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The presence of defects in additive manufactured maraging steel is a widespread problem as its dependence on processing parameters significantly influences it. Using X-ray computed tomography, along with optical microscope data limited to 2D images, quantifies the internal porosity present on a compact tension sample typically employed in fatigue testing. The primary goal of this research is to analyse the pores obtained after the fabrication of a compact tension sample and their main definition parameters, such as sphericity, aspect ratio, surface, and volume, and obtain validation of which method is valid for each of the parameters analysed. The current study aims to enhance the understanding of defects in maraging steel samples through non-destructive 3D analysis. Conventional 2D analyses are limited to surface measurements, providing incomplete information. The proposed method will provide a comprehensive understanding of the defects inside the maraging steel sample, thereby improving the reliability of this material for further applications. This study will contribute to academic and industrial communities by providing a novel approach to analysing maraging steel samples and, ultimately, developing improved materials for various applications. The study’s findings reveal that most pores are produced by gases that are trapped in the fabrication process, and keyhole pores only appear near the surface.

This research focuses on analysing the 18Ni300 maraging steel produced through laser powder bed fusion. Specifically, it aims to examine the phase components using X-ray diffraction, the microstructure through scanning electron microscopy, and the hardness of the different structures present in the manufactured material. The primary goal is to meticulously analyse the material and its microstructures. By doing so, a correlation between the hardness and each structure type, be it cellular or columnar, can be established. This will allow us to pinpoint any defects in the material before any surface chemical treatment is carried out and facilitate a thorough examination of its microstructure. A consistent pattern emerges across the samples through systematic measurement of microhardness distribution in various locations and detailed examination of the structure. The findings of the study reveal that the hardness of cellular and columnar structures exhibits a significant variation based on the location of the measurement about cell boundaries. The hardness value is notably higher in the combination of cellular and multiple layers, as the data indicate.

In order to improve understanding of the fatigue behaviour in additive manufactured samples, this research delves into the challenging interplay between building parameters, particularly fabrication angles, and the presence of pores. The primary objective is to explore the characterisation of these pores and unravel their relationship with the fatigue properties of the material under investigation. Through a systematic analysis of porosity distribution in various fabrication orientations, supplemented by a detailed examination of the elemental dispersion around specific porous structures using energy-dispersive X-ray spectroscopy, a consistent behavioural pattern emerges across the samples. In assessing fatigue behaviour, an examination of the variables reveals that only area and aspect ratio significantly influence the behaviour of the samples. Such studies can contribute substantially to academic research in the field of material science and engineering.

This paper presents an extensive literature review focusing on the utilisation of crack tip plasticity as a crucial parameter in determining and enhancing crack growth models. The review encompasses a comprehensive analysis of various methodologies, predominantly emphasising numerical simulations of crack growth models while also considering analytical approaches. Although experimental investigations are not the focus of this review, their relevance and interplay with numerical and analytical methods are acknowledged. The paper critically examines these methodologies, providing insights into their advantages and limitations. Ultimately, this review aims to offer a holistic understanding of the role of crack tip plasticity in the development of effective crack growth models, highlighting the synergies and gaps between theoretical, experimental, and simulation-based approaches.

This work presents a new approach for studying crack growth resulting from fatigue, which utilizes the plastic contribution of crack-tip opening displacement (CTODp). CTODp is used to predict austenitic stainless-steel crack propagation. Unlike linear elastic fracture mechanics analysis, the method presented here is also helpful for tasks other than small-scale yielding. The approach was based on correlating full-field displacement information with post-processing digital images. This work describes a detailed post-processing protocol that can be used to calculate CTODp. The results for steel compact-tension specimens were especially promising. Of note, there was a linear relationship between the propagation rate of fatigue cracks and the CTODp range.

In this work, the influence of the tool geometry on friction stir spot welding (FSSW) was studied on sheets made of AA6061-T6 aluminum alloy. Four different AISI H13 tools with simple cylindrical and conical pin profiles and 12 mm and 16 mm shoulder diameters were used to perform the FSSW joints. Sheets of 1.8 mm thickness were used during the experimental work to prepare the lap-shear specimens. The FSSW joints were performed at room temperature. For each joining condition, four specimens were carried out. Three specimens were used to find the value of the average tensile shear failure load (TSFL), while the fourth one was used to examine the micro-Vickers hardness profile and to observe the microstructure of the cross-section of the FSSW joints. The investigation concluded that higher mechanical properties corresponding to the finer microstructure were obtained by the conical pin profile and the higher shoulder diameter compared with the specimens performed using the cylindrical pin tool and lower shoulder diameter due to the higher strain hardening and the higher frictional heat generation, respectively.

Accurate knowledge of the plastic zone of fatigue cracks is a very direct and effective way to quantify the damage of components subjected to cyclic loads. In this work, we propose an ultra-fine experimental characterisation of the plastic zone based on Vickers micro-indentations. The methodology is applied to different compact tension (CT) specimens made of aluminium alloy 2024-T351 subjected to increasing stress intensity factors. The experimental work and sensitivity analysis showed that polishing the surface to #3 μm surface finish and applying a 25 g-force load for 15 s produced the best results in terms of resolution and quality of the data. The methodology allowed the size and shape of both the cyclic and the monotonic plastic zones to be visualised through 2D contour maps. Comparison with Westergaard’s analytical model indicates that the methodology, in general, overestimates the plastic zone. Comparison with S355 low carbon steel suggests that the methodology works best for alloys exhibiting a high strain hardening ratio.

A study on the accuracy of the approximation of the displacement field around of crack tip in a sample made from bridge steel (S355) is main objective of contribution. Linear elastic fracture mechanics (LEFM) theory in framework of multi-parameter formulation, i.e. postulated by Williams is used to determine of coefficients of Williams power series terms. Over deterministic method was used to calculate the terms based on the least squares regression technique, applied on data from numerical simulation and experiment on S355 steel grades. Comparison between the stress fields (by principal stress 1 and von Mises stress HMH) obtain from experimental measurement DIC, Hybrid method and obtain from reconstruction by using various number of Williams power terms are quantified in order to get key information around the crack tip region on bridge steel specimens.

The fatigue overload behaviours of coarse grain (~30 μm), ultrafine grain (360 nm) and nanocrystalline (~30 nm) Ni are compared under constant amplitude loading at R = 0.1 after a 100% overload. Synchrotron X-ray diffraction is applied to map the elastic crack-tip strain fields at the mid-thickness of a compact tension specimen of nanocrystalline Ni at various stages through the loading cycles, from which the variation in stress before, during and after overload is estimated. Digital image correlation is used to measure the crack length and the displacement fields at the specimen surfaces for both grain sizes, from which the fatigue crack growth (FCG) rate, crack opening displacement and stress intensity factor range are determined. The FCG for coarse grain Ni is most significantly retarded whereas the nanocrystalline Ni is least affected by the overload due to an increased yield stress and a more planar crack surface morphology. As a result, FCG retardation by plasticity, surface roughness and residual stress-induced crack closure are reduced. Keywords: Nanocrystalline, Retardation mechanisms, Energy dispersive X-ray diffraction, Crack path, J-integral

The current work aims at estimating the stress intensity factor deep inside the bulk from elastic strain data measured by synchrotron X-ray diffraction. Key features affecting the evaluation of the stress intensity factor are the number of terms in the analytical model describing the crack tip field, the extension and position of the area of interest of the experimental data, the effect of the experimental data collected within the plastic zone and the number of elastic strain data points used. Here a parametric study of these features is presented in terms of their influence for the stress intensity factor determination. It was found that 3 or 4 terms in Williams’ expansion is often sufficient; the data should be collected from across the full range of angles around the crack tip; and the number of points/number of terms should be greater than 40.

Most mechanical components are subjected to the complex fatigue loading conditions, where both amplitude and direction of loading cycles change over the time. The estimation of damage caused by these complex loading scenarios are often done by simplified uniaxial fatigue theories, which ultimately leads to higher factor of safety during the final design considerations. Critical plane-based fatigue theories have been considered more accurate for computing the fatigue damage for multiaxial loading conditions in comparison to energy-based and equivalent stress-based theories. Two recently developed fatigue theories have been evaluated in this work for the available test data. Test data includes significant amount of biaxial load paths.

A study on the accuracy of the approximation of the displacement field around of crack tip in a sample made from bridge steel (S355) is main objective of contribution. Linear elastic fracture mechanics (LEFM) theory in framework of multi-parameter formulation, i.e. postulated by Williams is used to determine of coefficients of Williams power series terms. Over deterministic method was used to calculate the terms based on the least squares regression technique, applied on data from numerical simulation and experiment on S355 steel grades. Comparison between the stress fields (by principal stress s1 and von Mises stress sHMH) obtain from experimental measurement DIC, Hybrid method and obtain from reconstruction by using various number of Williams power terms are quantified in order to get key information around the crack tip region on bridge steel specimens.

Most mechanical components experience multi-axial cyclic loading conditions during service. Experimental analysis of fatigue cracks under such conditions is not easy and most works tend to focus more on the simpler but less realistic case of uni-axial loading. Consequently, there are many uncertainties related to the load sequence effect that are now well known and are not normally incorporated into the growth models. The current work presents a new methodology for evaluating overload effect in biaxial fatigue cracks. The methodology includes evaluation of mixed-mode (KI and KII) stress intensity factor and the Crack Opening Displacement for samples with and without overload cycle under biaxial loading. The methodology is tested under a range of crack lengths. All crack-tip information is obtained with a hybrid methodology that combines experimental full-field digital image correlation data and Williams' elastic model describing the crack-tip field.

The main goal of this work is describing the experience in using Project Based Learning (PBL) methodology in Materials Science courses in several Engineering degrees. The courses were taught simultaneously in four different Spanish universities. In addition, the impact of this proposal on the acquisition of transversal skills through the perceptions of students and teachers is assessed. In order to do so, voices of over 54 students and 5 lecturers involved in the work have been gathered and studied descriptively. Discussion groups and self-reports have been collected and subsequently analysed. The analysis of the data collected by these two instruments has been coded and categorized into general dimensions. The results show how, through the PBL, self-learning is encouraged and the development of transversal skills such as teamwork are enhanced. Meanwhile, the lecturers consider PBL an appropriate methodology for Materials Science courses; however its implementation requires a higher work load. The faculty acknowledged PBL as a very interesting tool to work and evaluate transversal competences. Hence, the PBL methodology stands as one of the most effective methods that meet the demands of the 21st century and enables students to acquire not only content based knowledge, but also other abilities.

In this work, the multiaxial fatigue behaviour of 316 and 304 stainless steel was studied. The study was based on the critical plane approach which is based on observations that cracks tend to nucleate and grow in specific planes. Three different critical plane models were employed to this end, namely Fatemi−Socie (FS), Smith−Watson−Topper (SWT) and the newly proposed Sandip−Kallmeyer−Smith (SKS) model. The study allowed equi-biaxial stress state, mean strain and non−proportional hardening effects to be taken into consideration. Experimental tests including different combinations of tension, torsion and inner pressure were performed and were useful to identify the predominant failure mode for the two materials. The results also showed that the SKS damage parameter returned more conservative results than FS with lower scatter level in both materials, with prediction values between FS and SWT.

The evolution of crack-tip strain fields in a thin (plane stress) compact tension sample following an overload (OL) event has been studied using two different experimental techniques. Surface behaviour has been characterised by Digital Image Correlation (DIC), while the bulk behaviour has been characterised by means of synchrotron X-ray diffraction (XRD). The combination of both surface and bulk information allowed us to visualise the through-thickness evolution of the strain fields before the OL event, during the overload event, just after OL and at various stages after it. Unlike previous work, complete 2D maps of strains around the crack-tip were acquired at 60m spatial resolution by XRD. The DIC shows less crack opening after overload and the XRD a lower crack-tip peak stress after OL until the crack has grown past the compressive crack-tip residual stress introduced by the overload after which the behaviour returned to that for the baseline fatigue response. While the peak crack-tip stress is supressed by the compressive residual stress, the crack-tip stress field changes over each cycle are nevertheless the same for all Kmax cycles except at OL.

In the past two decades, crack-tip mechanics has been increasingly studied with full-field techniques. Within these techniques, Digital Image Correlation (DIC) has been most widely used due to its many advantages, to extract important crack-tip information, including Stress Intensity Factor (SIF), Crack Opening Displacement, J-integral, T-stress, closure level, plastic zone size, etc. However, little information is given in the literature about the experimental setup that provides best estimations for the different parameters. The current work aims at understanding how the experimental conditions used in DIC influence the crack-tip information extracted experimentally. The influence of parameters such as magnification factor, size of the images, position of the images with respect the crack-tip and size of the subset used in the correlation is studied. The influence is studied in terms of SIF and T-stress by using Williams’ model. The concept of determination of the K-dominance zone from experimental data has also explored. In this regard, cyclic loading on a fatigue crack in a compact tension (CT) specimen, made of aluminium 2024-T351 alloy, has been applied and the surface deformation ahead of the crack tip has been examined. The comparison between theoretical and experimental values of KI showed that the effect of subset size on the measured KI is negligible compared to the effect of size of the image.

In this paper a methodology for evaluating crack initiation under biaxial conditions is presented. The methodology consists of evaluating the crack length automatically with digital processing of highmagnification images of the crack. The methodology was applied to study five different strain conditions on a low carbon ferritic-pearlitic steel specimen with tubular shape. A hole of 150 μm diameter was drilled to enforce the crack to initiate at a particular spot. Different combinations of axial and torsional strains were analysed during the initiation stage of the crack. The setup employed allowed detection of the crack to within 6 μm from the edge of the hole on average and monitoring of the crack during early stages. Fatigue crack propagation curves clearly showed oscillations due to microstructure. It was also observed that these oscillations decreased as the torsional component of the strain was increased.

A study on the approximation of the stress field in the vicinity of crack tip in a compact tension specimen made from Al 2024-T351 is presented. Crack tip stress tensor components are expressed using the linear elastic fracture mechanics (LEFM) theory in this work, more precisely via its multi-parameter formulation, i.e. by Williams power series (WPS). Determination of coefficients of terms of this series is performed using a least squares-based regression technique known as over deterministic method (ODM) for which displacements data obtained experimentally via optical measurements are taken as inputs. The stress fields reconstructed based on the displacement data obtained experimentally by means of optical measurements are verified by means of the stress field approximations derived for the normalized CT specimen via hybrid elements.

This work analyses the prediction capabilities of a recently developed critical plane model, called the SKS method. The study uses multiaxial fatigue data for S355-J2G3 steel, with in-phase and 90° out-of-phase sinusoidal axial-torsional straining in both the low cycle fatigue and high cycle fatigue ranges. The SKS damage parameter includes the effect of hardening, mean shear stress and the interaction between shear and normal stress on the critical plane. The collapse and the prediction capabilities of the SKS critical plane damage parameter are compared to well-established critical plane models, namely Wang-Brown, Fatemi-Socie, Liu I and Liu II models. The differences between models are discussed in detail from the basis of the methodology and the life results. The collapse capacity of the SKS damage parameter presents the best results. The SKS model produced the second-best results for the different types of multiaxial loads studied.

This work presents an in-situ characterisation of crack-tip strain fields following an overload by means of synchrotron X-ray diffraction. The study is made on very fine grained bainitic steel, thus allowing a very high resolution so that small changes occurring around the crack-tip were captured along the crack plane at the mid-thickness of the specimen. We have followed the crack as it grew through the overload location. Once the crack-tip has progressed past the overload event there is strong evidence that the crack faces contact in the region of the overload event (though not in the immediate vicinity of the current locations of the crack tip) at Kmin even when the crack has travelled 1mm beyond the overload location. It was also found that at Kmax the peak tensile strain ahead of the crack-tip decreases soon after the overload is applied and then gradually recovers as the crack grows past the compressive region created by the overload.

This work presents a novel methodology for characterising fatigue cracks under biaxial conditions. The methodology uses high magnification Digital Image Correlation (DIC) technique for measuring displacement and strain crack-tip fields. By applying micro-speckle pattern on the metal surface it is possible to achieve high magnification for DIC technique. The speckles were created by electro-spray technique. The validity of this novel technique is demonstrated by direct comparison with standard extensometer measurements, under tension-compression and torsion conditions. In order to image the correct region, the notch effect on the fatigue life was also evaluated.

This paper focus on the study of biaxial fatigue cracks based on a methodology that enables evaluation of the overload effect in fatigue. The methodology is based on the experimental evaluation via full-field technique of digital image correlation of the effective stress intensity factor and the crack opening displacement (COD). The tests were performed on cylindrical specimens made of low carbon steel subjected to tension-tension and a combination of tension and torsion loads. The experimental data was used to compare the crack growth behaviour with an overload cycle under uniaxial and biaxial loading. A hybrid method was also employed to evaluate the value of the Stress Intensity Factor (SIF) before and after applying the overload. The results showed a reliable estimation of closure level and SIF for both uniaxial and biaxial loading condition. A new procedure previously developed for uniaxial loads was adapted to the study of biaxial loads. This new procedure was used to identify important differences produced by the overload event.

A study on the accuracy of the approximation of the displacement field around of crack tip in a sample made from bridge steel (S355) is main objective of contribution. Linear elastic fracture mechanics (LEFM) theory in framework of multi-parameter formulation, i.e. postulated by Williams is used to determine of coefficients of Williams power series terms. Over deterministic method was used to calculate the terms based on the least squares regression technique, applied on data from numerical simulation and experiment on S355 steel grades. Comparison between the stress fields (by principal stress σ 1 and von Mises stress sHMH) obtain from experimental measurement DIC, Hybrid method and obtain from reconstruction by using various number of Williams power terms are quantified in order to get key information around the crack tip region on bridge steel specimens. [ABSTRACT FROM AUTHOR]