The fatigue of materials and structures is a subject that has been under investigation for almost 160 years; yet reliable fatigue life predictions are still more of an empirical art than a science. The traditional safe-life approach to fatigue design is based upon the total time to failure of a virtually defect free component. This approach is heavily reliant on the use of safety factors and empirical equations, and therefore much scatter in the fatigue life predictions is normally observed. Furthermore, the safe-life approach is unsuitable for many important applications such as aircraft, pressure vessels, welded structures, and microelectronic devices. In these applications the existence of initial defects is practically unavoidable and the time of propagation from an initial defect to final failure is comparable with the total life of the component. In the early 1970’s, the aircraft industry pioneered a new approach for the analysis of fatigue crack growth, known as damage tolerant design. This approach utilises fracture mechanics principles to consider the propagation of fatigue cracks from an initial crack length until final fracture, or a critical crack length, is reached. Since the first implementation of damage tolerant design, much research and development has been undertaken. In particular, theoretical and experimental fracture mechanics techniques have been utilised for the investigation of a wide variety of fatigue crack growth phenomena. One such example is the retardation and acceleration in crack growth rate caused by spike overloads or underloads. It is generally accepted, however, that the current level of understanding of fatigue crack growth phenomena and the adequacy of fatigue life prediction techniques are still far from satisfactory. This thesis theoretically investigates various non-linear individual and interaction phenomena associated with fatigue crack growth. Specifically, the effect of plate thickness on crack growth under constant amplitude loading, crack growth retardation due to an overload cycle, and small crack growth from sharp notches are considered. A new semianalytical method is developed for the investigations, which utilises the distributed dislocation technique and the well-known concept of plasticity-induced crack closure. The effects of plate thickness are included through the use of first-order plate theory and a fundamental solution for an edge dislocation in plate of arbitrary thickness. Numerical results are obtained via the application of Gauss-Chebyshev quadrature and an iterative procedure. The developed methods are verified against previously published theoretical and experimental data. The elastic out-of-plane stress and displacement fields are first investigated using the developed method and are found to be in very good agreement with past experimental results and finite element simulations. Crack tip plasticity is then introduced by way of a strip-yield model. The effects of thickness on the crack tip plasticity zone and plasticity-induced crack closure are studied for both small and large-scale yielding conditions. It is shown that, in general, an increase in plate thickness will lead to a reduction in the extent of the plasticity and associated crack closure, and therefore an increase in the crack growth rates. This observation is in agreement with many findings of past experimental and theoretical studies. An incremental crack growth scheme is implemented into the developed method to allow for the investigation of variable amplitude loading and small fatigue crack growth. The case of a single tensile overload is first investigated for a range of overload ratios and plate thicknesses. This situation is of practical importance as an overload cycle can significantly increase the service life of a cracked component by temporarily retarding the crack growth. Next to be studied is growth of physically small cracks from sharp notches. Fatigue cracks typically initiate from stress concentrations, such as notches, and can grow at rates higher than as predicted for a long established crack. This can lead to non-conservative estimates for the total fatigue life of a structural component. For both the overload and small crack cases, the present theoretical predictions correlate well with past experimental results for a range of materials. Furthermore, trends observed in the experiments match those of the predictions and can be readily explained through use of crack closure arguments. This thesis is presented in the form of a collection of published or submitted journal articles that are the result of research by the author. These nine articles have been chosen to best demonstrate the development and application of the new theoretical techniques. Additional background information and an introduction into the chosen field of research are provided in order to establish the context and significance of this work. / http://proxy.library.adelaide.edu.au/login?url= http://library.adelaide.edu.au/cgi-bin/Pwebrecon.cgi?BBID=1349588 / Thesis (Ph.D.) - University of Adelaide, School of Mechanical Engineering, 2008

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Nondestructive evaluation techniques were employed to fully characterize three 2.3L camshafts tested in an engine simulator for an equivalent of 100,000 miles. Optical microscopy, acoustic microscopy (SAM), and profilometry were used to characterize wear and fatigue, crack depth, and surface roughness, respectively. Results show cracking to occur mainly in the opening ramp of the most abusively ground cam lobes. No clear evidence was found for subsurface cracking at depths as great as 200 μm from the lobe's surface. Profilometry results show no evidence of any major tribological effect due to the sliding friction of the follower. Fractography studies show a difference between fracture surfaces among the cracks examined; straight cracks exhibit features resembling fatigue propagation, while fracture surfaces from pitted cracks show a more brittle behavior. Small grinding cracks (approximately 300 μm in length) were found in the opening ramps of the most abusively ground lobes prior to testing. Knoop and Nanoindenter microhardness indicate a near-surface rehardening for the most abusively ground lobe (confirmed by metallography), and temper burn for the remaining lobes. X-ray residual stress results made in the opening ramp of the tested lobes show evidence of residual stress relaxation. X-ray line width data as a function of depth does not correlate with residual stress. / Master of Science

Die Theodor-Heuss-Brücke in Düsseldorf ist die älteste Schrägseilbrücke Deutschlands. Seit ihrer Fertigstellung 1957 ist die Verkehrsbelastung stetig gestiegen. Wie bei vielen anderen Brücken mit orthotropen Fahrbahnplatten führte dies mit der Zeit zu Schäden. Aufgrund von Ermüdungsdefiziten, die eine Nachrechnung der Brücke zeigt, wurde ein Monitoringsystem aus über 80 Sensoren am Bauwerk installiert und über ein Jahr betrieben. Der Beitrag zeigt die Entwicklung des Monitoringkonzepts, seine Umsetzung und die Auswertung als Grundlage einer messdatenbasierten Lebensdauerprognose. Die Messdaten ermöglichen eine genauere Prognose der Restlebensdauer. Grundlage der Auswertungen ist ein messtechnisch validiertes numerisches Berechnungsmodell. Durch Verknüpfung der Messdaten mit den numerischen Berechnungen und historischen Verkehrszählungen werden Belastungshistorien und Ermüdungsschädigungen abgeleitet. Zudem leiten sich aus dem Monitoring weitere Erkenntnisse zum Tragverhalten ab, wie die temperaturabhängige mittragende Wirkung der Fahrbahn im Winter oder der dominierende Einfluss von Achslasten anstelle von Gesamtgewichten der Fahrzeuge. Die Auswertungen zeigen, dass für die meisten Tragelemente und Anschlüsse eine deutliche Verbesserung gegenüber der rechnerischen Prognose erreicht werden kann. Das Monitoring ist ein Baustein zum Erhalt historischer Bauwerke und erhöht die Genauigkeit in der Bewertung der Tragwerke.

<p>Computer simulation is widely used to predict the fatigue life of engine oil coolers that fail under pressure cycles. The objective of this study is to develop a practical simulation methodology to accurately predict the fatigue life of an engine oil cooler undergoing pressure cycle testing. The study focuses on two key areas of the simulation process. First, it investigates the effect of using linear and nonlinear FEA to provide stress or strain results for subsequent fatigue analysis. Second, due to lack of fatigue material properties for the aluminum coreplate material, approximate material models derived from tensile properties are used in fatigue life calculation. The study has attempted to find out the material model that gives the best correlation in life prediction. The life prediction correlation based on the Seeger, the Modified Universal Slopes and the Modified Mitchell models, together with the Modified Universal Slopes-Al model, are evaluated.</p> <p>It is concluded that the Modified Universal Slopes-Al model, which is a re-assessment of the Modified Universal Slopes model based on the fatigue data of 16 wrought aluminum alloys, gives the best life prediction for simulations using either linear or nonlinear approaches. Life prediction using nonlinear finite element results together with this approximate material model is recommended to be the best approach. On the other hand, a simple and quick linear analysis, followed by fatigue life calculation using this material model still gives life estimates with an acceptable level of confidence.</p> <p>In the last part of the study, the life prediction performance using different strain-life criteria, together with either Morrow or Smith-Watson-Topper (SWT) mean stress correction, are evaluated. It is found that SWT mean stress correction method is worse than that of Morrow in EOC fatigue life prediction in both linear and nonlinear approaches. Using the principal strain criterion with SWT mean stress correction gives conservative life prediction in both approaches. On the other hand, there are no significant differences in life prediction correlations using the principal strain, the Brown-Miller combined strain and the maximum shear strain strain-life criteria, with Morrow mean stress correction. As such, the Brown-Miller combined strain criterion with Morrow mean stress correction is the recommended strain-life model used in fatigue life calculation.</p> / Master of Applied Science (MASc)

Polymer matrix composites (PMC's) are now being used more and more extensively and over wider ranges of service conditions. Large changes in pressure, chemical environment or temperature influence the mechanical response of such composites. In the present effort, we focus on temperature, a parameter of primary interest in almost all engineering applications. In order to design composite structures without having to perform extensive experiments (virtual design), the necessity of establishing theoretical models that relate the macroscopic response of the structure to the microscopic properties of the constituents arises. In the first part of the present work, a new stiffness versus temperature model is established. The model is validated using data from the literature. The influence of the different polymer's properties (Molecular weight, crystallinity, and filler content) on the model are studied by performing experiments on different grades of four polymers PMMA, PEEK, PPS, and PB. This statistical model is proven to be applicable to very different polymers (elastomers, thermoplastics, crystalline, amorphous, cross-linked, linear, filled, unfilledâ ¦) over wide temperature ranges (from the glassy state to the flow region). The most attractive feature of the proposed model is the capability to enable a description of the polymer's mechanical behavior within and across the property transition regions. In order to validate the feasibility of using the model to predict the mechanical response of polymer matrix composites, the stiffness-temperature model is used in various micromechanical models (rule of mixtures, compression models for the life prediction of unidirectional PMC's in end-loaded bendingâ ¦). The model is also inserted in the MRLife prediction code to predict the remaining strength and life of unidirectional PMC's in fatigue bending. End-loaded fatigue experiments were performed. A good correlation between theoretical and experimental results is observed. Finally, the model is used in the Classical Lamination Theory; some laminates were found to exhibit stress reversals with temperature and behaved like thermally activated mechanical switches. / Ph. D.

To achieve satisfactory levels of strength, fracture toughness, and reliability for man-rated systems such as jet engines, fiber reinforced ceramic matrix composites are needed. An elevated temperature axial testing system is developed to investigate and characterize fatigue behavior of Nicalon fiber reinforced enhanced silicon carbide matrix. composites at 1800 of under fully reversed cyclic loading. Notch effect on quasi-static tensile response is also considered. Quasi-static and fatigue damage mechanisms and failure modes are examined using various specimen geometries, load levels, fatigue ratios, and laminates stacking sequences by employing a number of NDE techniques. Issues such as damage tolerance and durability are addressed by conducting interrupted fatigue tests at various stages of life for different load levels. Results are compared to the predictions of remaining strength and life, obtained using a performance simulation code. Initial results indicate existence of a threshold stress value which limits the use of the material system. / Ph. D.

There is an intense, worldwide effort to develop durable lithium ion batteries with high energy and power densities for a wide range of applications, including electric and hybrid electric vehicles. For improvement of battery technology understanding the capacity fading mechanism in batteries is of utmost importance. Novel electrode material and improved electrode designs are needed for high energy- high power batteries with less capacity fading. Furthermore, for applications such as automotive applications, precise cycle-life prediction of batteries is necessary. One of the critical challenges in advancing lithium ion battery technologies is fracture and decrepitation of the electrodes as a result of lithium diffusion during charging and discharging operations. When lithium is inserted in either the positive or negative electrode, there is a volume change associated with insertion or de-insertion. Diffusion-induced stresses (DISs) can therefore cause the nucleation and growth of cracks, leading to mechanical degradation of the batteries. With different mathematical models we studied the behavior of diffusion induces stresses and effects of electrode shape, size, concentration dependent material properties, pre-existing cracks, phase transformations, operating conditions etc. on the diffusion induced stresses. Thus we develop tools to guide the design of the electrode material with better mechanical stability for durable batteries. Along with mechanical degradation, chemical degradation of batteries also plays an important role in deciding battery cycle life. The instability of commonly employed electrolytes results in solid electrolyte interphase (SEI) formation. Although SEI formation contributes to irreversible capacity loss, the SEI layer is necessary, as it passivates the electrode-electrolyte interface from further solvent decomposition. SEI layer and diffusion induced stresses are inter-dependent and affect each-other. We study coupled chemical-mechanical degradation of electrode materials to understand the capacity fading of the battery with cycling. With the understanding of chemical and mechanical degradation, we develop a simple phenomenological model to predict battery life. On the experimental part we come up with a novel concept of using liquid metal alloy as a self-healing battery electrode. We develop a method to prepare thin film liquid gallium electrode on a conductive substrate. This enabled us to perform a series of electrochemical and characterization experiments which certify that liquid electrode undergo liquid-solid-liquid transition and thus self-heals the cracks formed during de-insertion. Thus the mechanical degradation can be avoided. We also perform ab-initio calculations to understand the equilibrium potential of various lithium-gallium phases.

Microstructural features at different scales affect the constitutive stress-strain response and the fatigue crack initiation life in Ni-base superalloys. While numerous efforts have been made in the past to experimentally characterize the effects of these features on the stress-strain response and/or the crack initiation life, there is a significant variability in the data with sometimes contradictory conclusions, in addition to the substantial costs involved in experimental testing. Computational techniques can be useful tools to better understand these effects since they are relatively inexpensive and are not restricted by the limitations in processing techniques. The effect of microstructure on the stress-strain response and the variability in fatigue life were analyzed using two Ni-base superalloys; DS GTD111 which is a directionally solidified Ni-base superalloy, and IN100 which is a polycrystalline Ni-base superalloy. Physically-based constitutive models were formulated and implemented as user material subroutines in ABAQUS using the single crystal plasticity framework which can predict the material stress-strain response with the microstructure-dependence embedded into them. The model parameters were calibrated using experimental cyclic stress-strain histories. A computational exercise was employed to quantify the influence of idealized microstructural variables on the fatigue crack initiation life. Understanding was sought regarding the most significant microstructure features using explicit modeling of the microstructure with the aim to predict the variability in fatigue crack initiation life and to guide material design for fatigue resistant microstructures. Lastly, it is noted that crystal plasticity models are often too computationally intensive if the objective is to model the macroscopic behavior of a textured or randomly oriented 3-D polycrystal in an engineering component. Homogenized constitutive models were formulated and implemented as user material subroutines in ABAQUS, which can capture the macroscale stress-strain response in both DS GTD111 and IN100. Even though the study was conducted on two specific Ni-base superalloys; DS GTD111 and IN100, the objective was to develop generic frameworks which should also be applicable to other alloy systems.