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Focus on Fatigue and Fracture of Engineering Materials, Volume II

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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (29 February 2024) | Viewed by 17503

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Prof. Dr. Joel De Jesus

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Department of Mechanical Engineering, University of Coimbra, 3030788 Coimbra, Portugal
Interests: structural integrity; fatigue and fracture; additive manufacturing; composite materials; fatigue in corrosion environments
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Dr. Ricardo Branco

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Department of Mechanical Engineering, University of Coimbra, 3030-788 Coimbra, Portugal
Interests: glass-fiber reinforced polymers; 3D printed polymers; fatigue of polymers; ageing effects
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Dr. Diogo Neto

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Department of Mechanical Engineering, University of Coimbra, 3004-531 Coimbra, Portugal
Interests: computational mechanics; non-linear solid mechanics; elastoplastic behavior of materials; thermomechanical analysis; additive manufacturing; fatigue crack growth
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Special Issue Information

Dear Colleagues,

Considering that fatigue and fracture phenomena are responsible for 80% to 90% of failures in mechanical components, it is essential to study these phenomena to guarantee long-term durability and reliability. The introduction of new materials and new manufacturing processes brings new challenges to design and requires more focused research. This Special Issue aims to be a forum for the analysis of new trends in fracture mechanics and fatigue design in all materials, with special attention to new materials and new production processes as well as new failure models and new design criteria. Papers dealing with the effects of processing techniques, microstructure features, loading history, the environmental medium, and the modeling of mechanical behavior, as well as papers dealing with advanced applications, are encouraged. Both experimental and numerical approaches will be accepted. The Special Issue is open to both original research and review articles.

Prof. Dr. Joel De Jesus
Dr. Ricardo Branco
Dr. Diogo Neto
Guest Editors

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Keywords

fatigue
fracture
fatigue crack growth
corrosion fatigue
low cycle fatigue
high cycle fatigue
numerical fatigue analysis
fatigue crack initiation
variable amplitude fatigue
fatigue damage accumulation
failure analysis
stress-based, strain-based, and energy-based criteria
linear elastic fracture mechanics
elasto-plastic fracture mechanics
computational fracture mechanics

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Published Papers (9 papers)

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Research

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20 pages, 10611 KiB

Open AccessArticle

Numerical Analysis of the Wing Leading Edge Electro-Impulse De-Icing Process Based on Cohesive Zone Model

by Fangping Ma, Zhengtao Zhu, Di Wang and Xiaoming Jin

Appl. Sci. 2024, 14(7), 2777; https://doi.org/10.3390/app14072777 - 26 Mar 2024

Viewed by 892

Abstract

Aircraft icing has historically been a critical cause of airplane crashes. The electro-impulse de-icing system has a wide range of applications in aircraft de-icing due to its lightweight design, low energy consumption, high efficiency, and other advantages. However, there has been little study into accurate wing electric-impulse de-icing simulation methods and the parameters impacting de-icing efficacy. Based on the damage mechanics principle and considering the influence mechanisms of interface debonding and ice fracture on ice shedding, this paper establishes a more accurate numerical model of wing electric-impulse de-icing using the Cohesive Zone Model (CZM). It simulates the process of electric-impulse de-icing at the leading edge of the NACA 0012 wing. The numerical results are compared to the experimental results, revealing that the constructed wing electro-impulse de-icing numerical model is superior. Lastly, the effects of varying ice–skin interface shear adhesion strengths, doubler loading positions, and impulse sequences on de-icing effectiveness were studied. The de-icing rate is a quantitative description of the electro-impulse’s de-icing action, defined in the numerical model as the ratio of cohesive element deletions to the total elements at the ice–skin interface. The findings reveal that varying shear adhesion strengths at the ice–skin interface significantly impact the de-icing effect. The de-icing rate steadily falls with increasing shear adhesion strength, from 66% to 56%. When two, four, and seven impulses were applied to doubler two, the de-icing rates were 59%, 71%, and 71%, respectively, significantly increasing the de-icing efficiency compared to when impulses were applied to doubler one. Doubler one and two impulse responses are overlaid differently depending on the impulse sequences, resulting in varying de-icing rates. When the impulse sequence is 20 ms, the superposition results are optimal, and the de-icing rate reaches 100%. These studies can guide the development and implementation of a wing electric-impulse de-icing system. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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17 pages, 7124 KiB

Open AccessArticle

Investigating the Influence of Holes as Crack Arrestors in Simulating Crack Growth Behavior Using Finite Element Method

by Yahya Ali Fageehi and Abdulnaser M. Alshoaibi

Appl. Sci. 2024, 14(2), 897; https://doi.org/10.3390/app14020897 - 20 Jan 2024

Cited by 6 | Viewed by 1446

Abstract

The primary focus of this paper is to investigate the application of ANSYS Workbench 19.2 software’s advanced feature, known as Separating Morphing and Adaptive Remeshing Technology (SMART), in simulating the growth of cracks within structures that incorporate holes. Holes are strategically utilized as crack arrestors in engineering structures to prevent catastrophic failures. This technique redistributes stress concentrations and alters crack propagation paths, enhancing structural integrity and preventing crack propagation. This paper explores the concept of using holes as crack arrestors, highlighting their significance in increasing structural resilience and mitigating the risks associated with crack propagation. The crack growth path is estimated by applying the maximum circumferential stress criterion, while the calculation of the associated stress intensity factors is performed by applying the interaction integral technique. To analyze the impact of holes on the crack growth path and evaluate their effectiveness as crack arrestors, additional specimens with identical external dimensions but without any internal holes were tested. This comparison was conducted to provide a basis for assessing the role of holes in altering crack propagation behavior and their potential as effective crack arrestors. The results of this study demonstrated that the presence of a hole had a significant influence on the crack growth behavior. The crack was observed to be attracted towards the hole, leading to a deviation in its trajectory either towards the hole or deflecting around it. Conversely, in the absence of a hole, the crack propagated without any alteration in its path. To validate these findings, the computed crack growth paths and associated stress intensity factors were compared with experimental and numerical data available in the open literature. The remarkable consistency between the computational study results for crack growth path, stress intensity factors, and von Mises stress distribution, and the corresponding experimental and numerical data, is a testament to the accuracy and reliability of the computational simulations. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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17 pages, 9030 KiB

Open AccessArticle

Fatigue Crack Growth Analysis in Modified Compact Tension Specimen with Varying Stress Ratios: A Finite Element Study

by Abdulnaser M. Alshoaibi

Appl. Sci. 2023, 13(24), 13160; https://doi.org/10.3390/app132413160 - 11 Dec 2023

Cited by 3 | Viewed by 2008

Abstract

In this study, the primary objective is to analyze fatigue crack propagation in linear elastic fracture mechanics using the SMART crack growth module in the ANSYS Workbench, employing the finite element method. The investigation encompasses several crucial steps, including the computation of stress intensity factors (SIFs), determination of crack paths, and estimation of remaining fatigue life. To thoroughly understand crack behavior under various loading conditions, a wide range of stress ratios, ranging from R = 0.1 to R = 0.9, is considered. The research findings highlight the significant impact of the stress ratio on the equivalent range of SIFs, fatigue life cycles, and distribution of deformation. As the stress ratio increases, there is a consistent reduction in the magnitude of the equivalent range of stress intensity factor. Additionally, a reciprocal relationship is observed between the level of X-directional deformation and the number of cycles to failure. This indicates that components experiencing lower levels of deformation tend to exhibit longer fatigue life cycles, as evidenced by the specimens studied. To verify the findings, the computational results are matched with the crack paths and fatigue life data obtained from both experimental and numerical sources available in the open literature. The extensive comparison carried out reveals a remarkable level of agreement between the computed outcomes and both the experimental and numerical results. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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16 pages, 5548 KiB

Open AccessArticle

Fatigue Crack Growth Studies under Mixed-Mode Loading in AISI 316 Stainless Steel

by Abdulnaser M. Alshoaibi and Abdullateef H. Bashiri

Appl. Sci. 2023, 13(16), 9446; https://doi.org/10.3390/app13169446 - 21 Aug 2023

Cited by 1 | Viewed by 2088

Abstract

The objective of this study is to examine the behavior of fatigue crack growth (FCG) in the mixed mode (I/II) of the AISI 316 austenitic stainless steel alloy, considering mode mixity angles of 30°, 45°, and 60°. This particular alloy is widely used in the marine industry and various structural components because of its exceptional properties, such as high corrosion resistance, good formability, weldability, and high-temperature strength. By investigating the crack growth behavior, the study seeks to provide insights into the material’s durability and potential for long-term use in demanding applications. To analyze fatigue crack growth behavior using linear elastic fracture mechanics (LEFM), this study utilizes compact tension shear (CTS) specimens with varying loading angles. The CTS specimens provide an accurate simulation of real-world loading conditions by allowing for the application of various loading configurations, resulting in mixed-mode loading. The ANSYS Mechanical APDL 19.2 software, which includes advanced features such as separating, morphing, and adaptive remeshing technologies (SMART), was utilized in this study to precisely model the path of crack propagation, evaluate the associated fatigue life, and determine stress intensity factors. Through comparison with experimental data, it was confirmed that the loading angle had a significant impact on both the fatigue crack growth paths and the fatigue life cycles. The stress-intensity factor predictions from numerical models were compared to analytical data. Interestingly, it was observed that the maximum shear stress and von Mises stresses occurred when the loading angle was 45 degrees, which is considered a pure shear loading condition. The comparison shows consistent results, indicating that the simulation accurately captures the behavior of the AISI 316 austenitic stainless steel alloy under mixed-mode loading conditions. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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13 pages, 2698 KiB

Open AccessArticle

A Method for Plotting Failure Envelopes of Unidirectional Polymer Composite Materials under Different Strain Rates

by Hao Liu, Yuezhao Pang, Dandan Su, Yifan Wang and Ge Dong

Appl. Sci. 2023, 13(16), 9214; https://doi.org/10.3390/app13169214 - 13 Aug 2023

Viewed by 1622

Abstract

This article emphasizes the significance of investigating the nonlinear behavior and strength characteristics of polymer composite materials under various strain rates. The study utilizes test results of a unidirectional (UD) composite material subjected to compression at different angles relative to the reinforcement direction, using quasi-static, static, and dynamic strain rates. The analysis focused on a UD layer experiencing compressive stresses perpendicular to the fiber reinforcement and in-plane shear stresses. A novel model is presented, enabling the calculation and prediction of the strength of a UD composite under uniaxial loading at different angles to the fiber direction, considering various strain rates. The developed model facilitates the derivation of equations for the failure envelopes of UD Carbon Fiber-Reinforced Polymers (CFRPs) under quasi-static, static, and dynamic loading conditions. To construct the failure envelopes of CFRPs, it is necessary to acquire experimentally determined values of tensile and compressive strength in the direction perpendicular to the reinforcement, as well as the ultimate strength in uniaxial compression of a specimen with reinforcement at a 45° angle to the loading axis. The failure envelopes generated using the proposed model exhibit excellent agreement with experimental data, with coefficients of determination ranging from 0.864 to 0.957, depending on the deformation rate. Consequently, the developed model holds promise for predicting the strength of other UD polymer composite materials. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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19 pages, 12381 KiB

Open AccessArticle

Experimental Study of the Fatigue Life of Off-Highway Steel Wheels Using the Rim Section Test Approach

by Luigi Solazzi and Alberto Mazzoni

Appl. Sci. 2023, 13(16), 9119; https://doi.org/10.3390/app13169119 - 10 Aug 2023

Cited by 1 | Viewed by 1692

Abstract

Wheels are structural components designed to sustain dynamic loads and avoid fatigue failures in service. For their validation, when standard fatigue tests are not feasible due to premature tyre wear, alternative methods should be used. In this paper, the rim section test approach is evaluated for the fatigue life assessment of steel rims for off-highway wheels. Customized specimens were studied by finite element analysis and subjected to bending fatigue tests to obtain the fatigue curve for the critical point of the rim. The results were also compared to fatigue data from standard tests of the base material, confirming the importance of testing components in conditions as similar as possible to the final ones in service. Additional measurements of the specimens’ surface hardness showed how this approach is valid to consider the effects of possible work hardening induced in the components by the production process. The residual stress state, instead, does not seem to be considered appropriately, since the initial compressive residual stresses of the component were released during the manufacturing of the specimens. The overall results of the study confirmed the suitability of the section test approach as an alternative method for the fatigue life evaluation of structural components. Moreover, it could be used for specific investigations concerning the influence of the production process parameters on wheel rims. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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20 pages, 4039 KiB

Open AccessArticle

Resonant Fatigue Tests on Drill Pipe Connections with Different Geometries and Sizes

by Ciro Santus, Lorenzo Romanelli, Alessandro Burchianti and Tomoya Inoue

Appl. Sci. 2023, 13(14), 8006; https://doi.org/10.3390/app13148006 - 8 Jul 2023

Cited by 2 | Viewed by 2038

Abstract

In this study, a resonant bending fatigue test rig, designed and implemented by the University of Pisa, is presented, providing a detailed description of the set-up of the machine, the strain gauges calibrations, and the control system used with the main electronic devices. Several geometries of drill pipe connections and pipe samples made of different materials were tested, and all the obtained experimental fatigue results are presented in the paper and compared to previous experimental data. Fractographic images are provided to clearly show that, in two kinds of drill pipe connections, the crack initiation was found at the connection zone, whereas for another connection geometry, it was found at the pipe body. In order to interpret these latter results, a discussion about the section modulus of bending of the various sections of the drill pipes was provided, along with an FE model of a specific zone of one of these connections. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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14 pages, 2384 KiB

Open AccessArticle

Experimental and Numerical Investigation of the Mesoscale Size Effect in Notched Woven Composites

by Andrea Ferrarese, Carlo Boursier Niutta, Alberto Ciampaglia, Raffaele Ciardiello, Davide S. Paolino and Giovanni Belingardi

Appl. Sci. 2023, 13(7), 4300; https://doi.org/10.3390/app13074300 - 28 Mar 2023

Cited by 3 | Viewed by 1448

Abstract

The uniaxial strength of 2 × 2 twill carbon fiber-epoxy composite with circular open holes is governed by the stress concentration induced by the notch, as well as by the variation of the material response with the stress localization. In this study, these concurrent phenomena were studied using an experimental-numerical approach, considering the effect of the composite heterogeneity. An innovative simplified mesoscale model using shell elements to replicate the woven pattern was developed. The material properties of the model were identified with a data-driven optimization scheme that minimizes the difference between the experimental full-field strain, measured with Digital Image Correlation, and the one predicted by the model itself. The elastic properties identified for the material at tow level are analogous to that of a unidirectional composite, with longitudinal and transverse moduli of around 102 GPa and 15 GPa, respectively. The calibrated model was used to analyze the stress concentration and localization induced by circular notches with increasing diameter. A size effect describing the increase in the carbon fiber tow strength following the increase in stress localization was observed. The mesoscale material strength was found to increase by about 2.5 times in the presence of the notch, from 2131 to 3922 MPa in fiber direction, partially balancing the stress intensification effect of the hole that leads to an approximately three-fold stress increase in the material. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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Review

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20 pages, 324 KiB

Open AccessReview

A Comparative Analysis of 3D Software for Modeling Fatigue Crack Growth: A Review

by Abdulnaser M. Alshoaibi and Yahya Ali Fageehi

Appl. Sci. 2024, 14(5), 1848; https://doi.org/10.3390/app14051848 - 23 Feb 2024

Cited by 2 | Viewed by 3334

Abstract

Fatigue crack growth modeling is critical for assessing structural integrity in various engineering applications. Researchers and engineers rely on 3D software tools to predict crack propagation accurately. However, choosing the right software can be challenging due to the plethora of available options. This study aimed to systematically compare and evaluate the suitability of seven prominent 3D modeling software packages for fatigue crack growth analysis in specific applications. The selected software tools, namely ABAQUS, FRANC3D, ZENCRACK, LYNX, FEMFAT, COMSOL Multiphysics, and ANSYS, were subjected to a comprehensive analysis to assess their effectiveness in accurately predicting crack propagation. Additionally, this study aimed to highlight the distinctive features and limitations associated with each software package. By conducting this systematic comparison, researchers and engineers can gain valuable insights into the strengths and weaknesses of these software tools, enabling them to make informed decisions when choosing the most appropriate software for their fatigue crack growth analysis needs. Such evaluations contribute to advancing the field by enhancing the understanding and utilization of these 3D modeling software packages, ultimately improving the accuracy and reliability of structural integrity assessments in relevant applications. Full article

(This article belongs to the Special Issue Focus on Fatigue and Fracture of Engineering Materials, Volume II)

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