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A life prediction method is developed for spot-welds subject to fatigue loading. Stress intensity factors are used with the Walker equation to develop two crack growth approaches to the problem. The predictions fit data for lap joint configurations well, but not so for peel joint geometries. / Master of Science

Modern durability and damage tolerance predictions for composite material systems rely on accurate estimates of the local stress and material states for each of the constituents, as well as the manner in which the constituents interact. In this work, an number of approaches to estimating the stress states and interactions are developed. First, an elasticity solution is presented for the problem of a penny-shaped crack in an N-phase composite material system opened by a prescribed normal pressure. The stress state around such a crack is then used to estimate the stress concentrations due to adjacent fiber fractures in a composite materials. The resulting stress concentrations are then used to estimate the tensile strength of the composite. The predicted results are compared with experimental values. In addition, a cumulative damage model for fatigue is presented. Modifications to the model are made to include the effects of variable amplitude loading. These modifications are based upon the use of remaining strength as a damage metric and the definition of an equivalent generalized time. The model is initially validated using results from the literature. Also, experimental data from APC-2 laminates and IM7/K3B laminates are used in the model. The use of such data for notched laminates requires the use of an effective hole size, which is calculated based upon strain distribution measurements. Measured remaining strengths after fatigue loading are compared with the predicted values for specimens fatigued at room temperature and 350°F (177°C). / Ph. D.

Composite materials are under consideration for the replacement of steel helical tendons in unbonded flexible pipes utilized by the offshore oil industry. Higher strength to weight ratios and increased corrosion resistance are the primary advantages of a composite material for this application. The current study focuses on the life prediction of a PPS/AS-4 carbon fiber composite proposed for the above employment. In order to accomplish this task, the properties of the material were experimentally characterized at varying temperatures, aging times and loadings. An analytic technique was developed to predict tensile rupture behavior from bend-compression rupture data. In comparison to tensile rupture tests, bend-compression rupture data collection are uncomplicated and efficient; thus, this technique effectively simplifies and accelerates the material characterization process. The service life model for the flexible pipe composite armor was constructed with MRLife, a well established performance simulation code for material systems developed by the Materials Response Group at Virginia Tech. In order to validate MRLife for the current material, experimental data are compared to life prediction results produced by the code. MRLife was then applied to predict the life of the flexible pipe composite armor in an ocean environment. This analysis takes into account the flexible pipe structure and the environmental and mechanical loading history of an ocean service location. Several parameter studies of a flexible pipe in a hypothetical environment were conducted. These analyses highlight certain loadings and conditions which are particularly detrimental to the life of the material. / Master of Science

As fiber reinforced polymer (FRP) structures find application in highway bridge structures, methodologies for describing their long-term performance under service loading will be a necessity for designers. The designer of FRP bridge structures is faced with out-of-plane damage and delamination at ply interfaces. The damage most often occurs between hybrid plys and dominates the life time response of a thick section FRP structure. The focus of this work is on the performance of the 20.3 cm (8 in) pultruded, hybrid double web I-beam structural shape. Experimental four-point bend fatigue results indicate that overall stiffness reduction of the structure is controlled by the degradation of the tensile flange. The loss of stiffness in the tensile flange results in the redistribution of the stresses and strains, until the initiation of failure by delamination in the compression flange. These observations become the basis of the assumptions used to develop an analytical life prediction model. In the model, the tensile flange stiffness is reduced based on coupon test data, and is used to determine the overall strength reduction of the beam in accordance the residual strength life prediction methodology. Delamination initiation is based on the out-of-plane stress sz at the free edge. The stresses are calculated using two different approximations, the Primitive Delamination Model and the Minimization of Complementary Energy. The model successfully describes the onset of delamination prior to fiber failure and suggests that out-of-plane failure controls the life of the structure. / Master of Science

Ausgangspunkt für die angestellten Untersuchungen bildet das Wissen um die unbefriedigende Treffsicherheit in der Lebensdauerabschätzung bei Belastungen mit ausgeprägten Mittelwertänderungen. Die Grundlage zur Weiterentwicklung theoretischer Lebensdauervorhersagemodelle auf Basis von Nenn- und örtlichen Beanspruchungen wurde mit experimentellen Untersuchungen an Werkstoff- und gekerbten Proben geschaffen, sowohl für einfache als auch gezielt abgeleitete, realitätsnahe komplexe Belastungs-Zeit-Abläufe. Es stehen zwei, ihrem zeitlich abhängigen Materialverhalten nach unterschiedliche Werkstoffe im Mittelpunkt der Betrachtungen. Ziel war es, die grundsätzliche zeitabhängige Reaktion der Werkstoffe auf die Belastung zu erkennen und diese Erkenntnisse mittels integra-len Parametern für die Verbesserung der Treffsicherheit der Lebensdauerabschätzung zu nutzen. Die Abschätzung der experimentell ermittelten Lebensdauern mit dem Nennspannungskonzept, die statistische Auswertung der Schädigungssummen und die Untersuchung der Korrelation von Schädigungssumme und zunächst frei wählbaren Parametern mittels multipler Regressionsanalyse führt zur Festlegung auf drei die Geometrie, den Werkstoff und die Belastung beschreibende Parameter. Bei beiden Werkstoffen wird durch Verwendung einer sogenannten korrigierten mit der Regressionsgleichung bestimmten Schädigungssumme eine Erhöhung der Treffsicherheit der Lebensdauervorhersage nachgewiesen. Den gesammelten Erfahrungen und Erkenntnissen entsprechend werden Empfehlungen zur Anwendung der behandelten Lebensdauerabschätzungsverfahren auf der Grundlage örtlicher Beanspruchungen gegeben. Mit den Versuchen innerhalb der Arbeit wurde eine experimentelle Basis geschaffen, die eine Weiterentwicklung von Ansätzen zur Berücksichtigung des transienten Materialverhaltens in Konzepten auf der Basis örtlicher Beanspruchungen ermöglicht.

Ausgangspunkt für die angestellten Untersuchungen bildet das Wissen um die unbefriedigende Treffsicherheit in der Lebensdauerabschätzung bei Belastungen mit ausgeprägten Mittelwertänderungen. Die Grundlage zur Weiterentwicklung theoretischer Lebensdauervorhersagemodelle auf Basis von Nenn- und örtlichen Beanspruchungen wurde mit experimentellen Untersuchungen an Werkstoff- und gekerbten Proben geschaffen, sowohl für einfache als auch gezielt abgeleitete, realitätsnahe komplexe Belastungs-Zeit-Abläufe. Es stehen zwei, ihrem zeitlich abhängigen Materialverhalten nach unterschiedliche Werkstoffe im Mittelpunkt der Betrachtungen. Ziel war es, die grundsätzliche zeitabhängige Reaktion der Werkstoffe auf die Belastung zu erkennen und diese Erkenntnisse mittels integra-len Parametern für die Verbesserung der Treffsicherheit der Lebensdauerabschätzung zu nutzen. Die Abschätzung der experimentell ermittelten Lebensdauern mit dem Nennspannungskonzept, die statistische Auswertung der Schädigungssummen und die Untersuchung der Korrelation von Schädigungssumme und zunächst frei wählbaren Parametern mittels multipler Regressionsanalyse führt zur Festlegung auf drei die Geometrie, den Werkstoff und die Belastung beschreibende Parameter. Bei beiden Werkstoffen wird durch Verwendung einer sogenannten korrigierten mit der Regressionsgleichung bestimmten Schädigungssumme eine Erhöhung der Treffsicherheit der Lebensdauervorhersage nachgewiesen. Den gesammelten Erfahrungen und Erkenntnissen entsprechend werden Empfehlungen zur Anwendung der behandelten Lebensdauerabschätzungsverfahren auf der Grundlage örtlicher Beanspruchungen gegeben. Mit den Versuchen innerhalb der Arbeit wurde eine experimentelle Basis geschaffen, die eine Weiterentwicklung von Ansätzen zur Berücksichtigung des transienten Materialverhaltens in Konzepten auf der Basis örtlicher Beanspruchungen ermöglicht.

<div>Additive manufacturing (AM) or 3D printing has gained significant advancement in recent years. However the potential of 3D printed metals still has not been fully explored. A main reason is the lack of accurate knowledge of the load capacity of 3D printed metals, such as fatigue behavior under cyclic load conditions, which is still poorly understood as compared with the conventional wrought counterpart.</div><div><br></div><div>The goal of the thesis is to advance the knowledge of fatigue behavior of 15-5 PH stainless steel manufactured through laser powder bed fusion process. To achieve the goal, a combined numerical and experimental study is carried out. First, using a rotary fatigue testing experiment, the fatigue life of the 15-5 PH stainless steel is measured. The strain life curve shows that the numbers of the reversals to failure increase from 13,403 to 46,760 as the applied strain magnitudes decrease from 0.214\% from 0.132\%, respectively. The micro-structure analysis shows that predominantly brittle fracture is presented on the fractured surface. Second, a finite element model based on cyclic plasticity including the damage model is developed to predict the fatigue life. The model is calibrated with two cases: one is the fatigue life of 3D printed 17-4 stainless steel under constant amplitude strain load using the direct cyclic method, and the other one is the cyclic behavior of Alloy 617 under multi-amplitude strain loads using the static analysis method. Both validation models show a good correlation with the literature experimental data. Finally, after the validation, the finite element model is applied to the 15-5 PH stainless steel. Using the direct cyclic method, the model predicts the fatigue life of 15-5 PH stainless steel under constant amplitude strain. The extension of the prediction curve matches well with the previously measured experimental results, following the combined Coffin-Manson Basquin Law. Under multi-amplitude strain, the kinematic hardening evolution parameter is incorporated into the model. The model is capable to capture the stresses at varied strain amplitudes. Higher stresses are predicted when strain amplitudes are increased. The model presented in the work can be used to design reliable 3D printed metals under cyclic loading conditions.</div>

This thesis was concerned on the investigation of mechanical properties of centrally notched and unnotched AS-4/PEEK (APC-2) composite laminates due to static tensile and tension-tension (T-T) fatigue tests empirically and systematically. Then, statistical analyses were used to determine and quantify the significant thermomechanical variables that influence the durability/life of the composite laminates. Typical laminates were made from sixteen prepregs of APC-2 and manufactured by a modified curing process. After drilling one hole with various diameters in the center of the samples respectively, the lay-ups were conducted on tension fracture and T-T fatigue test at different temperatures. From the parametric study we achieved the important results as follows. The cross-ply laminate possesses the higher ultimate strength, fatigue strength and longitudinal stiffness than those of the quasi-isotropic at the same temperature. Notch effect decays the laminate strength seriously, but changes the stiffness irregularly. As test temperature rising both strength and stiffness of lay-ups degrade significantly. Combining both effects of notch and temperature under severe environmental condition, it is found the cross-ply laminate possesses more resistance than that of the quasi-isotropic to cyclic loading. However, the quasi-isotropic laminate is more capable of sustaining the original strength than that of the cross-ply. Finally, the multiple regression analysis results showed that the hygrothermal environmental effects and cyclic loading were decoupled for APC-2 composite system. A semi-empirical model, reliably set up after the said programs, predicts conservative values, and should be adequate for use in preliminary designs. That is the main contribution in this study. Also, for the purposes of design and application, the predicted models efficiently treat experimental data instead of conventional curve-fitting methods.

During the operations of an agricultural tractor, front axle and front axle support encounter the worst load conditions of the whole tractor. If the design of these components is not verified by systematic engineering approach, the customers could face with sudden failures. Erkunt Agricultural Machinery Company, which is located in Ankara, has newly designed and manufactured the front axle support of its agricultural tractors. In this study, the design of 2WD (Wheel Drive) Erkunt Bereket Agricultural Tractor&amp / #8217 / s front axle support has been verified by developing a verification method, which involves testing the tractor on a special test track and field and together with the computer aided engineering analysis, in order to prevent such failures in the lifetime of the tractor. For this purpose, a strain gage data acquisition system has been designed to measure the strain values on the component, while the tractor is operating on a test track and field. The locations of the strain gages have been determined by simulating the selected design load cases through finite element method. Measuring the maximum strains for the front axle support that have been experienced by the tractor while operating, the stress values have been calculated and the design safety has been investigated considering the material&amp / #8217 / s tensile strength. Secondly, the fatigue life of the component regarding the acquired strain data has been predicted. These processes have led the company to verify the design of the front axle support.