A comparison of lifetime prediction methods for a thermal fatigue experiment

Abstract

This paper is dedicated to the comparison of several numerical models for estimating the lifetime in a fatigue experiment. The models simulate the SPLASH experiment, which produces thermal fatigue by locally quenching stainless steel specimens. All models predict first a stabilized mechanical state (plastic shakedown) and then a lifetime prediction using several fatigue crack initiation criteria. The numerical methods are either completely nonlinear or combine approximate elastic solutions obtained from minimizing a potential energy or closed form solutions with a Neuber or Zarka technique to estimate directly the elastoplastic state. The fatigue criteria used are Manson, dissipated energy and dissipated energy combined with a hydrostatic pressure term. The latter had provided a best prediction over a series of anisothermal and isothermal LCF experiments in a classical fatigue analysis. The analysis shows that for fatigue criteria taking into account the triaxiality of the mechanical response we obtain a systematic and conservative error. As a consequence of this work, we show that simplified models can be used for lifetime prediction. Moreover the paper provides a general technique to asses from the point of view of the design engineer the combination between a numerical method and a fatigue criterion.

Numerical simulation of thermal fatigue behavior in a cracked disc of AISI H-11 tool steel

“…Some of the setups include a disc heated by induction on the periphery [1][2][3][4][5][6][7][8][9][10][11][12], triangular blade heated by induction [13], electrical heating of tube followed by water splashing to induce thermal shock [14][15][16][17][18], hot dipping of cylinders in molten aluminum [19,20], laser heating [21,22], focused halogen lamps heating [23,24], convection/combustion heating [25,26], furnace heating with water quenching [27,28] and actual dies [29,30]. Out of these experimental setups most researchers have worked on the heated disc problem.…”

Acceleration techniques for the numerical simulation of the cyclic plasticity behaviour of mechanical components under thermal loads

“…In particular, in presence of creep and thermal fatigue, authors such in [8,9,10] suggest only a limited number of cycles to be simulated; even if this procedure seems not well defined, it has to be considered that the presence of visco-elasticity generally strongly reduces the stabilization time. On the other hand, some authors [11,12] use the kinematic model with stabilized material condition from the beginning of simulation, at the same time neglecting the initial transient cyclic deformation.…”

Characteristics of the thermal fatigue resistance for 3.1C, 0.8Si, 0.9Mn, 1.7Cr, 4.5Ni and 0.3Mo ICDP cast iron roll at 600 °C

“…[3][4][5][6][7][8][9][10][11][12][13][14][15][16][17] Several research works related to thermal fatigue resistance of die materials (i.e. steels, cast irons) were carried out where reasons for initiation and growth of cracks at hot working dies (forging, die casting) [17][18][19][20][21][22][23][24][25][26][27][28][29][30] and hot working rolls [3][4][5][6]9,[31][32][33][34] were investigated using various laboratory tests. However, detailed knowledge about the influence of the stress state, the temperature and the oxidation on the initiation and propagation of thermal cracks in hot working applications is still lacking.…”