Dans le domaine aéronautique, la détection des défauts sur structures composites sefait lors des phases de maintenance. Celles-ci sont prévues de manière à détecter lesdéfauts avant que ceux-ci ne deviennent critiques pour la tenue des structures en service.L’optimisation des intervalles de maintenance représente donc un fort intérêt que ce soitau niveau financier ou opérationnel. Les dommages des structures composites sont aujourd’hui traités par la non-propagationdes défauts : lorsque ceux-ci apparaissent et qu’ils sont détectés, les pièces sont immédiatementréparées ou remplacées. Afin d’améliorer ces intervalles de maintenance, lecomportement des défauts soumis aux spectres de charges aéronautique nécessite d’êtrecaractérisé. Cela permettrait une transition vers une philosophie de tolérance aux dommages,en définissant des phases de propagation non-critique pour la tenue mécanique desstructures. Dans ce contexte, la propagation de délaminage est étudiée sous chargement de fatigue.En mode I de propagation, les effets de la fréquence de sollicitation et du rapport de chargesur la propagation de délaminage en fatigue sont déterminés. Ceux-ci amorcent l’étudede la propagation de délaminage sous spectre de charges à niveau variable. Les effets del’historique de chargement sont mis en évidence. En mode II de propagation, les effets de la fréquence de sollicitation sur la propagationde délaminage sont abordés pour quatre matériaux à l’aide d’un montage d’essaisvibratoires dédié. Une analyse thermique des essais est également conduite. De plus, leseffets du rapport de charge sont déterminés pour ce mode de propagation. / The detection of damage in composite aeronautical structures is carried out duringmaintenance phases. These operations are planned so that damage is detected beforereaching any critical size for the in-service structures. The optimization of maintenanceintervals is therefore of great interest both financially and operationally. Damage in composites structures is currently dealt through the no-growth approach :when damage appears and is detected, the affected parts are immediately repaired orreplaced. In order to improve the maintenance schedule, the behaviour of defects subjectedto aeronautical load spectra needs to be characterized. This would enable a transitiontowards a damage tolerance philosophy with a slow-growth approach by defining noncriticalpropagation phases for the mechanical strength of structures. In this context, delamination propagation under fatigue loading is studied. The effectsof loading frequency and load ratio on fatigue delamination propagation are determinedin mode I. Then a study of delamination propagation under complex load spectra isconducted for blocks at different loading amplitudes. Effects of the loading history arehighlighted. For the propagation in mode II, loading frequency effects on delamination propagationare investigated for four different composite materials using a dedicated vibration testingdevice. A thermal analysis is also conducted during high frequency tests. In addition, loadratio effects are determined for this propagation mode.

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The design of any mechanical components requires an understanding of the general statical, dynamical and environmental conditions where the components will be operating to give a satisfactory results in terms of performance and endurance. The premature failure of any components is undesirable and potentially catastrophic, therefore predictions on performances and endurances of components to proceed with repair or substitution is vital to the stability of the structure where the component is inserted. The capability of a component of withstanding fatigue loading conditions during service is called fatigue life and the designed predictions can be conservative or non conservative. Improvements to a strain based approach to fatigue were obtained in this study, studying the effects of mean stresses on fatigue life and investigating cyclic mean stress relaxation of two aluminum alloys, 7075-T6511 and 7249-T76511, used in structural aircraft applications. The two aluminum alloys were tested and their fatigue behavior characterized. The project, entirely funded by NAVAIR, Naval Air Systems Command, and jointly coordinated with TDA, Technical Data Analysis Inc., was aimed to obtain fatigue data for both aluminum alloys, with particular interest in 7249 alloy because of its enhanced corrosion resistance, and to give guidelines for improving the performances of FAMS, Fatigue Analysis of Metallic Structures, a life prediction software from the point of view of both mean stress effects and mean stress relaxation. The sensitivity of engineering materials to mean stresses is of high relevance in a strain based fatigue approach. The performance of the most common models used to calculate mean stress correction factors was studied for the two aluminum alloys 7075 and 7249 to give guidelines in the use of those for life predictions. Not only mean stresses have a high influence on fatigue life, but they are also subjected to transient cyclic behaviors. The following study considered both an empirical approach and a plasticity theory approach to simulate and include these transient effects in life calculations. Results will give valid directions to a successful modification of FAMS like any other life calculation software to include in the picture transient phenomena. / Ph. D.

Adhesive bonding is one of the most attractive joining techniques for any structural application, including high profile examples in the aerospace, automotive, marine construction and electrical industries. Advantages of adhesive bonding include; superior fatigue performance, better stress distribution and higher stiffness than conventional joining techniques. When the design of bonded joints is considered, fatigue is of critical importance in most structural applications. There are two main issues that are of importance; a) in-service damage characterisation during fatigue loading and, b) lifetime prediction under both constant and variable amplitude fatigue loading. If fatigue damage characterisation is considered, there has been some work to characterise damage in-situ using the backface strain (BFS) measurement technique, however, there has been little investigation of the effects of different types of fatigue behaviour under different types of geometry and loading. Regarding fatigue lifetime prediction of bonded joints, most of the work in the literature is concentrated with constant amplitude fatigue, rather than variable amplitude fatigue. Fatigue design of a bonded structure based on constant amplitude fatigue, when the actual loading on the structure is of the variable amplitude fatigue, can result in erroneous lifetime prediction. This is because of load interaction effects caused by changes in load ratio, mean load etc., which can decrease the fatigue life considerably. Therefore, the project aims to a) provide a comprehensive study of the use of BFS measurements to characterise fatigue damage, b) develop novel techniques for predicting lifetime under constant amplitude fatigue and c) provide an insight into various types of load interaction effects. In this project, single lap joints (SLJ) and compound double cantilever beam geometries were used. Compound double cantilever beams were used mainly to determine the critical strain energy release rate and to obtain the relationship between strain energy release rate and fatigue crack growth rate. The fatigue life of SLJs was found to be dominated by crack initiation at lower fatigue loads. At higher fatigue loads, fatigue life was found to consist of three phases; initiation, stable crack propagation and fast crack growth. Using these results, a novel damage progression model was developed, which can be used to predict the remaining life of a bonded structure. A non-linear strength wearout model (NLSWM) was also proposed, based on strength wearout experiments, where a normalised strength wearout curve was found to be independent of the fatigue load applied. In this model, an empirical parameter determined from a small number of experiments, can be used to determine the residual strength and remaining life of a bonded structure. A fracture mechanics approach based on the Paris law was also used to predict the fatigue lifetime under constant amplitude fatigue. This latter method was found to under-predict the fatigue life, especially at lower fatigue loads, which was attributed to the absence of a crack initiation phase in the fracture mechanics based approach. A damage mechanics based approach, in which a damage evolution law was proposed based on plastic strain, was found to predict the fatigue life well at both lower and higher fatigue loads. This model was able to predict both initiation and propagation phases. Based on the same model, a unified fatigue methodology (UFM) was proposed, which can be used to not only predict the fatigue lifetime, but also various other fatigue parameters such as BFS, strength wearout and stiffness wearout. The final part of the project investigated variable amplitude fatigue. In this case, fatigue lifetime was found to decrease, owing to damage and crack growth acceleration in various types of variable amplitude fatigue loading spectra. A number of different strength wearout approaches were proposed to predict fatigue lifetime under variable amplitude fatigue loading. The NLSWM, where no interaction effects were considered was found to over-predict the fatigue life, especially at lower fatigue loads. However, approaches such as the modified cycle mix and normalised cycle mix approaches were found to predict the fatigue life well at all loads and for all types of variable amplitude fatigue spectra. Progressive damage models were also applied to predict fatigue lifetime under variable amplitude fatigue loading. In this case a fracture mechanics based approach was found to under-predict the fatigue life for all types of spectra at lower loads, which was established to the absence of a crack initiation phase in this method. Whereas, a damage mechanics based approach was found to over-predict the fatigue lifetime for all the types of variable amplitude fatigue spectra, however the over- prediction remained mostly within the scatter of the experimental fatigue life data. It was concluded that, the damage mechanics based approach has potential for further modification and should be tested on different types of geometry and spectra.

Reliant le moteur à turboréacteur à la voilure de l’avion, le mât-réacteur est une véritable « pièce maitresse » de l’avion. En effet, il transmet tous les efforts de l’avion au moteur. Il est soumis à des variations de températures allant de -40°C en croisière à290°C voir 400°C lors des phases de décollage. En plus, le mât-réacteur est à la merci de contraintes vibratoires très élevées qui,n’étant pas correctement maitrisées lors des analyses en tolérances aux dommages, peuvent conduire à la ruine de l’appareil. Entre290°C et 400°C, la martensite constitutive des composants en acier inoxydable martensitique durci par précipitation (15-5PH) du mât-réacteur, subit donc un vieillissement par transformation microstructurale. Ce vieillissement a un impact considérable sur les propriétés mécaniques, à savoir à une augmentation de la limite d’élasticité et de la contrainte à rupture aux dépens d’une réduction drastique de la ténacité et la ductilité. Afin de compléter la caractérisation des effets du vieillissement sur les propriétés mécaniques tout en considérant que ces structures sont dimensionnées suivant un principe de tolérance aux dommages, l’objectif de ce travail est d’étudier la résistance à la fissuration par fatigue de cet acier en fonction du vieillissement et de la température d’essai. La démarche adoptée repose sur une connaissance des comportements monotone et cyclique pour analyser les mécanismes en fissuration. Des essais de comportement cyclique ont ainsi été effectués à la température ambiante et à 300°C à différents niveaux de déformation imposés, sur l’acier 15-5PH dans son état de réception, puis pour des conditions vieillissement réalisées entre 300°C et 400°C et des temps d’exposition allant jusqu’à 10 000h. Les résultats obtenus mettent en évidence l’absence d’influence du vieillissement sur l’écrouissage cyclique de l’acier 15-5PH, aussi bien à température ambiant qu’à 300°C. Pour la plage de valeurs de ΔK balayée, le comportement en fissuration de l’acier 15-5PH sous amplitude de chargement constante n’est pas modifié par le vieillissement.Cependant, l’étendue du domaine stable de propagation est quant à elle réduite en fonction du degré de vieillissement à température ambiante. Cette réduction est due à la chute de ténacité du matériau avec le vieillissement. Les surfaces de rupture sont majoritairement transgranulaires pour toutes les conditions examinées. Toutefois, les régions proches de la rupture finale de certains états vieillis présentent des îlots de rupture statique à la température ambiante. Ces ilots sont inexistants à 300°C. Par ailleurs, sous l’effet de surcharges répétées, un effet retard sur la vitesse de fissuration a été mis en évidence. Ce retard est fonction à la fois du taux de surcharge, de la période de surcharge, du nombre de surcharge et du rapport de charge du chargement de base, mais est insensible au vieillissement. Par ailleurs, on dénote une fois de plus, une réduction de l’étendue du domaine de propagation stable à température ambiante. Des simulations de la propagation des fissures sous amplitude de chargement variable ont été effectuées à l’aide du modèle incrémental de prévisions de durées de vie en fissuration développé au LMT-Cachan. Les résultats issus de ce modèle ont ensuite fait l’objet d’une comparaison avec le modèle PREFFAS utilisé chez AIRBUS. Le modèle incrémental rend bien compte de certains effets de surcharges répétées. Il se révèle en outre moins conservatif que le modèle PREFFAS. Une méthodologie de prise en compte dans le modèle incrémental des effets de vieillissement fondée sur une équivalence temps/température de type Hollomon-Jaffe est enfin proposée. / Connecting the turbofan engine to the wing of the aircraft, the engine pylon is a true « masterpiece » of the aircraft. Indeed, it transmits all the aircraft engine efforts. It is subject to temperature variations from -40°C in cruise to 290°C-400°C during take off and landing. In addition, the engine pylon is a prey to very high vibratory stresses, which should be properly taken into account during damage tolerances analysis to avoid the loss of the aircraft. Between 290°C and 400°C, the martensite of components in precipitation-hardenable stainless steel (15-5 PH) of engine pylon undergoes microstructural transformation (« ageing »). This ageing has a significant impact on the mechanical properties, characterized by an increase in yield strength and tensile stress and drastic reduction in toughness and ductility. To complete the characterization of the effects of ageing on the mechanical properties while considering that these structures are designed according to a principle of damage tolerance, the aim of this work is to study the fatigue crack growth behavior (FCGB) of this material according to the ageing conditions and the test temperature. The approach is based on knowledge of monotonous and cyclic behavior to analyze the fatigue crack mechanisms. The cyclic behavior tests have been carried out at room temperature and 300°C at different strains imposed levels, on the 15-5PH steel in its as-received and then to the ageing conditions realized, between 300°C and 400°C and exposure times of up to 10 000h. The results highlight the lack of influence of ageing on the cyclic hardening of 15-5 PH steel, both at room temperature to 300°C. For the range of ΔK values tested, the FCGB of the 15-5PH steel under constant load amplitude is not affected by ageing. However, the extent of the stable propagation domain is itself reduced according to the degree of aging at room temperature. This reduction is due to the fall of fracture toughness due to ageing. The fracture surfaces are mainly transgranular for all conditions examined. However, the areas close to the final rupture ofsome ageing statements present islands indicative of a static failure mode at room temperature. These islands are absent to 300°C.Under the effect of repeated loads, a delayed effect on the crack velocity has been demonstrated. This delay is a function of the overload rate, overload period, the number of overloads and the baseline load ratio, but insensitive to ageing. Furthermore, are duction in the extent of the area stable propagation is also noticed at room temperature. Fatigue crack growth simulations undervariable amplitude loading were made through the incremental model for damage tolerance analysis developed by LMT-Cachan. The model results were then subject to a comparison with the PREFFAS model used at AIRBUS. The incremental model is well aware ofsome of the effects of repeated overloads. It also proves less conservative than the model PREFFAS. For taking account the effects of ageing in the incremental model, simply report the hardening observed on old material, the cyclic hardening parameters are notaffected. A methodology based on time/temperature equivalence provided by Hollomon-Jaffe - and taking into account the effects of ageing in the incremental model is finally proposed.

The current thesis work is based on fatigue testing of welded structures which is completed in collaboration with Volvo CE. Improvement of the technology and customers demands for higher quality products with lower price makes the VCE to invest on the product development projects. One of the projects in VCE focuses on the weight and production cost optimization of the bogie beam on the hauler. The present project is a completion of the previous project with the objective of the fatigue testing of the bogie beam of the hauler under oscillating loads for verification of the expected fatigue life assessed with FEM. In the process of this work, an existing test rig is modified. The strains over the beam are measured through strain gauges mounted on the beam. The simulated model, the stresses and strains are investigated. The fatigue life is evaluated with different fatigue assessment methods. Finally, the outcomes of all the methods for fatigue investigation of the beam are compared and verified. / Detta examensarbete, som utförts för Volvo CE, behandlar utmattningsprov av svetsade konstruktioner. Teknikutveckling och förändrade kundkrav på högre kvalitet till en lägre kostnad är drivkrafter för Volvo CE att investera i produkt- och metodutvecklingsprojekt, som exempelvis det aktuella projektet att optimera vikt och tillverkningskostnad för boggi-balkar till dumprar. Detta projekt är en fortsättning av ett tidigare arbete som hade som mål att verifiera utmattningslivslängden för en boggibalk till en dumper predikterad med FEM, genom att utmattningsprova balken för oscillerande last. Som en del av projektet modifieras en existerande provningsrigg. Töjningar på balken mats med ett antal töjningsgivare monterade på balken. Spännings och töjningfrån den simulerade modellen analyseras och utmattningslivslängden jämförs för olika metoder för att prediktera utmattning. Slutligen jämförs och veriferas dessa metoder.

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Tato disertační práce vychází z výzkumu v rámci francouzsko-českého programu doktorátu pod dvojím vedením na pracovišti Institut français de mécanique avancée v Clermont-Ferrand a na Ústavu fyziky materiálu AV v Brně. Úvodní výzkumný úkol na brněnském pracovišti se zabýval numerickou analýzou pole napětí v okolí čela trhliny v tenké kovové fólii. Zvláštní pozornost byla zaměřena na vliv speciálního typu singularity v průsečíku čela trhliny s volným povrchem. Těžiště disertační práce spočívá v numerickém modelování a stochastické analýze problémů šíření trhlin se složitou geometrií v dvojrozměrném prostoru. Při analýze těchto problémů se dříve zřídka používaly numerické metody, a to z důvodu vysoké náročnosti na výpočtový čas. V této disertaci je ukázáno, že aplikací moderních metod numerické mechaniky a vhodných technik v analýze spolehlivosti lze tyto problémy řešit s pomocí numerických metod i na PC. Ve spolehlivostní analýze byla využita lineární aproximační metoda FORM. Pro rychlost šíření trhlin se vycházelo z Parisova-Erdoganova vztahu. Pro parametry tohoto vztahu byl použit dvourozměrný statistický model, který postihuje vysokou citlivost na korelaci obou parametrů. Mechanická odezva byla počítána rozšířenou metodou konečných prvků (XFEM), která eliminuje výpočetní náročnost a numerický šum související se změnou sítě v klasické metodě konečných prvků. Prostřednictvím přímé diferenciace bylo odvozeno několik vztahů pro derivace funkce odezvy, čímž se dosáhlo lepší numerické stability a konvergence spolehlivostní analýzy a výrazného zkrácení doby výpočtu. Problém zatížení s proměnou amplitudou byl řešen aplikací transformace zatížení metodou PREFFAS. Využití distribuce výpočtů v síti PC umožnilo další zrychlení analýzy.

Tato disertační práce vychází z výzkumu v rámci francouzsko-českého programu doktorátu pod dvojím vedením na pracovišti Institut français de mécanique avancée v Clermont-Ferrand a na Ústavu fyziky materiálu AV v Brně. Úvodní výzkumný úkol na brněnském pracovišti se zabýval numerickou analýzou pole napětí v okolí čela trhliny v tenké kovové fólii. Zvláštní pozornost byla zaměřena na vliv speciálního typu singularity v průsečíku čela trhliny s volným povrchem. Těžiště disertační práce spočívá v numerickém modelování a stochastické analýze problémů šíření trhlin se složitou geometrií v dvojrozměrném prostoru. Při analýze těchto problémů se dříve zřídka používaly numerické metody, a to z důvodu vysoké náročnosti na výpočtový čas. V této disertaci je ukázáno, že aplikací moderních metod numerické mechaniky a vhodných technik v analýze spolehlivosti lze tyto problémy řešit s pomocí numerických metod i na PC. Ve spolehlivostní analýze byla využita lineární aproximační metoda FORM. Pro rychlost šíření trhlin se vycházelo z Parisova-Erdoganova vztahu. Pro parametry tohoto vztahu byl použit dvourozměrný statistický model, který postihuje vysokou citlivost na korelaci obou parametrů. Mechanická odezva byla počítána rozšířenou metodou konečných prvků (XFEM), která eliminuje výpočetní náročnost a numerický šum související se změnou sítě v klasické metodě konečných prvků. Prostřednictvím přímé diferenciace bylo odvozeno několik vztahů pro derivace funkce odezvy, čímž se dosáhlo lepší numerické stability a konvergence spolehlivostní analýzy a výrazného zkrácení doby výpočtu. Problém zatížení s proměnou amplitudou byl řešen aplikací transformace zatížení metodou PREFFAS. Využití distribuce výpočtů v síti PC umožnilo další zrychlení analýzy.

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