High-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures

A modified model is developed to characterize and evaluate high-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures by considering the stress ratio effect. The model is informed by the relationship surface between maximum nominal stress, stress ratio and fatigue life. New formulae are derived to deal with the test data for estimating the parameters of the proposed model. Fatigue tests are performed on Co-based superalloy 9Cr Co subjected to constant amplitude loading at four stress ratios of 1, 0.3, 0.5 and 0.9 in three environments of room temperature(i.e., about 25 °C) and elevated temperatures of 530 °C and 620 °C, and the interaction mechanisms between the elevated temperature and stress ratio are deduced and compared with each other from fractographic studies. Finally, the model is applied to experimental data, demonstrating the practical and effective use of the proposed model. It is shown that new model has good correlation with experimental results.     

Out of phase thermal mechanical fatigue investigation of a directionally solidified superalloy DZ125

Out of phase(OP) thermal mechanical fatigue(TMF) behavior of a directionally solidified(DS) superalloy DZ125 was experimentally and numerically studied. Two different temperature conditions, which are 500–1000 °C and 400–900 °C, were considered in the present research.Stress and strain responses as well as fatigue life results were presented and discussed. Scanning electron microscope(SEM) and metallographic analysis were used to study the damage mechanism. An oxidation assisted crack initiation and propagation phenomenon were found to explain the shorted life under TMF cycles. In order to characterize the stress and strain deformations under TMF loadings, a modified Chaboche's constitutive model was applied. Additionally, the TMF life of the material was modeled and predicted by Neu–Sehitoglu damage law with high accuracy.     

Testing and evaluation for fatigue crack propagation of Ti-6Al-4V/ELI and 7050-T7452 alloys at high temperatures

This paper seeks to evaluate crack propagation properties and residual lives of metallic alloys subjected to fatigue loading at room and high temperatures. Fatigue crack growth tests were performed on Ti-6Al-4V/ELI and 7050-T7452 subjected to constant-amplitude and actual randomspectra loading at room temperature of about 25 ℃ and at high temperatures of 250 ℃ and 150 ℃ to determine their crack growth properties and residual lives. The damage mode and mechanisms at high temperature were compared with those at room temperature on the basis of the results of fractographic analysis. Temperature-dependent residual lives under actual random-spectra load history were evaluated based on a modified accumulation damage rule accounting for the load interaction.Good correlation was achieved between the predictions and actual experiments, demonstrating the practical and effective use of the proposed method.     

Effect of Processing and Composition on the Structure and Properties of P/M EP741NP Type Alloys

A study was carried out on the effects of processing and composition on the structure and properties of P/M EP741NP type alloys. The objectives of this study were to understand the role of Hf in a P/M superalloy containing high niobium used in aircraft engines and to determine the effects of extrusion and forging the powders as contrasted to HIPing (hot isostatic pressing) only. Two alloys of the P/M EP741NP composition were atomized: one alloy contained 0.26%Hf and the other was Hf free. After the as-atomized powders from both alloys were characterized, the powders were extruded into billets, forged and heat treated. After each process, the microstructures were characterized by SEM and the phases were extracted and identified by X-ray diffraction. The presence of Hf in the residues was probed by EDS (energy dispersive spectroscopy). The alloys were given the published Russian heat treatment as well as a more conventional heat treatment more typical of western powder alloys. Tensile, creep and stress rupture mechanical property tests were run. Results of the structural behavior of the alloys after each processing step will be presented and discussed. The role of the Hf on the mechanical proper- ties will be discussed.     

Damage characteristics and constitutive modeling of the 2D C/Si C composite: Part I – Experiment and analysis

This paper reports an experimental investigation on the macroscopic mechanical behaviors and damage mechanisms of the plain-woven(2D) C/Si C composite under in-plane on- and offaxis loading conditions. Specimens with 15, 30, and 45 off-axis angles were prepared and tested under monotonic and incremental cyclic tension and compression loads. The obtained results were compared with those of uniaxial tension, compression, and shear specimens. The relationships between the damage modes and the stress state were analyzed based on scanning electronic microscopy(SEM) observations and acoustic emission(AE) data. The test results reveal the remarkable axial anisotropy and unilateral behavior of the material. The off-axis tension test results show that the material is fiber-dominant and the evolution rate of damage and inelastic strain is accelerated under the corresponding combined biaxial tension and shear loads. Due to the damage impediment effect of compression stress, compression specimens show higher mechanical properties and lower damage evolution rates than tension specimens with the same off-axis angle. Under cyclic tension–compression loadings, both on-axis and off-axis specimens exhibit progressive damage deactivation behaviors in the compression range, but with different deactivation rates.     

Coupling damage and reliability model of low-cycle fatigue and high energy impact based on the local stress–strain approach

Fatigue induced products generally bear fatigue loads accompanied by impact processes,which reduces their reliable life rapidly. This paper introduces a reliability assessment model based on a local stress–strain approach considering both low-cycle fatigue and high energy impact loads.Two coupling relationships between fatigue and impact are given with effects of an impact process on fatigue damage and effects of fatigue damage on impact performance. The analysis of the former modifies the fatigue parameters and the Manson–Coffin equation for fatigue life based on material theories. On the other hand, the latter proposes the coupling variables and the difference of fracture toughness caused by accumulative fatigue damage. To form an overall reliability model including both fatigue failure and impact failure, a competing risk model is developed. A case study of an actuator cylinder is given to validate this method.     

Study on pressure wave propagation in two-phase flow in liquid oxygen feed pipe between pumps

A study on the character of pressure wave propagation was proposed for the gas liquid oxygen two-phase flow in the pipe between pumps.According to the practical working conditions,the homogenous model based on the compressibility theory regarding a single bubble in an infinite liquid,and Redlich-Kwong gas equation was derived a model for the low temperature and high pressure case,especially considering the change of the ratio of density of gas to one of liquid.The numerical tests were conducted.The results not only show the agreement between numerical simulation for this model and experiment at the normal temperature and pressure is good,but also show that the modifications of the model for the low temperature and high pressure condition are necessary.The study is of reference to further study of oscillation restrain and relative pipe tests.      

THE INFLUENCE OF DEFORMATIONCONDITIONS ON THE FLOW STRESS ANDMICROSTRUCTURE OF ALLOY GH169

In this paper the dependence of flow stress in alloy GH169 on the deformation temperature, strain and strain rate based on the data of hot working simulation test is defined for the first time. Experimental results indicate that for the alloy GH169 the values of flow stress at high temperatures are much higher than those of alloy steel and the work hardening is remarkable. The deformation conditions have significant influence on the flow stress and microstructure of alloy GH169. It is found that under certain conditions fine grain structure can be obtained even though the deformation processes are carried out at high temperatures. This finding is beneficial to the raise of productivity of forming processes. Increasing the cooling rate after deformation is also favourable to the development of fine grain structure. To sum up, the microstructure of alloy GH169 can be controlled effectively through thermomechanical treatment.     

Through-thickness heterogeneity in creep properties of friction stir welding 7B50-T7451 aluminum alloy thick plate joint: Experiments and modeling

Through-thickness heterogeneity in creep properties of 7B50-T7451 aluminum alloy Friction Stir Welding(FSW) joints was investigated. Creep tests for three slices of the FSW joint were conducted at the temperature of 150–200 °C and applied stress of 60–225 MPa. The theta projection method was used to predict creep curves and minimum creep rate. The results show that the minimum creep rate increases and creep rupture life decreases with the increase of creep temperature and applied stress. Creep p...     

Active Aerothermoelastic Control of Hypersonic Double-wedge Lifting Surface

Designing re-entry space vehicles and high-speed aircraft requires special attention to the nonlinear thermoelastic and aerodynamic instability of their structural components. The thermal effects are important since temperature environment brings dramatic influences on the static and dynamic behaviors of flight structures in supersonic/hypersonic regimes and is likely to cause instability, catastrophic failure and oscillations resulting in structural failure due to fatigue. In order to understand the dynamic behaviors of these ＂hot＂ structures, a double-wedge lifting surface with combining freeplay and cubic structural nonlinearities in both plunging and pitching degrees-of-freedom operating in supersonic/hypersonic flight speed regimes has been analyzed. A third order piston theory aerodynamic is used to estimate the applied nonlinear unsteady aerodynamic loads. Also considered is the loss of torsional stiffness that may be incurred by lifting surfaces subject to axial stresses induced by aerodynamic heating. The aerodynamic heating effects are estimated based on the adiabatic wall temperature due to high speed airstreams. As a recently emerging technology, the active aerothermoelastic control is aimed at providing solutions to a large number of problems involving the aeronautical/aerospace flight vehicle structures. To prevent such damaging phenomena from occurring, an application of linear and nonlinear active control methods on both flutter boundary and post-flutter behavior has been fulfilled. In this paper, modeling issues as well as numerical simulation have been presented and pertinent conclusions outlined. It is evidenced that a serious loss of torsional stiffness may induce the dynamic instability; however active control can be used to expand the flutter boundary and convert unstable limit cycle oscillations （LCO） into the stable LCO and/or to shift the transition between these two states toward higher flight Mach numbers.     

Thermal–structure coupling analysis and multi-objective optimization of motor rotor in MSPMSM

With the high speed, the rotor of magnetically suspended permanent magnet synchronous motor(MSPMSM) suffers great thermal stress and mechanical stress resulting from the temperature rise problem caused by rotor losses, which leads to instability and inefficiency.In this paper, the mechanical–temperature field coupling analysis is conducted to analyze the relationship between the temperature field and structure, and multi-objective optimization of a rotor is performed to improve the design reliability and efficiency. Firstly, the temperature field is calculated by the 2 D finite element model of MSPMSM and the method of applying the 2 D temperature result to the 3 D finite element model of the motor rotor equivalently is proposed. Then the thermal–structure coupling analysis is processed through mathematic method and finite element method(FEM),in which the 3 D finite element model is established precisely in a way and approaches the practical operation state further. Moreover, the impact produced by the temperature and structure on the mechanical strength is analyzed in detail. Finally, the optimization mathematical model of the motor rotor is established with Sequential Quadratic Programming-NLPQL selected in the optimization scheme. Through optimization, the strength of the components in the motor rotor increases obviously and satisfies the design requirement, which to a great extend enhances the service life of the MSPMSM rotor.     

Temperature effect on buckling properties of ultra-thin-walled lenticular collapsible composite tube subjected to axial compression

This paper seeks to outline the temperature effect on the buckling properties of ultra-thin-walled lenticular collapsible composite tube(LCCT) subjected to axial compression.The buckling tests of the LCCT specimens subjected to axial compression were carried out on INSTRON-500 N servo-hydraulic machine in dry state and at the temperatures of 25 C, 100 C and 80 C. The load–displacement curves and buckling initiation loads were measured and the buckling initiation mechanism was discussed from experimental observations. Experiments show that the buckling initiation load, on average, is only about 2.2% greater at the low temperature of 80 C than at the room temperature of 25 C due to the material hardening, demonstrating an insignificant increase in the buckling initiation load, whereas it is about 19.5% lower at the high temperature of 100 C than at the room temperature owing to the material softening, implying a significant decrease in the buckling initiation load. The failure mode of the LCCT in axial compression tests at three different temperatures can be reckoned to be characteristic of the buckling initiation and propagation around the central region until rupture. The finite element(FE) model is presented to simulate the buckling initiation mechanism based on the eigenvalue-based methodology. Good correlation between experimental and numerical results is achieved.     

Influences of milling and grinding on machined surface roughness and fatigue behavior of GH4169 superalloy workpieces

Surface topography of superalloy GH4169 workpieces machined by milling and grinding is different significantly. Meanwhile, surface roughness, as one of the main indicators of machined surface integrity, has a great influence on the fatigue behavior of workpieces. Based on analyzing the formation mechanism and characteristics of surface roughness utilizing different machining processes and parameters, the machined surface roughness curve can be decoupled into two parts utilizing frequency spectrum analysis, which are kinematic surface roughness curve and stochastic surface roughness curve. The kinematic surface roughness curve is influenced by machining process,parameters, geometry of the cutting tool or wheel, the maximum height of which is expressed as R'_z.By subtracting the kinematic part from the measurement curve, the stochastic surface roughness curve and its maximum height R'_zcan be obtained, which is influenced by the defects of cutting tool edge or abrasive grains, built-up edges(BUE), cracks, high frequency vibration and so on. On the other hand, the results of decoupling analysis of surface roughness curves indicate that Raand Rz values of milling GH4169 are 2–5 times and 1–3 times as high as those of grinding, while R'_zvalue of milling is 13.85%–37.7% as high as that of grinding. According to the results of fatigue life tests of specimens machined by milling and grinding, it can be concluded that fatigue behavior of GH4169 decreases with the increase of R'_zmonotonically, even utilizing different machining processes.     

Surface integrity and fatigue behavior when turning γ-TiAl alloy with optimized PVD-coated carbide inserts

This paper presents a comprehensive investigation on the effects of tool and turning parameters on surface integrity and fatigue behavior in turning c-Ti Al alloy. The wear of inserts surface, cutting forces, and surface roughness were studied to optimize PVD-coated carbide inserts.Surface topography, residual stresses, microhardness, and microstructure were analyzed to characterize the surfaces layer under different turning parameters. Surface integrity and fatigue life tests of c-Ti Al alloy were conducted under turning and turning-polishing processes. The results show that compared to CNMG120412-MF4, CNMG120408-SM is more suitable because it obtained low cutting force, surface roughness, and tool wear. With increasing the cutting speed and depth, the depths of the compressive residual stress layer, hardening layer, and plastic deformation layer increased. For turning and turning-polishing specimens, the compressive residual stress was relaxed by less than 20%–30% after 10~7 cycles. The fatigue life of a turning-polishing specimen with R_a= 0.15 mm has increased 3 times from that of a turning specimen with R_a= 0.43 mm.     

Thermal shock damage behavior of CVD ZnS by oxygen propane flame：A numerical and experimental study

Chemical vapor deposition zinc sulfide （CVD ZnS） is widely used as an infrared window material to transmit infrared signals, keep the aerodynamic shape and protect its imaging system, which often suffers high temperature and complicated thermal stresses. The purpose of this paper is to investigate the thermal shock damage of CVD ZnS through a finite element method and oxygen propane flame experiments. The finite element model is developed to simulate the temperature and thermal stress fields by an oxygen propane flame. Then, the thermal shock experiments are performed to investigate the thermal shock damage behavior. The results show that the temperature rising rate of the shock surface is fast during the initial heating stage resulting in high thermal stress. After the thermal shock experiment, the scanning electron microscope （SEM） photographs shows that the shock surface of the specimen becomes rough and the microcracks occur in the thermal shock zone. Good agreements are achieved between the numerical solutions and the experimental results.     

Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

Thermal barrier coatings （TBCs） were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia （YSZ）, were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition （EB-PVD）. The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.     

Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

Thermal barrier coatings (TBCs) were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia (YSZ), were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition (EB-PVD). The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.     

Preparation and Mechanical Properties of Glass Coats with High Temperature Radar Absorber

BaO-La2O3-B2O3 （BLB） glass, suitable to be used as a sealing between metals, was chosen to be the binder in preparing glass coats on the Ti-alloy substrate. The SiCN nano-powder was introduced as the filler for the absorbing coat because it is considered to be a good high temperature absorber. The effect of the coating temperature and coating time on the tensile strength of the glass coat was investigated and the proper coating parameters to get good mechanical properties were determined. In addition, the effects of the SiCN content on the tensile strength of the absorbing coat were also discussed. Results show that it is possible to prepare the glass coat using the BLB glass as a binder. That the coat formed at 730℃ for 30 min has the best tensile strength witnesses 730 ℃, 30 min to be the proper parameter to prepare the glass coat. The BLB glass coat without SiCN powder possesses good tensile strength and the introduction of the SiCN absorber into the glass coat will lower the tensile strength. As the SiCN content increases, the tensile strength of the absorbing coat decreases, which could be attributed to the aggregation of SiCN in the coats.     

Preparation and Mechanical Properties of Glass Coats with High Temperature Radar Absorber

BaO-La2O3-B2O3 (BLB) glass, suitable to be used as a sealing between metals, was chosen to be the binder in preparing glass coats on the Ti-alloy substrate. The SiCN nano-powder was introduced as the filler for the absorbing coat because it is considered to be a good high temperature absorber. The effect of the coating temperature and coating time on the tensile strength of the glass coat was investigated and the proper coating parameters to get good mechanical properties were determined. In addition, the effects of the SiCN content on the tensile strength of the absorbing coat were also discussed. Results show that it is possible to prepare the glass coat using the BLB glass as a binder. That the coat formed at 730 ℃ for 30 min has the best tensile strength witnesses 730 ℃, 30 min to be the proper parameter to prepare the glass coat. The BLB glass coat without SiCN powder possesses good tensile strength and the introduc-tion of the SiCN absorber into the glass coat will lower the tensile strength. As the SiCN content increases, the tensile strength of the absorbing coat decreases, which could be attributed to the aggregation of SiCN in the coats.     

Grinding temperature and energy ratio coefficient in MQL grinding of high-temperature nickel-base alloy by using different vegetable oils as base oil

Vegetable oil can be used as a base oil in minimal quantity of lubrication(MQL). This study compared the performances of MQL grinding by using castor oil, soybean oil, rapeseed oil, corn oil, sunflower oil, peanut oil, and palm oil as base oils. A K-P36 numerical-control precision surface grinder was used to perform plain grinding on a workpiece material with a high-temperature nickel base alloy. A YDM–III 99 three-dimensional dynamometer was used to measure grinding force,and a clip-type thermocouple was used to determine grinding temperature. The grinding force, grinding temperature, and energy ratio coefficient of MQL grinding were compared among the seven vegetable oil types. Results revealed that(1) castor oil-based MQL grinding yields the lowest grinding force but exhibits the highest grinding temperature and energy ratio coefficient;(2) palm oil-based MQL grinding generates the second lowest grinding force but shows the lowest grinding temperature and energy ratio coefficient;(3) MQL grinding based on the five other vegetable oils produces similar grinding forces, grinding temperatures, and energy ratio coefficients, with values ranging between those of castor oil and palm oil;(4) viscosity significantly influences grinding force and grinding temperature to a greater extent than fatty acid varieties and contents in vegetable oils;(5) although more viscous vegetable oil exhibits greater lubrication and significantly lower grinding force than less viscous vegetable oil, high viscosity reduces the heat exchange capability of vegetable oil and thus yields a high grinding temperature;(6) saturated fatty acid is a more efficient lubricant than unsaturated fatty acid; and(7) a short carbon chain transfers heat more effectively than a long carbon chain. Palm oil is the optimum base oil of MQL grinding, and this base oil yields 26.98 N tangential grinding force,87.10 N normal grinding force, 119.6 °C grinding temperature, and 42.7% energy ratio coefficient.