Fatigue and Fracture of Materials and Structures: Contributions from ICMFM XX and KKMP2021 (Structural Integrity, 24)

This book presents selected contributions from ICMFM XX and the Polish National Conference―KKMP. The XX International Colloquium on Mechanical Fatigue of Metals (ICMFM XX) was organized on 15–17 September 2021, in the Faculty of Mechanical Engineering of the Wroclaw University of Science and Technology, in Wrocław City, Poland, in a remote form. Its aim was to facilitate and encourage the exchange of knowledge and experiences among the different communities involved in both basic and applied research in the field of fatigue of metals, looking at the problem of fatigue from a multiscale perspective, and exploring analytical and numerical simulative approaches, without losing the perspectives of the application. The Polish National Conference―KKMP 2021―was organized remotely with 50–80 prominent international participants from the fracture mechanics community. Preface Contents Part I Numerical Approaches Applied to Fatigue and Fracture Assessment 1 Numerical Simulation of Fatigue Crack Growth in Different Welded Joint Zones 1.1 Introduction 1.2 Experimental Results 1.3 Numerical Simulation 1.3.1 Numerical Results 1.4 Conclusions References 2 Calculation of the Stress State in Coatings by Analytical and Numerical Methods Considering Thermal Loads 2.1 Introduction 2.2 Development of an Analytical Model to Determine the Stress State in the Coating 2.3 Verification of the Developed Model 2.4 Discussion 2.5 Conclusions References 3 Numerical Simulation and Constructal Design Applied to Perforated Plate Subjected to Biaxial Buckling 3.1 Introduction 3.2 Computational Model 3.3 Constructal Law and Constructal Design Application 3.4 Results and Discussion 3.5 Conclusion References 4 Fatigue Damage Simulation of a Metal Sandwich Panel Under Four-Point Bending Conditions 4.1 Introduction 4.2 Materials and Methods 4.2.1 Geometrical Metal Sandwich Panel 4.2.2 Loading Conditions 4.3 Result and Discussion 4.4 Conclusion References 5 Analysis of Pulse Load of a Steel Roller in the Numerical Simulation Method 5.1 Introduction 5.2 Materials and Methods 5.2.1 Materials 5.2.2 Methods 5.3 Results and Discussion 5.3.1 Microscopic and Tomographic Analysis 5.3.2 Numerical Analysis 5.4 Conclusion References Part II Fatigue and Fracture Assessment of Joints and Complex Structures 6 Fatigue Analysis of Thin-Walled Welded Hollow Section Joints 6.1 Introduction 6.2 Description of the Experimental Campaign 6.3 Experimental Results 6.4 Fatigue Life Estimation 6.5 Conclusions References 7 Analytical Solutions of Water Hammer in Metal Pipes. Part I—Brief Theoretical Study 7.1 Introduction 7.2 Analytical Solutions 7.2.1 Frictionless Solution 7.2.2 Quasi-steady Friction Solution 7.2.3 Unsteady Friction Solution 7.3 Novel Solution of Velocity and Wall Shear Stress 7.4 Conclusions References 8 Analytical Solutions of Water Hammer in Metal Pipes. Part II—Comparative Study 8.1 Introduction 8.2 Numerical Solution of Transient Pipe Flow 8.3 Comparative Study 8.3.1 Simulation of Pressure Pulsations 8.3.2 Simulation of Velocity and Wall Shear Stress Pulsations 8.4 Conclusions References 9 Experimental and Theoretical Analysis of Hydraulic Cylinder Loads 9.1 Introduction 9.2 Materials and Methods 9.2.1 Experimental Research 9.2.2 Mathematical Modelling 9.3 Results 9.4 Conclusion References 10 A New Anti-fatigue Design Method for Welded Structures Based on Stiffness Coordination Strategy and Its Application 10.1 Introduction 10.2 A New Method of Three-Stage Anti-fatigue Design and Numerical Analysis of Core Parameters 10.2.1 Mechanical Explanation of Stress Concentration 10.2.2 The Execution Flow of Fatigue Resistance Design Method 10.2.3 Numerical Analysis of Structural Stress 10.3 Verification of Welded Joint Fatigue Test with Stiffness Coordination in Standard 10.3.1 Specimen Preparation and Fatigue Test 10.3.2 Analysis of Fatigue Test Results 10.4 Engineering Application of Method 10.4.1 The First Stage—Identification of Stress Concentration in Welded Joint 10.4.2 The Second Stage—Analysis of Stress Concentration in Welded Joint 10.4.3 The Third Stage—Stress Concentration Relief of Welded Joint 10.5 Conclusion References 11 Characterization of Multiaxial Strain Road Loads in Assessing the Durability of Automotive Coil Spring 11.1 Introduction 11.2 Methodology 11.2.1 Finite Element Analysis 11.2.2 Experimental Setup 11.2.3 Statistical Characterization 11.2.4 Multiaxial Life Prediction 11.3 Results and Discussion 11.4 Conclusion References 12 Identification of Key Fatigue Welds of Bogie Welded Frame 12.1 Introduction 12.2 Stress Analysis of Fillet Weld Joint Structure 12.2.1 Stress Analysis of Weld Throat Section 12.2.2 Numerical Analysis of Structural Stress of Double-Sided Fillet Welds 12.3 Identification of Key Welds for Fatigue of Welded Frames 12.4 Conclusion References 13 Susceptibility of Steel Sucker Rods Operated in Oil Well to Environmentally Assisted Fatigue 13.1 Introduction 13.2 Experimental 13.2.1 Materials 13.2.2 Electrochemical Investigations 13.2.3 Fatigue Testing 13.3 Results of Experimental Studies and Discussion 13.4 Concluding Remarks References 14 Increasing the Durability of Critical Parts in Heavy-Duty Industrial Machines by Deep Cryogenic Treatment 14.1 Introduction 14.2 Theoretical Basis of DCT 14.3 Results of Research 14.3.1 Cutting Tools and Bearings 14.3.2 Steel Rolling Mills 14.3.3 Gun Barrels 14.3.4 Perspectives of DCT in Mining Machines 14.4 Conclusions References 15 Risk-Based Inspection Strategies of Miter Gates Based on Structural Health Monitoring 15.1 Introduction 15.2 Structural Health Monitoring 15.3 Rainflow Counting 15.4 Methodology 15.5 Risk-Based Inspection Strategies References 16 Fatigue Behavior of Re-tightened Bolted Joints Affected by Vibration-Induced Loosening 16.1 Introduction 16.2 Material and Method 16.3 Experimental Results 16.4 Conclusion References 17 Friction Resistances in Internal Gear Pump with Modified Sickle Made of Plastic 17.1 Introduction 17.2 Test Methods and Materials 17.2.1 Hydraulic Tests 17.2.2 Tribological Tests 17.3 Presentation and Discussion of Test Results 17.3.1 Hydraulic Tests 17.3.2 Tribological Tests 17.4 Conclusion References 18 Defect Development in Ultra-Supercritical Steam Turbine Rotors According to British Standards 18.1 Introduction 18.2 Crack Growth Calculation Methodology 18.2.1 Creep Crack Growth 18.2.2 Fatigue Crack Growth 18.3 Characteristic Strain Model of Creep 18.3.1 Model Equations 18.3.2 Model Validation 18.4 Defect Growth at Rotor Axis 18.4.1 Thermal and Creep Analysis 18.4.2 Calculation of Creep Crack Growth 18.4.3 Calculation of Fatigue Crack Growth 18.5 Summary References Part III Probabilistic Fatigue and Fracture Approaches Applied to Materials and Structures 19 Fatigue Life Assessment Within the Frequency Domain for Explosive Cladded Joints Under Non-Gaussian Random Loading 19.1 Introduction 19.1.1 Random Loading and Frequency Domain 19.1.2 Explosive Cladded Materials 19.1.3 Explosive Cladded Materials Under Random Loading 19.1.4 Power Spectral Density Generation 19.1.5 Mean Stress Correction 19.1.6 Non-Gaussian Correction 19.1.7 Fatigue Life Estimation in Frequency Domain 19.2 Conclusions and Observations References 20 Cluster Analysis in the Choice of Operating Modes in Durability Analysis of Random Time-History Records 20.1 Introduction 20.2 Method 20.3 Case Study 20.3.1 Preliminary Analysis 20.3.2 Cluster Analysis of the Dataset 20.4 Discussion, Conclusions and Future Plans References 21 Comparison of Different Fatigue Laws for Probabilistic Modeling of Mechanical Fatigue with Censored Data Using Maximum Likelihood Estimation Method 21.1 Introduction 21.2 Fatigue Models 21.3 Results 21.3.1 Composite Material Dataset 21.3.2 Steel Dataset 21.4 Conclusion References 22 Evaluating Confidence Interval of Fatigue Damage from One Single Measured Non-stationary Time-History 22.1 Introduction 22.2 Expected Damage and Confidence Interval 22.3 Measured Time-Histories 22.3.1 Detecting Non-Stationarity of Time-Histories 22.3.2 Confidence Interval and Approximation of the Expected Damage 22.4 Results 22.5 Conclusion References 23 Review of the Models for Determining the Moment of the Initiation of the Fatigue Crack in the Frequency Domain for Random Loads with Non-Gaussian Distribution 23.1 Introduction 23.2 Fatigue Crack Initiation Models Defined in the Frequency Domain 23.2.1 Stress Models 23.2.2 Strain Models 23.2.3 Strain Energy Models 23.3 Conclusions and Observations References Part IV Failure Analysis and Recent Advances on Mixed-Mode Fatigue and Fracture 24 On High- and Very High Cycle Fatigue of Metals and Alloys at Axial Loading 24.1 H. Mugrabi Fatigue Curve [1] and Bifurcation Fatigue Curve [2–4] 24.2 Influence of Frequency on Fatigue Characteristics of Metals and Alloys 24.3 On the Mechanisms of Viscous and Brittle Failure 24.4 Conclusion References 25 Analysis of Aramid Fabric Damage Mechanisms as a Result of Different Load Speeds 25.1 Introduction 25.2 Materials and Research Methodology 25.3 Results and Discussion 25.4 Conclusion References 26 Experimental Identification of Viscoelastic Properties of Plates Made of Quiet Aluminum 26.1 Introduction 26.2 Identification Method 26.3 Experimental Results 26.4 Conclusions References 27 Influence of Different Surface- and Heat Treatments; Elevated Temperature, Orientation on the Fatigue Properties of Ti6Al4V Processed by L-PBF for Controlled Powder Properties 27.1 Motivation 27.2 Methodology 27.3 Results and Discussion 27.3.1 Powder Properties 27.3.2 Surface Roughness 27.3.3 Heat Treatment—Microstructure 27.3.4 Fatigue Performance 27.4 Conclusion and Discussion References 28 Fatigue Crack Growth Resistance of Heat-Resistant Steel 15H11MF After Operation in Blades of a Steam Turbine 28.1 Introduction 28.2 Materials and Methods 28.3 Results and Discussion 28.3.1 Analysis of the Fracture Cases of Rotor Blades in Steam Turbines 28.3.2 Substantiation of the Choice of the Mechanical Indicator Sensitive to the Steel Operational Degradation 28.3.3 Evaluation of the Technical State of Heat-Resistant Steel After Various Operation Times in Steam Turbine Rotor Blades 28.4 Conclusions References 29 Operational Degradation of Fatigue Strength of Structural Steels: Role of Corrosive-Hydrogenating Environments 29.1 Introduction 29.2 Effect of Operational Degradation on Fatigue Characteristics of Steels 29.3 Effect of Operational Cyclic Loading on Physical and Mechanical Properties of Steels 29.4 Concluding Remarks References 30 Global Statistical Analysis of Old Iron and Steel Properties Based on Old and Recent Literature Review 30.1 Introduction 30.2 Mechanical Properties of Wrought Irons (Static Loadings) 30.3 Chemical Composition Analysis of Irons and Steels 30.4 Principal Component Analysis (PCA) and Irons and Steels Chemical and Mechanical Characteristics 30.5 Conclusions References 31 Forming Stress-Induced Initial Damage in Case Hardening Steel 16MnCrS5 Under Cyclic Axial Loading in LCF Regime 31.1 Introduction 31.2 Materials and Methods 31.3 Experimental Setup and Procedure 31.4 Results 31.5 Conclusions References 32 Stress Ratio Effect on Fatigue Crack Growth Rate Based on Magnetic Flux Leakage Parameters 32.1 Introduction 32.2 Methodology 32.2.1 Specimens 32.2.2 Materials and Method 32.3 Results and Discussion 32.3.1 MMM Signals 32.3.2 Fatigue Crack Growth Rate 32.4 Conclusion References 33 Influence of Heat Treatment Temperature on Fatigue Toughness in Medium-Carbon High-Strength Steels 33.1 Introduction 33.2 Experimental Procedure 33.3 Results and Discussion 33.3.1 Low-Cycle Fatigue Tests 33.4 Conclusions References 34 Effect of Specimen Thickness on Fatigue Crack Growth Resistance in Paris Region in AISI 304 STEEL 34.1 Introduction 34.2 Materials, Mechanical Properties and Fatigue Specimens 34.3 Fatigue Crack Growth Rate Measurement 34.4 Results 34.4.1 AISI 304L—DIN 1.4307 34.4.2 AISI 304L—DIN 1.4306 34.5 Conclusion References 35 Fracture Mechanics Assessment of Notches Subjected to Very High-Cycle Fatigue Loading 35.1 Introduction 35.1.1 Gigacycle Fatigue 35.1.2 Theory of Critical Distances 35.2 Process of Evaluation 35.2.1 Application—Aluminum Alloy Specimens 35.2.2 Application—Steel Specimens 35.3 Conclusion References 36 Fatigue Failure of 51CrV4 Steel Under Rotating Bending and Tensile 36.1 Introduction 36.2 Material and Methods 36.3 Results and Discussion 36.4 Conclusions References 37 The Role of the Surface in Crack Initiation in Sharp and Bi-material Notches 37.1 Introduction 37.1.1 Background 37.1.2 Crack Initiation Criterion 37.2 Comparison of Sharp and Bi-material Notches 37.2.1 Numerical Calculation of the Stress Distribution References 38 Experimental Study on Failure Mechanisms of Novel Visco-Hyperelastic Material Target Under Ballistic Impact Conditions 38.1 Introduction 38.2 Material Characterization Tests 38.2.1 Quasi-Static Compression Tests 38.2.2 Dynamic Compression of Hyperelastic Target Material 38.3 Ballistic Impact Experiments 38.4 Conclusions References Part V Structural Integrity and Fatigue Assessment of Additive Manufactured Metals and Biomaterials 39 Fatigue Behavior of As-Built L-PBF Inconel 718 and Surface Roughness-Based Modeling 39.1 Introduction 39.2 Material and Experimental Details 39.3 As-Built Fatigue Behavior of L-PBF Inconel 718 39.4 Roughness-Based Fatigue Modeling 39.5 Conclusions References 40 Fatigue Behavior of the Titanium-Tantalum Alloy Obtained by Additive Manufacturing 40.1 Introduction 40.2 Material and Experimental Procedure 40.2.1 Specimens Manufacturing 40.2.2 Vickers Hardness Tests 40.2.3 Tensile and Fatigue Tests 40.3 Results and Discussion 40.4 Conclusions References 41 Some Observation Concerning Fatigue Response of Additively Manufactured Specimens from Ti-6Al-4V 41.1 Introduction 41.2 Fatigue Experiments 41.3 Analysis of Some of the Features Affecting Fatigue 41.3.1 Porosity 41.3.2 Residual Stresses 41.3.3 Surface Roughness 41.4 Conclusion References 42 Cyclic Plasticity and Low-Cycle Fatigue of an AISI 316L Stainless Steel Tested at Room Temperature 42.1 Introduction 42.2 Experiments 42.3 Calibration of Plasticity Models (Kinematic and Isotropic) 42.4 Strain-Life Curves (Regression Lines and Design Lines) 42.5 Conclusions References 43 Contribution to the Study of the Fatigue of Riveted Joints, Influence of the Material and of the Stress Ratio 43.1 Introduction 43.2 Specimens and Models 43.2.1 Riveted Specimens Design and Fabrication 43.2.2 Models Used for the Description of Wöhler Curves 43.3 Results at R = 0 43.4 Steel Specimens, R-dependency 43.5 Conclusions References The XX International Colloquium on Mechanical Fatigue of Metals (ICMFM XX) was organized on 15-17 September 2021, in the Faculty of Mechanical Engineering of the Wroclaw University of Science and Technology, in Wroclaw City, Poland, in a remote form.