The interaction between non-metallic inclusions and surface roughness in fatigue failure and their influence on fatigue strength

Saberifar, S.; Mashreghi, Ali; Mosalaeepur, M.; Ghasemi, Somayeh

doi:10.1016/j.matdes.2011.10.028

Cited by 33 publications

(8 citation statements)

References 14 publications

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“…Quantitative relationships between defect area and fatigue life have been studied for cast Al-Si alloys, particularly for A356 [40,41]. The integration of Paris' equation, in which the initial crack length was replaced by the √ area of the crack initiating defect resulted in a fair estimation of fatigue lives in the work of Saberifar et al [42]. This approach was used to analyze the results reported in the present paper.…”

Section: Fatigue Life Predictionmentioning

confidence: 97%

Effect of Platform Temperature and Post-Processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy

Martins

Provencher

Brochu

et al. 2021

Metals

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The effect of platform temperature combined with a T5 heat treatment on the fatigue life of additively manufactured aluminum alloy AlSi7Mg was characterized and understood. High-cycle fatigue tests were carried out on samples built with four platform temperatures (35 °C, 60 °C, 80 °C and 200 °C) and post-processing heat treatment strategies (F and T5). Microstructural and fractographic observations combined with microhardness measurements were performed. A log-normal statistical distribution regressed with 90% B-basis probabilities of survival revealed that specimens produced on a platform maintained at 80 °C and post-processed with a T5 heat treatment presented the highest fatigue life among the conditions tested. Precipitation of silicon within the aluminum cells during the T5 heat treatment is the proposed explanation for the improved fatigue life of the T5 samples. In the as-built condition, specimens produced at 200 °C were found to be less resistant to fatigue than the specimens built at lower temperatures. The coarser microstructure and lowest microhardness resulting from high-temperature manufacturing explain this reduced fatigue strength. All fatigue cracks initiated from manufacturing discontinuities. This led to a fatigue life prediction model based upon linear elastic fracture mechanics. The model was fitted to the experimental results of the F and T5 samples separately. With the exception of the 35 °C—T5 specimens, the predicted fatigue lives agree with the experimental results and literature.

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Section: Fatigue Life Predictionmentioning

confidence: 97%

Effect of Platform Temperature and Post-Processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy

Martins

Provencher

Brochu

et al. 2021

Metals

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“…Furthermore, fracture toughness shows the critical stress intensity factor of a crack that occurs to a material, which after some time the applied critical stress becomes rapid and irreplaceable. Thickness affects crack propagation [36]. Thin components have plain stress conditions, and thick components have plain strain conditions, which offer the lowest fracture toughness values [37].…”

Section: Fatigue Life Expectancy Methodsmentioning

confidence: 99%

Literature Review of Fatigue Life Performance of Ceramic Materials

Karadimas

Salonitis

2022

Advances in Transdisciplinary Engineering

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Ceramic materials are widely used nowadays in the aerospace sector. However, functional ceramics have not yet been fully researched in terms of their life expectancy under all possible loading scenarios. Ceramics have low toughness and high brittleness, but great thermal properties as it has been widely documented in the literature. A lack of research however with regards to ceramic material life expectancy models is evident. The fatigue life of ceramic materials is not thoroughly researched and there is a need for comparing them with more traditional materials used for similar purpose applications. In the present paper, the fatigue performance of several ceramic materials will be analyzed by using S-N curves, simulating the cumulative damage caused to these materials by different constant amplitude stresses applied from a wide range of applications and more specifically, aero-engine applications. Finally, the already existing literature on ceramic failure mechanisms and models will be evaluated and compared with the simulated life expectancy models to identify improvement opportunities and a guide for developing and deploying these materials to the extended use of applications.

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“…Non-metallic inclusions can be defined as undesirable metallic or non-metallic chemical compounds, such as oxides, nitrides or sulphides, that contain an extra compound such as carbonitrides, oxy-sulphides and others. Based on the origin of foreign particles, they can be categorized into endogenous inclusions and exogenous inclusions [25,26]; Endogenous-type inclusions form when high-temperature liquid metal reacts with some deoxidizers, such as aluminum or silicon, during the process of desulfurization. The chemical reaction makes a new product, which cannot be dissolved through slag.…”

Section: Introductionmentioning

confidence: 99%

Internal Cracks and Non-Metallic Inclusions as Root Causes of Casting Failure in Sugar Mill Roller Shafts

et al. 2019

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The sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.

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The interaction between non-metallic inclusions and surface roughness in fatigue failure and their influence on fatigue strength

Cited by 33 publications

References 14 publications

Effect of Platform Temperature and Post-Processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy

Effect of Platform Temperature and Post-Processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy

Literature Review of Fatigue Life Performance of Ceramic Materials

Internal Cracks and Non-Metallic Inclusions as Root Causes of Casting Failure in Sugar Mill Roller Shafts

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