Orientador: Marcelino Pereira do Nascimento / Banca: José Elias Tomazini / Banca: Carlos Antonio Reis Pereira Baptista / Resumo: Tubos de aço utilizados na exploração e prospecção de petróleo e gás natural estão sujeitos a carregamentos dinâmicos durante o transporte (transit fatigue) e também quando em serviço. Por este motivo é imperativo que os tubos utilizados apresentem excelente integridade estrutural a fim de evitar a ocorrência de falhas prematuras devido à fadiga. Contudo, como o processo de fabricação HFIW, largamente utilizado pela indústria, envolve conformação mecânica seguida de soldagem, defeitos estarão inerentemente presentes nos tubos, notadamente uma interface entre as bordas das chapas soldadas. No presente trabalho foi investigado como a junta soldada de tubos de aço API 5CT N80 tipo Q pode contribuir para redução da vida em fadiga e como o processo como um todo pode levar a anisotropia mecânica dos tubos. Para preservar ao máximo as características originais dos tubos foram realizados ensaios de fadiga axiais utilizando corpos de prova não previstos pelas normas técnicas vigentes, com espessuras iguais as das paredes dos tubos dos quais foram retirados. Foi também desenvolvido e testado um dispositivo para realização de ensaios de fadiga utilizando trechos de tubo, o qual mostrou potencial para a realização de ensaios futuros. Os resultados dos ensaios axiais (realizados de modo a comparar a região da junta soldada como uma posição a 90° dela) indicaram que a junta soldada pode agir como um tipo de concentrador de tensões, contribuindo para a diminuição da resistência à fadiga dos tubos de maneira inversamente proporcional à carga aplicada. Também foi observado que defeitos resultantes do processo de fabricação (muitos deles macroscópicos) podem atuar como pontos para a nucleação de trincas de fadiga e que, portanto, não deveriam estar presentes no produto final. Ensaios de tração, ... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Steel pipes, used in the oil and gas industry in prospection and exploration activities, are often subjected to cyclic loading during their transportation (transit fatigue) and during their service life. Considering this, these steel pipes must have excellent structural integrity in order to avoid premature failure by fatigue mechanisms. However, the HFIW manufacturing process, widely used by the industry, involves mechanical forming and welding and, therefore, defects are inherently present in the finished products, remarkably an interface between the edges of the steel sheets that are welded into tubes. In this work it has been investigated how the HFIW manufacturing process can reduce the fatigue resistance of API 5CT N80 type Q steel tubes and lead to a mechanical anisotropy of the finished product. To keep the specimens characteristics closer to the real steel pipes, axial fatigue tests have been performed with round specimens which had their thickness equal to the thickness of the walls of the pipes from which they had been taken from. It has been developed also a device and a method to test small length sections of steel tubes, which have shown potential to be used in the future as a new methodology for the study of fatigue in steel pipes. The results of the axial fatigue tests (carried out to compare the welded joint to a position situated 90° from it) indicate that the welded joint can act as a stress raiser and contributes to reduce the fatigue resistance of the steel pipes, in a inversely proportional relationship with the increasing of the applied dynamic loading. It has been observed also that some defects, which result from the manufacturing process, can act as points for the nucleation of fatigue cracks and, for this, they should not be present in the manufactured product. Tensile tests, metallographic analysis, ... (Complete abstract click electronic access below) / Mestre

The nature and scope of this thesis can be divided into four categories: • FORMING PARAMETERS • Identification of various laser forming parameters in order to produce specimens of similar dimension (radius of curvature). • TEMPERATURE AND MICROSTRUCTURE • To study the effect of maximum temperature reached during the forming operation on the microstructure of the various specimens. • FATIGUE LIFE • Compare the fatigue life of the specimens produced by various laser parameters to that of the original material, and also the fatigue life of mechanical formed specimens. • RESIDUAL STRESS PROFILE Determine if the laser forming process induces detrimental residual stress magnitudes in the specimens. The main objective of this thesis was to gain an understanding of the way in which laser forming affects the fatigue performance and residual stress magnitude / distribution of dual phase steel. Although lasers have been used successfully in various manufacturing processes (welding, cutting, marking, etc.), little information is available on the influence of laser forming on many automotive alloys such as dual phase steel. The first part of the work involved a literature review of the process and factors affecting the laser forming process. It became clear from the literature overview that laser forming of sheet material thicker than 1mm is complex in nature. The variables that can influence the process are complicated and their interaction with each other is not easily controlled. The main parameters that were thus controlled in this study are as follows: • Laser power (P) • Laser head travel speed (v) • Laser beam size (mm) The chapters that follow the literature review, deals with the laser forming process of dual phase steel and the production of fatigue specimens using various laser parameters. It was found that the following laser parameters resulted in specimens with approximately the same radius of curvature: Laser power KW Beam diameter mm Interval spacing % Overlap Scanning velocity m/min Line Energy J/m 5 20 10 50 2,5 2000 3,1 14 10,5 25 2 1550 1,5 7,5 7,5 0 1,2 1250 From the results obtained from fatigue testing specimens produced with the above settings, it is clear that the laser forming process has the potential to be employed as a production stage in the manufacture of wheel centre discs while maintaining adequate fatigue strength. Large beam diameters which cause heat penetration through the thickness of the specimen and hence microstructure breakdown should be avoided, since it was shown that these specimens exhibited impaired mechanical properties than those produced with a smaller laser beam diameter. The microstructural changes observed during the forming process needs to be considered since the mechanical properties of the material changes with a change in microstructure. A dramatic change in microstructure was observed; therefore it is of crucial importance that microstructural evaluation plays an important part in deciding optimum laser parameters for the forming process of ferrous alloys. During residual stress analysis, trends were observed between measurements taken at the same location of the samples; regardless whether measurements were taken on the laser irradiated side or the reverse side of the specimen. The only difference was the magnitude of the relieved residual stress. In most cases the obtained relieved residual stress was much smaller in magnitude than that of the original plate (in the bulk of the material). The surface indicated a slight tensile residual stress for most samples evaluated. A good correlation in distribution profile was obtained between microhardness and relieved residual stress distribution at the ‘middle of sample’ location. This indicates that an increase in hardness indicates an increase in residual stress magnitude for the laser formed specimens. In conclusion, this research has proved that it is possible to deform metal plate of a 3,5mm thickness with a CO2 laser system. The research also established the effect of process parameters on the final product’s shape/bend angle and characterised the effect of the laser forming process on the material’s mechanical properties and structural integrity.

Forming is the fastest way of changing the shape of a piece of metal. It is the most economical process to use for high-volume mass production when the shape of a part is such that it can be made by one of the forming operations

A study has been carried out to investigate the growth and closure behavior of short cracks in 2024-T351 aluminum alloy and four different conditions of 4340 steel using through thickness cracks of straight fronts. The experiments were carried out to study the influence of stress level, stress ratio, yield strength and prior austenitic grain A sizes in notched and unnotched specimens. The stereoimaging technique was developed and adapted to obtain crack closing and opening points, and also near tip displacement fields. Experimental results are presented with a general discussion. It was found that long cracks showed good correlation when analyzed in terms of effective stress intensity range. However,correlations were poor for short cracks. lt was found that short cracks show less closure behavior than long cracks. The estimates of initial crack lengths based on linear elastic data were made. These estimates differed significantly from the actual initial crack lengths for completely reversed cycling tests. Suggestions have been made to the equivalent initial flaw size approach and conclusions have been drawn. / Ph. D.

The oil tankers that operate on the Trans-Alaska Pipeline Service (TAPS) route have exhibited a large number of structural fatigue cracks. These cracks can be attributed to the increase in use of high strength steel in tanker construction and to the harsh operating environment in the Gulf of Alaska. In response to the TAPS fatigue problem, this project examines the topic of preliminary design for fatigue resistance. The TAPS tankers have previously been the target of several studies on the subject of fatigue cracking. Most of these studies have concentrated on reducing the costs and risks involved with operating the current tanker fleet. Preliminary design, however, is oriented at reducing the fatigue risk in future tanker designs. To that end, the design method outlined within concentrates on the level of analysis that is appropriate for preliminary design. The design method consists of four steps: the specification of a wave environment, generation of a hydrodynamic model and subsequent wave loads, evaluation of cyclic stresses and an assessment of fatigue damage. A series of example calculations that is typical of preliminary design has been performed for one of the TAPS tanker classes. These calculations employed Buckley's climatic wave spectra, a 3-dimensional panel based hydrodynamics package by Lin and a Miner's rule fatigue assessment based on the S-N curves of the British Welding Institute. The example calculations yield two important results. First, relatively inexpensive methods can yie1d important and accurate fatigue results; for a side shell longitudinal at the water line the example calculations predict a fatigue life of approximately 3 operating years. This corresponds quite well to the published inspection data and obviously represents insufficient fatigue life. Second, local panel pressures can have a significant contribution to, and even dominate, total fatigue damage in the side shell. This contrasts with conventional fatigue studies of ship hulls which focus on global loads; i.e., hull girder bending. / Ph. D.

Torsional fatigue tests were conducted on 4370 steel oil quenched and tempered at 1000° F in (l) the uncharged state, (2) the hydrogen charged state, and (3) in a hydrogen environment. The tests were conducted on both smooth (K_t = l.l) and V-notch (K_t = 3.8) test specimens. A statistical analysis conducted at the 99% confidence limit for the smooth test specimens indicated that precharging with hydrogen increased the fatigue life of the material and also the fracture surface of the test specimens changed from a circumferential crack to a 45° diagonal crack. At a 90% confidence limit, charging with hydrogen did not affect the fatigue life of the V-notched specimens. At a 99% confidence limit for both the smooth and V-notched test specimens, testing in a hydrogen environment increased the fatigue life of the material. Bending fatigue tests were also conducted on the same material and the results indicated that charging with hydrogen decreased fatigue life of smooth test specimens (K_t = l.l) but increased the fatigue life for V-notched specimens (K_t = 2.4 and 3.8). / Ph. D.

The percentage of reduction in fatigue limit of AISI 4340 steel due to one chromium plating was 21 percent, based on the fatigue limit of unplated AISI 4340 steel. / Master of Science

Weathering steel has been a primary construction material for bridges in the United States. Notches caused by corrosion are observed on the flange of steel I-beams. These notches reduce the cross section area of the structure and are threats to bridge safety. A606-04 Type 4 cold rolled weathering steel samples were studied in this thesis to understand the effect of notches that caused by corrosion. Weathering steel samples were in the shape of plates, which simulated flange of I-beams. The plate samples were notched across their surfaces by applying electrical current through an electrochemical circuit composed of an anode, a cathode and electrolyte. Sixteen samples were notched and cut into appropriate shape for fatigue testing. S-N (Stress-Number of cycles to failure) diagram established from fatigue data indicated that the fatigue strength decreased below AASHTO category B. Weibull analysis was also performed to understand the reliability distribution. / Includes bibliography. / Thesis (M.S.)--Florida Atlantic University, 2014. / FAU Electronic Theses and Dissertations Collection

Thesis (Sc.D.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1981. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Includes bibliographical references. / by Subramanian Suresh. / Sc.D.

Orientador: Tomaz Manabu Hashimoto / Coorientador: Olivério Moreira de Macedo Silva / Banca: Peterson Luiz Ferrandini / Banca: Kátia Regina Cardoso / Resumo: Este trabalho teve como objetivo estudar o efeito do jateamento e a diferença de três modos distintos de jateamento no comportamento em fadiga de molas de aço SAE 9254. Os seguintes métodos foram avaliados: molas sem jateamento; molas jateadas no processo P1 (jateamento a frio seguido de jateamento com a mola comprimida); molas jateadas no processo P2 (jateamento a quente seguido de jateamento com a mola comprimida) e molas jateadas no processo P3 (jateamento a quente seguido de jateamento com granalha fina). Foi avaliado o desempenho em fadiga das molas em três níveis diferentes de tensão aplicada, sendo que as molas para cada processo em estudo foram extraídas de um mesmo lote de arame. Foi observado que o método de jateamento P3 apresentou o melhor desempenho seguido do método de jateamento P2 e posteriormente do método convencional e o pior resultado foi das molas sem jateamento. Os resultados desta dissertação mostram que o jateamento pode aumentar de 3560 % a 15216 % a vida em fadiga das molas, dependendo do método de jateamento empregado, essa diferença no resultado do teste de fadiga é resultado do estado de tensões residuais compressivas na superfície das molas. A análise da fratura mostrou que o método de jateamento também influenciou no modo de falha das molas / Abstract: The propose of this dissertation is to study the effect of shot peening method, comparing three different shot peening methods for suspension springs manufacture, it was performed fatigue test on the springs produced with steel grade SAE 9254. The following shot peening methods were evaluated: springs without shot peening; springs produced at P1 shot peening method (shot peening at ambient temperature followed by stress peening); springs produced at shot peening P2 method (hot shot peening followed by stress peening) and springs produced at shot peening P3 method (hot shot peening followed by shot peening with fine shot size). The fatigue tests were performed in three different stress levels, whereas all the springs used at this study are from the same lot. The P3 shot peening method, had a better fatigue life performance, followed by P2 shot peening method, the third better performance was the P1 shot peening method, and the worst results was the springs without shot peening process. It was concluded that the different results in fatigue life is due to residual stress condition at spring surface. The analysis performed at fracture origin showed that the springs broke due to different reason / Mestre