a spherical void located in the centre of each cell. The micromechanics model is applied to analyze the rupture mechanisms associated with mixed mode ductile fracture. The stress state is characterized by the stress triaxiality T and the Lode parameter mu which adequately describe the stress state ahead of a crack tip under mixed mode loading of an isotropic elasto-plastic material. The main focus is the influence of mu on void growth and coalescence behavior. It is shown that the Lode parameter exerts a strong influence upon this behavior.
This work investigates the microstructure, mechanical characteristics, and texture evolution of friction stir welding (FSW) of AA6061-T6 metal matrix composites (MMCs) reinforced with silicon carbide (SiC) and zinc (Zn) particles. The SZ region of the SiC and Zn particle-reinforced aluminium matrix (Al-matrix) composites has ultra-fine grain refinements of 4.79 and 4.18 μm, respectively, compared to base metal (BM) particle sizes of 44.97 μm. Ultra-fine grain refinement in the SZ zone produces dynamic recrystallization with particulate-driven nucleation, Zenner Hollomon, and homogeneous SiC/Zn particle distribution in the Al-matrix. Recrystallization texture components P {011} <112>, cube {001} <101>, rotating cube (H) {001} <110>, and F {111} <112>, along with primary shear texture components (B/B¯, and C), suggested DRX at the joint interface in the SiC-reinforced Al-matrix composite. However, the Zn-reinforced Al-matrix composite has a high plain strain, recrystallization, and deformation texture components of copper {112} <111>, Brass {011} <211>, cube {001} <101>, Goss {110}, and P 011 <112>, and major shear texture components (B/B¯ and C). SiC and Zn-reinforced Al-matrix composites have 110 ± 4 and 120 ± 5 HV0.2 average microhardness, respectively. Also, SiC and Zn-reinforced Al-matrix composites have 224 and 236 MPa tensile strengths, respectively.
This study investigates the influence of square and hexagon tool pin profiles on the butt joint of AA7075-T6 plates through friction stir welding. In contrast to the AA7075-T6 base metal with a grain size of 32.736 μm, both square (4.43 μm) and hexagon (5.79 μm) pin profiles led to a significant reduction in grain size within the stir zone (SZ) of the weld cross-section. The SZ region exhibited a gradient in recrystallization and a notable fraction of high angle grain boundaries, attributed to continuous dynamic recrystallization influenced by variations in temperature and strain rate. Pole figure analysis revealed predominant shear texture elements (B/ B‾ and C) with minor A1*/A2* and A/ A‾, indicating elevated strains within the SZ. Orientation distribution function (ODF) analysis identified recrystallization texture elements such as Goss {110} <001>, cube {001} <101>, and P {011} <112>, along with shear texture components F {111} <112> and rotating cube (H) {001} <110>. Tensile and nanoindentation analyses demonstrated that the weld joint using a square-shaped pin profile exhibited higher strength, elongation, and elastic modulus compared to other weld joints. These findings suggest that the square tool pin geometry enhances material flow and grain refinement during welding, thereby improving the mechanical properties of the joint.
The aim of this study is to investigate the influence of yield strength of the filler material and weld metal penetration on the load carrying capacity of butt welded joints in high-strength steels (HSS) (i.e., grade S700 and S960). These joints are manufactured with three different filler materials (under-matching, matching, and over-matching) and full and partial weld metal penetrations. The load carrying capacities of these mentioned joints are evaluated with experiments and compared with the estimations by finite element analysis (FEA), and design rules in Eurocode3 and American Welding Society Code AWS D1.1. The results show that load carrying estimations by FEA, Eurocode3, and AWS D1.1 are in good agreement with the experiments. It is observed that the global load carrying capacity and ductility of the joints are affected by weld metal penetration and yield strengths of the base and filler materials. This influence is more pronounced in joints in S960 steel welded with under-matched filler material. Furthermore, the base plate material strength can be utilized in under-matched butt welded joints provided appropriate weld metal penetration and width is assured. Moreover, it is also found that the design rules in Eurocode3 (valid for design of welded joints in steels of grade up to S700) can be extended to designing of welds in S960 steels by the use of correlation factor of one.
In this study, the fatigue strength of inclined butt welds subjected to a proportional multiaxial stress state generated by uniaxial loading is studied in nominal and local stress concepts. The local methodologies studied included principal stress hypothesis, von Mises stress hypothesis and modified Wöhler curve method. Nominal methodologies included modified Gough-Pollard interaction equation, the design equation in Eurocode3 and the interaction equation in DNV standard. Results are evaluated along with data published in relevant literature. It is observed that both local and nominal stress assessment methods are able to estimate multiaxial fatigue strength. No obvious difference in fatigue strength is observed in the nominal stress concept, but the notch stress concept is able to capture a decrease in fatigue strength in shear-dominated joints. It is concluded that modified Wöhler curve method is a suitable tool for the evaluation of fatigue strength in joints dominated by both normal and shear stresses.
Graphene oxide (GO) has high aspect ratios than many nanosize fillers such as carbon nanotubes and clay, besides its better mechanical properties than many polymers; so they are preferred as a filler material in polymer matrix composites. In this study, the effect of GO on the mechanical properties of linear low-density polyethylene (LLDPE) were experimentally investigated. LLDPE-GO nanocomposites were prepared by melt compounding method, and the extruded nanocomposite was shaped by injection molding machine for the mechanical tests. The mechanical properties investigated included tensile properties, fatigue properties, as well as hardness properties. Differential scanning calorimeter (DSC) was employed to study the thermal characterization of the composites. The results revealed that the addition of GO nanosheets indeed had a positive effect on the tensile, fatigue, and hardness properties. The tensile strength, Young's modulus, and Shore D hardness value were increased by 27.4%, 31.3%, and 9%, respectively, with a GO loading ranging from 0 wt.% to 2 wt.%. The addition of GO had a significant effect on the fatigue properties of the composites such as nearly exponential increment in the cyclic numbers. The samples with 2 wt.% of GO could endure up to 10(6) cycles during the tests, which is 100 times that of pure LLDPE. The morphological analysis via X-ray diffraction (XRD) and transmission electron microscopy (TEM) indicated that GO nanosheets were well exfoliated in the LLDPE matrix. However, there is no significant effect on the melting temperature, crystallization temperature and crystallinity of LLDPE based on DSC result.
The aim of this study is to develop a methodology for static strength and failure mode simulation of hot-driven riveted joints. The purpose is to be able to accurately estimate a rivet joint's static strength behaviour and its failure mode without relying on experiments, to save both time and resources during the design of joints. The non-linear finite element analysis modelling framework considered the rivet joint configurations and geometry, the material properties of the plate and rivet as well as the clamping force of the hot-driven rivet. A ductile damage model was also implemented to capture the stress softening of the materials and the failure modes of the joints. Using experimental data from literature, the modelling framework is validated, and it is shown that it is able to capture the strength behaviour and failure modes of different configurations of rivet joints markedly well. The effect of the rivet pre-load on the mechanical response of the joint is also studied and it is shown that the strength of the joint increased with the increase in rivet pre-load. The modelling framework is then applied to an industrial component. The modelling framework is used to compare welding and riveting as joining methods in a component built in two grades of high-strength steel. It is found that the welded joint possessed greater strength compared to the proposed riveted joint. However, using the proposed simulation methodology developed, a riveted joint with matching strength to the welded joint could be designed.
Herein, we report the fabrication and characterization of high-strength Kevlar epoxy composite sheets for structural application. This process includes optimization of the curing conditions of composite preparation, such as curing time and temperature, and the incorporation of nanofillers, such as aluminum oxide (Al2O3), silicon carbide (SiC), and multi-walled carbon nanotubes (MWCNT) in different weight percentages. Differential scanning calorimetry (DSC) was utilized to investigate the thermal stability and curing behavior of the epoxy, finding that a minimum of 5 min is required for complete curing under an optimized temperature of 170 degrees C. Moreover, mechanical characterization, including flexural and drop-weight tests, were performed and found to be in good agreement with the DSC results. Our results show that nanofiller incorporation improves the mechanical properties of Kevlar epoxy composites. Among the tested samples, 0.5% MWCNT incorporation obtained the highest mechanical strength.
Several carbon steel tubing suffered severe corrosion in service which resulted in the leakage of production fluids from tubing string and, consequently, a decrease of well productivity. Optical metallographic microscopy, X-ray diffraction (XRD), combined with weight loss and characterization methods were used to determine the most probable causes of the failure. The results showed that the composition and structure of the tubing joints and couplings were in accordance with the parameter requirements of API 5CT for grade J55. Upon visual inspection, the corroded pipe exhibited significant thickness reduction in multiple locations, which justifies utilizing the triaxial yield of pipe body formula, assuming the minimum measured thickness as the nominal thickness of the pipe. When compared to the upper bound internal pressure requirements in API 5CT, the equivalent stress calculation showed significantly lower failure pressure levels, which provide strong evidence that the pipe could not withstand actual service conditions. The composition of corrosion products was mainly FeCO3 and Fe3O4, and scaling layer were composed of the heavy components of the crude oil, CaCO3 and corrosion products. The scaling layer was protecting the steel surface from corrosion and reducing the corrosion rate. Once the scaling layer was broken, the corrosion rates increased. Also, pitting corrosion rates simulations were conducted at locations with the highest corrosion risk. Results show that at the first 30 days, pitting corrosion rates are the highest at these locations due to many factors including high CO2 partial pressures, acidic pH at these locations, and larger production volumes resulting in an increase of wall shear stresses and higher velocities.
Sulfide stress cracking (SSC) is a leading cause of failure in sour service environments, where the presence of wet hydrogen sulfide (H2S) causes hydrogen embrittlement and significantly influences the performance and lifespan of casing and tubing pipes. This work presents a numerical investigation on predicting the onset and growth of SSC in a sour environment using a coupled deformation–diffusion phase-field finite element framework, which incorporates the role of sub-surface hydrogen concentration due to H2S exposure and mechanical loading effects on the crack growth response. The numerical results agree with the experimental data from the notched slow strain rate testing performed on high-strength low alloy steel (HSLA) in a sour environment at room temperature. Recently, the oil and gas industry has been heading towards unconventional gas well applications that expose crucial parts of a well construction, such as production casings, to high internal pressures and a sour environment. To simulate such conditions, a numerical study is conducted that examines the onset and growth of SSC in pre-notched pressurized pipes subjected to H2S exposure. The geometry and boundary conditions used for the pre-notched pipes adhere to the API 579 standard for fitness for a service assessment of equipment containing identified flaws or damage. The findings of this comprehensive numerical investigation provide valuable insights into the effectiveness of a coupled phase-field approach for SSC and demonstrate its potential as an engineering tool for structural integrity assessments that consider environmental effects.
This article presents a nonlocal gradient-enhanced damage model that uses direction-dependent damage evolution and interfacial damage to predict transgranular and intergranular cracks in polycrystalline materials at the microstructural level. The distinct grains within the polycrystalline morphology are modeled as anisotropic linear elastic domains with random spatial orientation and cubic symmetries. Transgranular micro-cracks are assumed to occur along specific preferential cleavage planes within each randomly oriented crystal and are described using a bulk damage variable. For intergranular fracture, a smeared description of interface decohesion is incorporated through an interface damage variable which depends on the modified interface kinematics based on a cohesive law that uses a smoothed displacement jump approximation. The coupled system of equations in the proposed computational framework is decoupled using an operator-split methodology to ensure a robust and straightforward computational implementation. Several numerical examples are presented, and simulations are performed on single crystal, bicrystals, and polycrystalline domains to demonstrate the capabilities and validation of the proposed model.
This study investigates the biomechanical performance of various dental materials when filled in different cavity designs and their effects on surrounding dental tissues. Finite element models of three infected teeth with different cavity designs, Class I (occlusal), Class II mesial-occlusal (MO), and Class II mesio-occluso-distal (MOD) were constructed. These cavities were filled with amalgam, composites (Young’s moduli of 10, 14, 18, 22, and 26 GPa), and glass carbomer cement (GCC). An occlusal load of 600 N was distributed on the top surface of the teeth to carry out simulations. The findings revealed that von Mises stress was higher in GCC material, with cavity Class I (46.01 MPa in the enamel, 23.61 MPa in the dentin), and for cavity Class II MO von Mises stress was 43.64 MPa, 39.18 MPa in enamel and dentin respectively, while in case of cavity Class II MOD von Mises stress was 44.67 MPa in enamel, 27.5 in the dentin. The results showed that higher stresses were generated in the non-restored tooth compared to the restored one, and increasing Young’s modulus of restorative composite material decreases stresses in enamel and dentin. The use of composite material showed excellent performance which can be a good viable option for restorative material compared to other restorative materials.
HDPE is commonly used in pipelines and piping for industrial and societal infrastructure. Like most polymers, HDPE's mechanical properties are sensitive to temperature and show time dependent properties. The temperature effect on both the short and long term compressive and tensile behavior of HDPE, in a combined manner, have not been investigated thoroughly in the past. Especially the constitutive behavior of HDPE, incorporating temperature effects on its long and short term behavior, could be essential when designing such infrastructural components. Hence, the temperature effect on the short and long term response in tension and compression of HDPE is investigated in this study. The short term tensile and compressive stress-strain behavior at 23, 40, 60, and 80 degrees C were obtained through experiments at constant displacement rate and temperature. Tensile and compressive stress relaxation (e.g. long term) behavior at 23, 40, 50, 60, 70, and 80 degrees C were investigated through stress relaxation tests. The experimental results from the short term tests showed that both the tensile and compression moduli and yield strength of HDPE decrease linearly with the increase in temperature. It is also shown from the long term test that relaxation modulus in tension and compression are highly dependent on temperature. Based on the experimental results, the constitutive three network model (TNM) was calibrated and implemented in a FEA model, which was then validated through a three point bending (3 PB) relaxation test with a prescribed temperature profile. The FEA model and the calibrated model results agree markedly well with the experimental results, which indicates that the model can be used reliably to predict the temperature dependent short and long term behavior of HDPE in design and analysis of HDPE components.
This study examines the compressive response of geometrically tailored pyramidal lattice structures composed of struts with I-shaped cross-sections. Geometrically tailored pyramidal lattices with micro-scale features are 3D printed using the Digital Light Processing (DLP) technique, and their effective elastic modulus, collapse strength and energy absorption capacity are experimentally evaluated under quasi-static compressive loading. Furthermore, detailed non-linear finite element (FE) calculations are performed to examine underlying collapse mechanisms and explore the vast design space offered by the proposed geometrical tailoring scheme. Both the experimental and numerical results show that the geometrically tailored lattice structures outperform conventional pyramidal lattices of equal weight in terms of elastic modulus (+24 %), collapse strength (+21 %) and energy absorption (+68 %). Notably, these strength improvements are attributed to lateral buckling that prompts the I-shaped struts to bend sideways during collapse. Specific cross-sectional designs demonstrate remarkable enhancements in strength and energy absorption, reaching up to 93 % and 161 %, respectively, differentiating them significantly from conventional designs.
BorECO®™ BA212E is a polypropylene block co-polymer which has become a common material in the manufacturing of large diameter non-pressurized gravity offshore intake pipelines. These lines are used for transportation of sea water for cooling of petrochemical process plants. The pipe sections are joined by butt heat fusion welding to create the pipeline. Recently a few premature failures of such pipelines have been reported in the field. Hence, there is a need to characterize the constitutive behavior of the pipe and weld material in order to properly design these pipes. The aim of this work is to determine the material constitutive behaviors of the pipe material and the welded joint material. Uniaxial tensile tests of both the pipe and weld joint material are conducted at various strain rates. Both the pipe and weld material show a rather high strain rate dependency, with the weld material having about half the yield strength than that of the pipe material. An analytical constitutive material model is developed for both the pipe and weld material, incorporating the effect of strain rate. The failure locus, expressed in terms of the equivalent plastic strain at failure vs. the stress triaxiality, for both materials is also determined as part of the constitutive model using notched dumbbell specimens. The constitutive model and failure loci for the pipe and weld material are implemented in a finite element model (FEM) and are validated by conducting a series of independent four-point bend experiments on both material types. The validation is carried out by comparing the FEM results of the four-point bend model with the experimental results, which show a rather good agreement.
This study aims to find suitable fatigue assessment methods for welded structures (cover plates and T-joints) subjected to axial and bending loading. The Hot Spot Stress (HSS), 1-mm stress (OM), Theory of Critical Distances (TCD), Stress Averaging (SA), and Effective Notch Stress (ENS) methods are evaluated in terms of accuracy and reliability. The evaluation is based on fatigue test data extracted from the literature and carried out in this study. It is found that the SA method can be used to assess the fatigue strength of cover plate joints under axial loading with relatively good accuracy and low scatter, followed by the ENS method. The HSS, TCD, SA, and ENS methods are conservative estimation methods for T-joints under bending, while the accuracy is low. Furthermore, fatigue design curves applicable for T-joints under bending are discussed, which can be used in the TCD method and SA method.