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Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II)

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 January 2024) | Viewed by 8767

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Prof. Dr. Dražan Kozak

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Mechanical Engineering Faculty in Slavonski Brod, University of Slavonski Brod, Trg Ivane Brlic Mazuranic 2, 35000 Slavonski Brod, Croatia
Interests: fracture mechanics; structural integrity analysis; finite element method; biomechanics; porous materials
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Prof. Dr. Nenad Gubeljak

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Faculty of Mechanical Engineering, University of Maribor, SI-2000 Maribor, Slovenia
Interests: welded joints; structural integrity assessment; fracture mechanics; finite element analysis, multi-scale modeling, fatigue
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Prof. Dr. Aleksandar Sedmak

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Innovation Centre, University of Belgrade, Belgrade, Serbia
Interests: welded joints; structural integrity assessment; fracture mechanics; finite element analysis; engineering materials
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Dear Colleagues,

Filler material used in welding should be the same class as base material, but welding codex often uses a filler with higher yield strength than the base material to shift eventual plastic deformation to the base metal, or with lower yield strength if cracking of the weld metal becomes inevitable. Welded joints are also often the location of potential flaws, where flaw assessment assumes homogeneous material properties, but welds are heterogeneous. There is a compendium of yield load solutions for strength mismatched fracture mechanics specimens developed to address the heterogeneity in the weld joint. However, solutions for the yield load at different combinations of the strength mismatch within the weld are missing, where mechanical testing and finite element simulations are necessary. In addition, the additive manufacturing materials can be made by advanced welding technology (by wire) or by powder laser additive technology. In both cases, residual stresses play important roles with respect to the geometry of the component and fatigue and fracture behaviour of the material. It is also an efficient tool to take into account residual stresses, which can strongly affect the stress distribution around the flaws in the heterogeneous weldments. In addition to more conventional approaches, the multi-scale methodology is computationally efficient and provides a possible means to bridge multiple-length scales (from 10 nm in MD simulation to 10 mm in FE model). This could be a useful tool in considering an acceptable level of accuracy with respect to yield load in heterogeneous welds. In this Special Issue, relevant contributions with respect to the aforementioned topics, as well as other additive manufactured structures, will all be considered.

Therefore, in this Special Issue, modern trends of testing and simulating heterogeneous welded and other additive manufactured components, including the multi-scale approach, resulting in appropriate flaw assessment procedures, are highlighted and discussed.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Prof. Dr. Dražan Kozak
Prof. Dr. Nenad Gubeljak
Prof. Dr. Aleksandar Sedmak
Guest Editors

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Keywords

welded and other additive manufactured components
fatigue and fracture of heterogeneous structures
mechanical testing
microstructure
multi-scale modelling
finite element analysis
structural integrity assessment
flaw assessment procedures for heterogeneous welds and other additive manufactured components

Related Special Issue

Numerical and Experimental Analysis of the Fracture Behaviour of Heterogeneous Welded Structures in Materials (11 articles)

Published Papers (6 papers)

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Research

0 pages, 10708 KiB

Open AccessArticle

Optimization of the Boundary Conditions of a Board Level Reliability Test Board to Maximize the Fatigue Life of Ball Grid Array Solder Joints under Thermal Cycling and Random Vibration

by Jisup Lee, Hyunsik Jeong and Gunhee Jang

Materials 2024, 17(3), 755; https://doi.org/10.3390/ma17030755 - 4 Feb 2024

Cited by 1 | Viewed by 977

Abstract

We investigated the screw hole position of a board level reliability (BLR) test board to improve the fatigue reliability of solder joints under thermal cycling and random vibration. We developed a finite element model of a BLR test board and derived the plastic strain energy density and 1-sigma stress, which are the main parameters influencing the fatigue life of solder joints under thermal cycling and random vibration, respectively. We analyzed the correlation between the screw hole position and the main parameters of the fatigue life through sensitivity analysis. By performing multi-objective optimization, we determined the screw hole position that maximizes the fatigue life of solder joints under thermal cycling and random vibration. With the optimal screw hole position, the fatigue life significantly increased under thermal cycling and random vibration compared to the BLR test board with the initial screw hole position. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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17 pages, 14909 KiB

Open AccessArticle

Determining the Role of Acicular Ferrite Carbides in Cleavage Fracture Crack Initiation for Two Medium Carbon Microalloyed Steels

by Gvozden Jovanović, Dragomir Glišić, Stefan Dikić, Bojan Međo, Branislav Marković, Nikola Vuković and Nenad Radović

Materials 2023, 16(22), 7192; https://doi.org/10.3390/ma16227192 - 16 Nov 2023

Viewed by 883

Abstract

Two medium-carbon microalloyed steels with a predominant acicular ferrite microstructure were investigated in this study in order to determine the initial micro-crack formation mechanism and the role of acicular ferrite structure in cleavage fracture. In order to ensure cleavage fracture, samples were investigated at −196 °C for uniaxial tension and four point bending fracture. Previous investigations have shown that cleavage fracture for steels with a predominant acicular ferrite microstructure has not been initiated by the fracture of coarse TiN particles as in ferrite-pearlite, bainite, or martensitic microalloyed steels. The average maximal thickness of cementite plates measured in this work is 0.798 µm and 0.966 µm, for V and TiV steel, respectively. The corresponding stress values required for their fracture according to Griffith’s equation are 1970 MPa and 1791 MPa, respectively. Estimated values of the effective surface energy for the V steel with an average cementite volume fraction of 3.8% range from 40 Jm⁻² to 86 Jm⁻², and for the TiV steel with an average cementite volume fraction of 18.3% range from 55 Jm⁻² to 82 Jm⁻². The fracture of coarse cementite plates was found to not to be responsible for the cleavage fracture initiation in case of both steels. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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14 pages, 4436 KiB

Open AccessArticle

Influence of Pulsed Arc Parameters on the Tig Welding Process for the Stainless Steel Duplex UNS S31803

by Vinicius Marques Alves Generoso, Lucas Menezes de Souza, Elaine Cristina Pereira, Sergio N. Monteiro and Afonso R. G. de Azevedo

Materials 2023, 16(21), 6870; https://doi.org/10.3390/ma16216870 - 26 Oct 2023

Cited by 1 | Viewed by 1058

Abstract

The influence of parameters involved in the pulsed electric arc, used as an energy source in the tungsten inert gas (TIG)-mediated welding of Duplex UNS S31803 stainless steel, to attend the manufacture of flexible pipes for the extraction of oil and gas is presented. A fundamental part in the manufacturing process of flexible pipelines is the welding of these strips so that corresponding TIG welds will be subjected to the same process and work conditions. Therefore, it is necessary to maintain the same properties in the welded regions. Covering the effects of each parameter of the pulsed electric arc such as peak and base current as welds, cyclic ratio, and pulsation frequency is a desirable endeavor. The final objective is the mitigation of problems that have a great impact on production, such as weld breakage during the conformation of the strip in the process and test failures. With this, tensile, bending, and ferrite percentage tests were performed on 12 samples that qualified as satisfactory in the visual aspect. A minimum tensile strength of 734.57 MPa and a maximum of 775.77 MPa were obtained where all values found are above the tensile strength limit of the base material of 620 MPa. With the completion of the study, it is possible to understand not only the response of the process to each parameter but also the tendency when changing them. Moreover, it is possible to explore the possibility of guiding the changes to achieve results about the visual aspect and the mechanical properties of the welded material. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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16 pages, 12828 KiB

Open AccessArticle

Effect of Temperature on S32750 Duplex Steel Welded Joint Impact Toughness

by Srđa Perković, Aleksandar Sedmak, Zoran Radaković, Zijah Burzić, Simon Sedmak, Ljubica Radović and Jovana Mandić

Materials 2023, 16(12), 4432; https://doi.org/10.3390/ma16124432 - 16 Jun 2023

Viewed by 1141

Abstract

The search for alternative materials that can be used for parts of aircraft hydraulic systems has led to the idea of applying S32750 duplex steel for this purpose. This steel is mainly used in the oil and gas, chemical, and food industries. The reasons for this lie in this material’s exceptional welding, mechanical, and corrosion resistance properties. In order to verify this material’s suitability for aircraft engineering applications, it is necessary to investigate its behaviour at various temperatures since aircrafts operate at a wide range of temperatures. For this reason, the effect of temperatures in the range from +20 °C to −80 °C on impact toughness was investigated in the case of S32750 duplex steel and its welded joints. Testing was performed using an instrumented pendulum to obtain force–time and energy–time diagrams, which allowed for more detailed assessment of the effect of testing temperature on total impact energy and its components of crack initiation energy and crack propagation energy. Testing was performed on standard Charpy specimens extracted from base metal (BM), welded metal (WM), and the heat-affected zone (HAZ). The results of these tests indicated high values of both crack initiation and propagation energies at room temperature for all the zones (BM, WM, and HAZ) and sufficient levels of crack propagation and total impact energies above −50 °C. In addition, fractography was conducted through optical microscopy (OM) and scanning electron microscopy (SEM), indicating ductile vs. cleavage fracture surface areas, which corresponded well with the impact toughness values. The results of this research confirm that the use of S32750 duplex steel in the manufacturing of aircraft hydraulic systems has considerable potential, and future work should confirm this. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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17 pages, 11380 KiB

Open AccessArticle

Influence of Repair Welding on the Fatigue Behavior of S355J2 T-Joints

by Peng Zhao, Banglong Yu, Ping Wang, Yong Liu and Xiaoguo Song

Materials 2023, 16(10), 3682; https://doi.org/10.3390/ma16103682 - 11 May 2023

Cited by 1 | Viewed by 1670

Abstract

This paper investigated the effect of repair welding on the microstructure, mechanical properties, and high cycle fatigue properties of S355J2 steel T-joints in orthotropic bridge decks. The test results found that the increase in grain size of the coarse, heat-affected zone decreased the hardness of the welded joint by about 30 HV. The tensile strength of the repair-welded joints was reduced by 20 MPa compared to the welded joints. For the high cycle fatigue behavior, the fatigue life of repair-welded joints is lower than that of the welded joints under the same dynamic load. The fracture positions of toe repair-welded joints were all at the weld root, while the fracture positions of the deck repair-welded joints were at the weld toe and weld root, with the same proportion. The fatigue life of toe repair-welded joints is reduced more than that of deck repair-welded joints. The traction structural stress method was used to analyze fatigue data of the welded and repair-welded joints, and the influence of angular misalignment on was considered. The fatigue data with and without AM are all within the ±95% confidence interval of the master S-N curve. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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18 pages, 12482 KiB

Open AccessArticle

Effects of Post-Weld Heat Treatment on Microstructure and Mechanical Properties of the Brazed Joint of a Novel Fourth-Generation Nickel-Based Single Crystal Superalloy

by Zhipeng Zhang, Jide Liu, Chongwei Zhu, Yuyu Huang, Xinguang Wang, Yizhou Zhou, Jianjun Wang and Jinguo Li

Materials 2023, 16(8), 3008; https://doi.org/10.3390/ma16083008 - 11 Apr 2023

Cited by 1 | Viewed by 1972

Abstract

A novel fourth-generation nickel-based single crystal superalloy was brazed with Co-based filler alloy. The effects of post-weld heat treatment (PWHT) on the microstructure and mechanical properties of brazed joints were investigated. The experimental and CALPHAD simulation results show that the non-isothermal solidification zone was composed of M₃B₂, MB-type boride and MC carbide, and the isothermal solidification zone was composed of γ and γ’ phases. After the PWHT, the distribution of borides and the morphology of the γ’ phase were changed. The change of the γ’ phase was mainly attributed to the effect of borides on the diffusion behavior of Al and Ta atoms. In the process of PWHT, stress concentration leads to the nucleation and growth of grains during recrystallization, thus forming high angle grain boundaries in the joint. The microhardness was slightly increased compared to the joint before PWHT. The relationship between microstructure and microhardness during the PWHT of the joint was discussed. In addition, the tensile strength and stress fracture life of the joints were significantly increased after the PWHT. The reasons for the improved mechanical properties of the joints were analyzed and the fracture mechanism of the joints was elucidated. These research results can provide important guidance for the brazing work of fourth-generation nickel-based single crystal superalloy. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behaviour of Welded and Other Additive Manufactured Structures (Volume II))

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