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Crack size and undermatching effects on fracture behavior of undermatched welded joints are presented and analyzed. Experimental and numerical analysis of the fracture behavior of high-strength low-alloyed (HSLA) steel welded joints with so-called small and large crack in undermatched weld metal and the base metal was performed, as a part of more extensive research previously conducted. J integral was determined by direct measurement using special instrumentation including strain gauges and a CMOD measuring device. Numerical analysis was performed by 3D finite element method (FEM) with different tensile properties in BM and WM. Results of J-CMOD curves evaluation for SUMITEN SM 80P HSLA steel and its weld metal (WM) are presented and analyzed for small and large cracks in tensile panels. This paper is focused on some new numerical results and observations on crack tip fields and constraint effects of undermatching and crack size keeping in mind previously performed experiments on the full-scale prototype. In this way, a unique combined approach of experimental investigation on the full-scale proto-type and tensile panels, as well as numerical investigation on mismatching and crack size effects, is achieved.

This paper presents a part of development of a non-standard method for testing of cylindrical test specimens for measurement of fracture properties of pipeline materials. This method for testing of cylindrical structures working under pressure is based on determining of fracture mechanics parameters on SENT (Single Edge Notched Tension) specimens and new PRNT (Pipe Ring Notched Tension) specimens. In this work, both types of specimens required for this testing were manufactured from polyamide PA12 by using SLS (selective laser sintering) additive manufacturing method. Testing of the specimens is performed on the universal device for testing of mechanical properties of materials Shimadzu, AGS-X 100 kN. The tensile testing is accompanied by GOM Aramis 2M system, used for digital image correlation. By using these two systems, test results are obtained for ring-shaped and SENT specimens, including forces, displacements and fracture mechanics parameters CMOD (Crack Mouth Opening Displacement) and CTOD-?5 (Crack Tip Opening Displacement obtained by ?5 technique), as well as crack growth. Repeatability of this process, along with valid result consistency, represent the basis for further development of the new method, including the determining of energy-based fracture mechanics parameters: J integral and stress intensity factor.

This paper deals with analysis and comparison of the equivalent plastic strain and temperature fields in the aluminium alloy 2024 T3 (AA2024 T3) joint, with macro/microstructure appearance and hardness profile. In the alloys hardened by heat treatment, grain size and particle size of the precipitate are functions of equivalent plastic strain, strain rate and temperature. By analysing the equivalent plastic strain fields and temperature fields it is possible, to some extent, to capture the effect of welding parameters and thermo-mechanical conditions on grain structure, and therefore hardness and strength in the welded joint. A coupled thermo-mechanical model is applied to study the material behaviour during the linear welding stage of friction stir welding. The 3-D finite element model has been created in ABAQUS/EXPLICIT software using the Johnson-Cook material law. The values of thermo-mechanical quantities during the welding stage are obtained from the numerical model and shown as distributions across the joint. The obtained values of these quantities are related to the microstructure of the joint zones and hardness distribution, and this relation is discussed.

In order to define a procedure for integrity assessment of pipelines and determining the fracture mechanics parameters, a new type of specimen with a sharp notch, Pipe Ring Notched Tension (PRNT) specimen, is tested. The aim of the study is to determine the influence of the specimen geometry (cylindrical shape, as well as number and length of stress concentrators) on parameters such as force, Crack Mouth Opening Displacement CMOD, Crack Tip Opening Displacement CTOD and J integral. The specimens were fabricated by an additive production method - selective laser sintering (SLS). EOS Formiga P100 machine is used, and the material is polyamide PA12. In addition to Pipe Ring Notched Tension specimens, Single Edge Notched Tension (SENT) specimens with identical cross section were also considered. All specimens were tested on a universal tensile testing machine. A tool specially designed to apply contact pressure to the inner walls in the tension direction was used, simulating the internal pressure. For determining the field of displacement and strain on the surface of the tested samples that occur during the loading, Aramis GOM 2M optical measurement system was used. Aramis is applied for determination of geometry fracture mechanics parameters: CMOD and CTOD (based on δ5 concept). In addition to the examination of fracture properties of additively manufactured PA12, the main topic of this work is the development of the non-standard testing procedure, which will be subsequently applied to the specimens cut from metallic or non-metallic pipes. As an important part of this procedure, the calculation of fracture parameters will be conducted based on the results presented here.

The influence of friction stir welding parameters on thermo-mechanical behavior of the material during welding is analyzed. An aluminum alloy is considered (Al 2024 T351), and different rotating and welding speeds are applied. The finite element model consists of the working plate (Al alloy), backing plate and welding tool. The influence of the welding conditions on material behavior is taken into account the application of the Johnson-Cook material model. The rotation speed of the tool affects the results. If increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, which stems from the plastic deformation of the material, is negligibly changed. When the welding speed, i.e. tool translation speed, is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming is becoming more pronounced. Summed, this leads to rather small change of the total generation. The changes of the heat generation influence both the temperature field and reaction force. Also, the inadequate selection of welding parameters resulted in occurrence of the defects (pores) in the model.

Fracture of welded joints has been an important research and industrial topic for a long time, having in mind the key role of welded joints in ensuring the safe operation and integrity of welded structures. This work contains an overview of application of micromechanical models to ductile fracture of welded joints. The main benefit of these models, in comparison with the classical fracture mechanics approach, is consideration of the local quantities (stress and strain) in prediction of damage development. The damage is quantified through the value of the damage parameter, which is typically related to the void nucleation, growth and coalescence for ductile fracture of metallic materials, i.e. the description of the material can be related to the actual material behaviour during fracture. Most of the presented studies, including those published by the present authors, are performed on steel as the base material, and the rest deal with aluminium alloys. [Projects of the Serbian Ministry of Education, Science and Technological Development, Grant no. 451-03-68/2020-14/200135, Grant no. 451-03-68/2020-14/200105]

True stress-strain curves of HSLA steel welded joint regions were estimated by using numerical simulation of strains measured by DIC and special iteration procedure to match the results. Strains were measured at certain level of loading in all regions of welded joint with different tensile properties, namely base metal (BM), weld metal (WM) and two subzones of Heat-Affected-Zone (fine grain, FGHAZ, and coarse grain – CGHAZ). By converting engineering stress (load divided by initial cross section area) into true stress, experimental true stress-true strain curves are obtained and used as initial iteration for the Finite Element Method (FEM) simulation, after being fitted by the power law relation for stress-strain curves. Obtained results are then compared with the experimental results to find the differences and make appropriate correction in power law curves and make as many iterations as needed before the differences become small enough. This procedure has been verified by an example of welded tensile panel.

Severe plastic deformation (SPD) is a popular group of techniques applied to achieve the nanostructuring of the metallic biomaterials and improvement of their mechanical characteristics. One of the most commonly used SPD methods is the high-pressure torsion (HPT) technique which enables the obtainment of the microstructure with small grains and high strength. In the present study, the influence of the plastic deformation and surface modification treatment on the tensile and corrosion properties of the Ti–13Nb–13Zr (wt%) alloy is investigated. In that purpose, the coarse-grained (CG) Ti–13Nb–13Zr (TNZ) alloy was subjected to the HPT processing by applying a pressure of 4.1 GPa with a rotational speed of 0.2 rpm and 5 revolutions at room temperature to obtain the ultrafine-grained (UFG) microstructure. The alloy microstructure before and after HPT processing was analysed using the scanning electron microscopy (SEM) and the X-ray diffraction (XRD). The homogeneity of the UFG TNZ alloy was determined by microhardness testing and microscopic observations. The nanotubular oxide layer on the surface of the TNZ alloy, both in CG and UFG condition, was formed by electrochemical anodization in 1 M H3PO4 + NaF electrolyte for 90 min. SEM analysis was used to characterise the morphology of the anodized surfaces, while energy dispersive spectroscopy was applied to determine the chemical composition of the nanostructured layers formed at the alloy surfaces. Mechanical properties of the TNZ alloy, before and after HPT processing and electrochemical anodization, were determined by tensile testing. After tensile testing, the fractographic analysis was conducted to identify the fracture mechanisms. The potentiodynamic polarization technique was used to determine the corrosion resistance of the alloy before and after plastic deformation and surface modification treatment. The obtained results showed that the alloy is reasonably homogeneous after the HPT processing. The XRD analyses reviled the presence of α′ and β phases in the CG TNZ alloy microstructure, while the additional ω phase was detected in the microstructure of the UFG TNZ alloy. The HPT obtained alloy exhibits higher hardness and improved tensile properties than the alloy in the as-received CG condition, while the electrochemical anodization leads to a decrease of its mechanical properties. Both CG and UFG alloys show excellent corrosion stability in Ringer’s solution. Moreover, electrochemical anodization leads to a decrease or an increase of the corrosion resistance of these materials, depending on the morphology of the formed nanotubular surface layers. The results indicate that the anodized CG TNZ alloy is characterized by a lower modulus of elasticity and better corrosion resistance properties than the anodized UFG TNZ alloy. Graphic Abstract: [Figure not available: see fulltext.] © 2020, The Korean Institute of Metals and Materials.

In this paper, structural and mechanical properties of APS - atmospheric plasma spray coating Al-12Si are presented. The aim of the research was the optimisation of the flow of powder to produce layers with optimal mechanical and structural properties that will be applied to the worn out parts of airplanes. Three groups of samples were produced, by utilising three powder feed rates: 30 g/min, 45 g/min and 60 g/min. Evaluation of layers’ microhardness was done using HV0.3 method and the bond strengthwas determined by testing of tensile strength. Surface morphology of the deposited powder particles was examined on SEM (Scanning Electron Microscope). The microstructure of the coating with the best measured mechanical properties was subsequently examined in etched condition on optical microscope and SEM (in accordance with the standard PN 585005, Pratt & Whitney). Also, fracture morphology of this coating in deposited state was examined using SEM. It was found that powder feed control with atmospheric plasma spraying can produce dense layers of Al-12Si coating with good bond strength.

Friction stir welding is one of the procedures for joining the parts in solid state. Thermo-mechanical simulation of the friction stir welding of high-strength aluminium alloys 2024 T3 and 2024 T351 is considered in this work. Numerical models corresponding to the linear welding stage are developed in Abaqus software package. The material behaviour is modelled by Johnson-Cook law (which relates the yield stress with temperature, strain and strain rate), and the Arbitrary Lagrangian-Eulerian technique is applied. The difference in thermo-mechanical behaviour between the two materials has been analysed and commented. The main quantities which are considered are the temperature in the weld area, plastic strain, as well as the rate of heat generation during the welding process. [Project of the Serbian Ministry of Education, Science and Technological Development, Grant no. TR 34016 and Grant no. ON 174004]

The industrial application of high-strength low-alloyed steel (HSLA) in welded structures has increased the demand for understanding fracture behavior and structural integrity assessment of this type of steel and produced welded joints. The aim of this paper is to simulate the experimental evaluation of the fracture mechanics specimens by using the micromechanical model. The investigation is performed on two standard single edge notch bend (SENB) specimens with imposed crack in the central region. Numerical analysis was carried out by using Simulia Abaqus software package on 2D models used to simulate the damage development on the local level. The comparison between numerical and experimental results is presented through measured values of J-integral, load-line displacement νLL and crack growth resistance (J-Δа) curves. This paper shows that numerical simulations are promising in respect to their accuracy. The application of this model enables to decrease the amount of expensive experiments for determination of the load level that causes crack propagation.

Application of pipelines is common in process industry and energetic facilities, as parts of storage and transport systems. Structural integrity and fracture resistance of the pipeline elements is typically assessed by testing fracture mechanics specimens, like compact tensile CT or single-edge notched bending, SENB. However, fabrication of these geometries is often not possible for thin-walled pressurized elements, commonly used in structures of process and energetic facilities. Therefore, some proposals for non-standard specimens have been given in the literature, differing by the position of the initial defects, in circumferential or axial direction, and by the degree of complexity of procedures for fabrication and testing. Recently proposed ring-shaped specimen (PRNB - Pipe Ring Notched Bend) is used here to assess the fracture resistance of pressurized cylinders with defects in axial direction, critical for the internal pressure loading. The specimens are simple to fabricate and have the same material history as the actual structure, such as thermo-mechanical treatment, assembly or exploitation conditions. In this work, the ring specimens are cut from the thin-walled non-alloy steel pipes for pressure purposes. Experimental-numerical procedure is applied for prediction of fracture behavior. The methods include material characterization, fracture testing and micromechanical analysis of specimen failure. The results obtained so far lead to conclusion that PRNB specimen is a good option for testing of fracture resistance of pipelines and small-scale vessels.

Pipelines are commonly used in process industry for transport of fluids, as well as granular solids, due to their numerous advantages in comparison to other transportation means. Pipe integrity is essential for a reliable work of the entire plant, as well as for safety assurance. Also, serious ecological consequences may follow the pipeline failure in some cases, i.e. due to the leak of toxic, flammable or otherwise dangerous fluids in a chemical or some other plant. Therefore, it is very important to examine the fracture behaviour of pipelines, which is done here by testing the recently proposed ring-shaped specimens exposed to bending. The specimens were fabricated from a seam pipe for pressure applications (allowed for usage on temperatures up to 300°C). Initial defects, very narrow notches, were machined either in the base metal and weld metal (seam) or in the base metal only. Regardless of the defect position, ductile fracture mechanism is observed in all specimens. The results show that the ring-shaped specimen can be successfully used for fracture characterisation of pipeline material, especially for thin-walled pipes which are not suitable for production of standard fracture mechanics specimens due to the insufficient wall thickness. [Project of the Serbian Ministry of Education, Science and Technological Development, Grant no. ON 174004]

Integrity of pipes is typically assessed by testing fracture mechanics specimens, such as compact tensile (CT) or single-edge notched bending (SENB). However, for some pipe dimensions it is not easy or possible to fabricate a specimen conforming to the requirements of standard procedures. A new type of specimen is proposed recently, which can be advantageous for relatively small pipe diameters and axial defects - the pipe ring notch bend specimen - PRNB. In this work, criteria for failure by ductile fracture of PRNB specimens are determined experimentally and by application of micromechanical analysis. The influence of size of the specimen, as well as size and shape of the stress concentrator, is analysed. The results of this study, along with previous authors results, lead to the conclusion that the pipe ring specimens can be applied in integrity assessment of pipes with defects. Also, the benefits of their application include much simpler fabrication and the same material history as the pipe itself. (C) 2017 Elsevier Ltd. All rights reserved.

Due to their excellent mechanical properties and corrosion resistance, titanium-based materials are widely represented in aeronautics, chemical industry and medicine, where they are considered the best replacement for damaged hard tissues. In order to obtain optimal properties for medical applications, commercially pure titanium (cpTi) is often alloyed. The ß-type titanium alloys containing Nb, Zr, Ta, Mo, Sn have attracted considerable attention, due to their unique combinations of high strength, low modulus of elasticity, superior corrosion resistance and biocompatibility. Also, titanium-based materials can be processed by surface modifications, including the anodization, which belongs to the group of chemical nanostructured surface modifications. Analysis of microstructure of two-phase Ti-13Nb-13Zr (TNZ) alloy was done by Scanning Electron Microscopy (SEM). Characterisation of surface, obtained by anodization in the H3PO4 + NaF solution, during 90 minutes process, was performed by SEM. Micro Tensile Specimens (MTS) were cut from TNZ and anodized TNZ disks and were subjected to the tensile test using servo-hydraulic testing machine Instron 1255. Stereometric measurement of strain at the surface of the MTS during tension was done using the Aramis system. Results showed that anodization process led to a creation of heterogeneous layer of nanotubes. Anodized TNZ alloy had lower elastic modulus and tensile strength comparing to the initial alloy. In order to better understand tensile behaviour, numerical analysis of non-anodized alloy was done. The 3D numerical model of MTS, which simulated the tensile test, was made in Abaqus software package. Good correlation between experimental and numerical results was obtained. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Book Series: Procedia Structural Integrity

Experimental investigation of the integrity of casing pipes, used in the oil drilling rigs, withdrawn after about 70,000 h of service, has been conducted, together with numerical simulation. Pipes were manufactured by the high frequency contact welding (HF) of API J55 steel. The influence of corrosion damage is investigated by means of pressure test of a pipe with different damage levels made by machining the circular holes. The finite element analysis of the damaged pipe subjected to internal pressure is conducted to simulate the stress state in the pipe and to establish the criteria for the maximum pressure that a damaged pipe can withstand. Several analytical expressions were used to estimate the maximum pressure in a damaged pipeline, and the solutions were compared to predictions of finite element models and experimental results.

Micromechanical modelling of ductile fracture by using the local approach has been presented as the review of previously obtained results for welded joints made of low alloyed high strength steel. Experimental work was performed on 3PB specimens and tensile panels, which were then modelled by finite element method, using two- and three-dimensional meshes, respectively. The local approach was used to simulate both for crack initiation and growth during ductile fracture process.

Temperature, plastic strain and heat generation during the plunge stage of the friction stir welding (FSW) of high-strength aluminium alloys 2024 T3 and 2024 T351 are considered in this work. The plunging of the tool into the material is done at different rotating speeds. A three-dimensional finite element (FE) model for thermomechanical simulation is developed. It is based on arbitrary Lagrangian-Eulerian formulation, and Johnson-Cook material law is used for modelling of material behaviour. From comparison of the numerical results for alloys 2024 T3 and 2024 T351, it can be seen that the former has more intensive heat generation from the plastic deformation, due to its higher strength. Friction heat generation is only slightly different for the two alloys. Therefore, temperatures in the working plate are higher in the alloy 2024 T3 for the same parameters of the plunge stage. Equivalent plastic strain is higher for 2024 T351 alloy, and the highest values are determined under the tool shoulder and around the tool pin. For the alloy 2024 T3, equivalent plastic strain is the highest in the influence zone of the tool pin. [Projekat Ministarstva nauke Republike Srbije, br. TR 34016 i br. TR 35006]

Working conditions of casing pipes in drilling rigs can significantly influence the initiation and development of damage in the material, and therefore also the safe service of the entire system. In this work, an integrity assessment of a pipe with initial defect (machined surface crack) is presented. The position of this defect is on the external surface; unlike transport pipes, where internal surface is often endangered due to the contact with the fluid, casing pipes are also often exposed to damages at the external surface. A pipe segment exposed to internal pressure is examined experimentally and numerically, using the finite element method. Experimental setup included tracking of crack mouth opening displacement (CMOD) values, as well as J integral. Criteria for pipe failure are determined on the finite element (FE) models of the pipe; fracture initiation and plastic collapse are considered as failure mechanisms. Several 3D models with different crack sizes are evaluated. 2D plane strain models are also examined, to determine the applicability limits of this simplified approach. Integrity assessment criteria for the analysed geometries are discussed. Assessment of fracture resistance of the pipeline material is also considered in this work. Besides the standard SENB specimens, Ring specimens cut from the pipe are tested, and the results are compared. Both specimen geometries are modelled using local approach to fracture, by application of the micromechanical Complete Gurson model (CGM), developed by Z.L. Zhang. It is shown that the Ring specimens have similar fracture conditions under bending load as SENB specimens. Since they are much simpler to fabricate from the pipe than standard specimens, it is concluded that they can be used for assessment of fracture of the pipes with axial cracks.

The topic of this work is analysis of fracture behaviour and resistance of the thin-walled seamless and seam steel pipes, through application of the recently proposed ring-shaped specimen (PRNB - Pipe Ring Notched Bend). The main loading of these pipes in exploitation is internal pressure, which is why axial defects present a significant threat to their integrity and work safety. The ring-shaped specimen geometry is fairly simple to fabricate from a new or exploited pipeline and the specimens have the same thermo-mechanical treatment, assembly conditions, etc. as the actual structure. Experimental-numerical procedure is applied for prediction of the fracture behaviour; this included material characterisation, testing of ring specimens by bending, as well as micromechanical analysis of ductile fracture. In experimental testing, the deformation of the specimens is monitored by using the stereometric measurement system. Numerical analysis is performed in software package Simulia Abaqus, including the application of the micromechanical Complete Gurson model (CGM). The results obtained in this study, along with some previously published results, lead to conclusion that PRNB specimen is a good option for testing of fracture resistance of cylindrical elements such as pipes.

Normal 0 false false false EN-US X-NONE X-NONE MicrosoftInternetExplorer4 Abstract. The subject of this work is examination of API J55 steel casing pipes manufactured by high frequency (HF) contact welding. Since the pipes were withdrawn after about 70 000 hours of service in an oil drilling rig, the influence of the exploitation conditions on the material properties is determined. Experimental analysis includes tensile, impact toughness and fatigue testing of the specimens cut from the exploited pipe and the new pipe manufactured from the same-grade material. Additionally, pipe with flaws (stress concentrators) is tested by subjecting to internal pressure. The analysed stress concentrators represent defects which are often found in the exploitation: localized corrosion damages (corrosion pits). They were simulated by machining on the external surface of the pipe wall. The behavior of the pipes with these defects is determined by strain measurement and finite element analysis in software package Abaqus. The dimensions of the defects are varied, in order to determine the dependence of load carrying capacity on their depth and length. Several expressions from the literature are applied for estimation of the maximum pressure in damaged pipelines, and the solutions are compared with the predictions of finite element models. Additionally, triaxiality values at the bottom of the defects are compared with those obtained on tensile specimens, having in mind the key role of this parameter in ductile fracture initiation. /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0mm 5.4pt 0mm 5.4pt; mso-para-margin:0mm; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;}

This paper presents experimental and numerical analysis of the change of temperature and force in the vertical direction during the friction stir welding of high-strength aluminium alloy 2024 T3. This procedure confirmed the correctness of the numerical model, which is subsequently used for analysis of the temperature field in the welding zone, where it is different to determine the temperature experimentally. 3D finite element model is developed using the software package Abaqus; arbitrary Lagrangian-Eulerian formulation is applied. Johnson-Cook material law and Coulomb’s Law of friction are used for modelling the material behaviour. Temperature fields are symmetrical with respect to the welding line. The temperature values below the tool shoulder, i.e. in the welding zone, which are reached during the plunge stage, are approximately constant during the entire welding process and lie within the interval 430-502°C. The temperature of the material in the vicinity of the tool is about 500°C, while the values on the top surface of the welding plates (outside the welding zone, but close to the tool shoulder) are about 400°C. The temperature difference between the top and bottom surface of the plates is small, 10-15°C. [Projekat Ministarstva nauke Republike Srbije, br. TR 34018 and ON 174004]

Modeling of the mechanical behavior of fiber-reinforced ceramic matrix composites (CMC) is presented by the example of Al2O3 fibers in an alumina based matrix. The starting point of the modeling is a substructure (elementary cell) which includes on a micromechanical scale the statistical properties of the fiber, matrix and fiber-matrix interface and their interactions. The numerical evaluation of the model is accomplished by means of the finite element method. The numerical results of calculating the elastic modulus of the composite dependance on the quantity of the fibers added and porosity was compared to experimental values of specimens having the same composition. [Projekat Ministarstva nauke Republike Srbije, br. ON174004 i TVH to project III45012]

Thermal shock of an alumina-based ceramic material, which occurs widely in metallurgical furnaces, was studied in this paper. The water quench test was applied to determine the thermal shock resistance of the material. The behavior of the ceramics after thermal shock treatments was investigated. The level of degradation of the samples was monitored using image analysis tools and the defects morphology characteristics were simultaneously determined. The stress state of the samples with simplified damage shapes was simulated by the finite element method (FEM) and the influence of the surface damage geometry on the stress in the sample was examined. The analysis revealed that the surface defects tend to spread on the surface of the specimen instead of increasing their depth. This explained the morphology of defects and the way of propagation of the damage that were in accordance with experimental observations.

The topic of this work is assessment of ductile fracture initiation and development in different zones of welded joint of a high strength low alloyed (HSLA) steel. A combined experimental-numerical procedure is applied for determination of properties of the weld metal and the heat affected zone - HAZ. One tensile specimen with rectangular cross-section is tested, and the surface strains are determined using stereometric 3D measurement (measurement system Gom Aramis with two cameras and software solution). This methodology enabled formation of the stress-strain curves for micromechanical analysis of fracture of specimens with initial fatigue pre-cracks. Two different geometries are considered: standard single-edge notched bend (SENB) specimens and surface-cracked tensile specimens. The cracks were positioned either in weld metal or in HAZ - within the fine-grained part. Micromechanical model (complete Gurson model, by Z.L. Zhang) is applied for assessment of crack growth onset and stable growth. Higher resistance to ductile fracture initiation and crack growth in HAZ is successfully predicted, as well as constraint effect caused by different crack shapes.

The objective of this study is determination of the effect of mechanical heterogeneity on ductile crack initiation and propagation in weldments using micromechanical approach. Welded single-edge notched bend (SENB) specimens were experimentally and numerically analysed. Material properties of welded joint zones were estimated using a combined experimental and numerical procedure; strains on a smooth tensile specimen were determined using ARAMIS stereometric measuring system in order to obtain true stress – true strain curves. High-strength low-alloyed steel was used as base metal, in quenched and tempered condition. J – R curves and crack growth initiation values of fracture mechanics parameter were experimentally and numerically obtained for specimens with a pre-crack in the heat-affected zone (HAZ) and weld metal (WM). The complete Gurson model (CGM) was used in prediction of J – R curves and crack growth initiation. It is shown that the resistance to crack initiation and growth can be predicted using micromechanical analysis, and that the results are significantly affected by mechanical heterogeneity of the weldment.

The influence of liquids on the state of stresses and tensile strengths in the longitudinal and circumferential direction of glass–polyester pipes is the subject of this paper. The pipes were manufactured in Corporation “Poliester” Priboj, and had a definite structure and known fabrication process. These analyses are of great importance for the use of glass–polyester pipes in the chemical industry. The tensile properties were tested and determined for specimens cut out of the pipes; flat specimens for the tensile properties in the longitudinal direction and ring specimens for the tensile properties in the circumferential direction. First, the tension test was performed on virgin samples (without the influence of any liquid), to obtain knowledge about the original tensile properties of the studied composite material. Subsequently, the samples were treated by water, as well as alkaline and acidic solutions: sodium hydroxide (strong alkali), ammonium hydroxide (weak alkali), phosphoric acid (weak acid) and nitric acid (strong acid). The solutions were selected because of considerable differences in their pH values. The pipe segments were exposed to each liquid for 3, 10, 30 and 60 days, at room temperature. Then the specimens cut from these segments were subjected to tension testing by the standard procedure. A comparison of the results was made based on the pH values of the aggressive media in which the examined material had been soaked, as well as based on the original tensile properties and the number of days of treatment. Micromechanical analyses of specimen breakage helped in the elucidation of the influence of the liquids on the structure of the composite pipe and enabled models and mechanisms that produced the change of strength to be proposed.

Among various micromechanical models for ductile fracture analysis using local approach, those based on the Gurson plastic flow criterion have been intensively developed in the past three decades. However, their application is still subject of many researches, with the aim to improve the assessment of ductile fracture in various, mainly metallic, materials. In this work, Gurson criterion is applied to welded joints produced with one or two different weld metals (one of these is overmatched, while the other is undermatched). Welded single-edge notched bend (SENB) specimens are examined, with an initial pre-crack located in the symmetry plane of each joint. Local approach is chosen for assessment of behaviour of the joints under the external loading, to capture the effect of material inhomogeneity and initial crack length on deformation and ductile fracture initiation in analysed specimens.

The effect of thermal residual stresses in bimaterial structure with initial crack located near a sharp interface is discussed in this paper. Bimaterial compact tension (CT) specimen is used in the analysis, and the residual stresses are introduced by cooling of the specimen. The residual stresses affect the stress and strain fields near the crack tip, and the crack-driving force is different compared with that in the homogeneous material without residual stresses. This difference can be quantitatively expressed through an additional crack-driving force term—the material inhomogeneity term, Cinh. In this paper, it is evaluated using the post-processing procedure based on the concept of configurational forces, following a finite-element analysis. The results indicate that accurate numerical analysis of pre-cracked bimaterials should include the effect of thermally induced residual stresses. This effect cannot be neglected, even for bimaterials with homogeneous mechanical properties and inhomogeneity in thermal properties only (e.g. welded joints of ferritic and austenitic steel). Based on the obtained results, data from this study can be used in engineering practice to improve integrity and work safety of various inhomogeneous structures.

In the present paper the Preisach model of hysteresis is applied to model cyclic behavior of elasto-plastic material. Rate of loading and viscous effects will not be considered. The problem of axial loading of rectangular cross section and cyclic bending of rectangular tube (box) will be studied in details. Hysteretic stress-strain loop for prescribed history of stress change is plotted for material modeled by series connection of three unite element. Also moment-curvature hysteretic loop is obtained for a prescribed curvature change of rectangular tube (box). One chapter of the paper is devoted to results obtained by FEM using Finite Element Code ABAQUS. All obtained results clearly show advantages of the Preisach model for describing cyclic behavior of elasto-plastic material. U posmatranom radu Prajzakov model histerezisa je primenjen na modeliranje cikličnog ponašanja elasto-plastičnih materijala. Pri tome brzina nanošenja opterećenja i viskozni efekti se ne uzimaju u obzir. U radu se detaljno proučava problem aksijalnog naprezanja pravougaonog poprečnog preseka i ciklično savijanje pravougaone čelične cevi. Konstruisana je histerezisna petlja za zadatu promenu cikličnog opterećenja za materijal modeliran sa tri osnovna elementa. Takođe, histerezis momenat-krivina za čeličnu pravougaonu cev je konstruisan za zadatu istoriju promene krivine. U posebnom poglavlju se obrađuju rezultati dobijeni primenom MKE korišćenjem programa ABAQUS. Svi dobijeni rezultati jasno pokazuju prednost Prajzakovog modela kod opisivanja cikličnog ponašanja elasto-plastičnih materijala.

The basic subject of this paper was the determination of the strain distribution in glass-polyester composite pipes subjected to internal pressure. Firstly, the test was performed on virgin pipe segments (without the influence of acidic solution) to determine the original properties of the examined composite pipes. Subsequently, the pipes were subjected to the influence of 25% acidic solution. Phosphoric and nitric acid were chosen, because of their frequent use in chemical industry, either as reactants or as products. The pipes were made by 'filament winding' method, with the angles of the glass fibers reinforcement [90°]2[±55°]4[90°]4. The tests were performed by subjecting the polymer composite pipes to internal pressure; the strain values were determined by strain gages in three directions: 0°, 90° and ± 45° with respect to the pipe axis. The tests were performed until the leakage occurred, up to the pressure value of approximately 100 bar, i.e. until the occurrence of the first cracks. Also, the micromechanical analysis on fracture surfaces was done by Scanning Electron Microscopy (SEM), which provided the knowledge about models and mechanisms of fracture due to the applied loading. Cilj ovog rada je određivanje raspodele deformacija kod staklo-poliestar kompozitnih cevi koje su istaložene dejstvu unutrašnjeg pritiska. Prethodno su izvršena ispitivanja na netretiranim cevima u cilju određivanja originalnih svojstava. Zatim su cevi tretirane 25%-im rastvorom kiselina. Upotrebljene su fosforna i azotna kiselina zbog njihove česte upotrebe u hemijskoj industriji. Cevi su izrađene metodom namotavanja ('filament winding'), pri čemu su uglovi namotavanja staklenih vlakana [90 ]2[±55°]4[90°]4. Vrednosti deformacija usled delovanja unutrašnjeg pritiska su registrovane mernim trakama postavljenim u tri pravca: 0°, 90° i ± 45° u odnosu na osu cevi. Ispitivanja su izvođena do pojave procurivanja pri vrednosti pritiska od 100 bar, tj. do pojave prvih prslina. Prikazana je i mikromehanička analiza izvedena na prelomnim površinama pomoću skenirajućeg elektronskog mikroskopa (SEM) čime su dobijena saznanja o modelima i mehanizmima loma usled dejstva primenjenog opterećenja.

A new original primal-mixed finite element approach and related hexahedral finite element HC:T/q for the analysis of behavior of solid bodies under thermal loading is presented. The essential contributions of the present approach is the treatment of temperature and heat flux as fundamental variables that are simultaneously calculated, as well as capability to introduce initial and prescribed temperature and heal flux. In order to minimize accuracy error and enable introductions afflux constraints, the tensorial character of the present finite element equations is fully respected. The proposed finite element is subjected to some standard benchmark tests in order to test convergence of the results, which enlighten the effectiveness and reliability of the approach proposed.

The aim of this study was to improve the resistance of turbo jet engine parts exposed to high temperatures and overheating and sudden changes in temperature. For this purpose, three thermal barrier coating (TBC) systems NiCrAlCoY2O3/ZrO2MgO, NiCrAlCoY2O3/ZrO2Y2O3 and NiCrAlCoY2O3/ZrO2CeO2Y2O3 were tested. They were deposited using the atmospheric plasma spray process (APS). In order to develop a TBC with the best thermal insulating properties and the highest reliability in relation to aging of materials under the influence of sudden changes in temperature, TBC systems that were deposited on cold and preheated substrates were tested. The network of microcracks on the surfaces of the ceramic layers in deposited condition was analyzed using scanning electron microscopy (SEM). Insulating characteristics of TBC systems were examined by measuring the temperature difference Delta T between the top and bottom surfaces of the samples at a temperature of 1200 degrees C. Testing of TBC for resistance to thermal cyclic behaviour was performed by exposing samples to alternate heating at 1200 degrees C and rapid cooling of the samples to 180 degrees C. Microhardnesses of the TBC system, after completion of thermal cycles, were compared with the values in deposited state. Analyses of thermal insulation properties and thermal cyclic behaviour have shown a correlation between the substrate temperature and quality of the TBC system in thermal cyclic conditions.

Silicon carbide is the material that in sintered form is suiTab. for protection from impact as part of the multilayered structure. Its role is to accumulate energy from the projectile, to plastically deform the projectile and to protect other layers of the material. Standard procedures for material testing include structure testing, surface defect shape and size determination and mechanical testing. The obtained information about surface defects was used to calculate the behavior of the sample exposed to bending and the finite element method was used for this simulation. The obtained results are in accordance with the experimental ones.[Projekat Ministarstva nauke Republike Srbije, br. TR34011 i br. ON174004]

Working conditions of casing pipes in drilling rigs can significantly influence the initiation and development of damage in the material, and therefore also the safe service of the entire system. In this work, an integrity assessment of a steel pipe with initial defect (machined surface crack) is presented. The position of this defect is on the external surface; unlike transport pipes, where internal surface is often endangered due to the contact with the fluid, casing pipes are often exposed to damages at the external surface. Analyzed crack is in axial direction, bearing in mind that this type of defect most significantly decreases the load carrying capacity of the cylindrical pressurized components. A pipe segment exposed to internal pressure is analyzed experimentally and numerically, using the finite element method. The experimental setup included the tracking of crack mouth opening displacement (CMOD) values, as well as J integral, which is determined by application of direct measurement. Criteria for pipe failure are determined on finite element models of the pipe; fracture initiation and plastic collapse are considered as failure mechanisms. The size of the crack is varied in the finite element models; several 3D models with different crack sizes (length and depth) are evaluated. Dependence of maximum internal pressure on the defect size is obtained. 2D plane strain models are also examined, with an aim to determine the applicability limits of this simplified approach. Based on the obtained results, integrity assessment criteria for the analyzed geometries are discussed.

The exploitation of casing steel pipes used in oil and gas drilling rigs typically involves a corrosive atmosphere, high pressures and elevated temperatures. These conditions can affect the initiation and development of defects in the material, which can jeopardi ze the safe service of the system. In this work, an assessment of the integrity of a damaged pipe, manufactured by high frequency contact welding (HF) of API J55 steel, is presented. The influence of an initial defect (machined surface crack) on the pipe structural integrity is analysed. Besides the defects at the internal surface, which is in contact with the transported fluid, casing pipes are also exposed to damage at the external surface, which is why such configuration is examined here. The analysed surface crack is in an axial direction, bearing in mind that this type of defect is the most severe for the cylindrical pressurised components. Internal pressure testing is conducted on a pipe closed by dished ends. The values of fracture parameters, crack mouth opening displacement CMOD and J integral, were tracked during the experiment. The applied procedure for J integral determination (so-called direct measurement) can be applied both on standard specimens and on structures. It includes the use of combined experimental – computational procedure. Finite element analysis is used for determining the criteria for the pipe failure, regarding both crack growth initiation and plastic collapse of the ligament. The size of the crack is varied in the finite element models, in order to determine the influence of its size on the maximum loading. Simplified 2D models are also examined, with the aim of

This paper deals with the heat generation in the Al alloy Al2024-T3 plate under different rotating speeds and plunge speeds during the plunge stage of friction stir welding (FSW). A three-dimensional finite element model (FEM) is developed in the commercial code ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb?s Law of friction. The heat generation in FSW can be divided into two parts: frictional heat generated by the tool and heat generated by material deformation near the pin and the tool shoulder region. Numerical results obtained in this work indicate a more prominent influence from the friction-generated heat. The slip rate of the tool relative to the workpiece material is related to this portion of heat. The material velocity, on the other hand, is related to the heat generated by plastic deformation. Increasing the plunging speed of the tool decreases the friction-generated heat and increases the amount of deformation-generated heat, while increasing the tool rotating speed has the opposite influence on both heat portions. Numerical results are compared with the experimental ones, in order to validate the numerical model, and a good agreement is obtained.

Fracture of steel welded joints produced with one or two weld metals is analysed; the latter (double mismatched) consist of overmatched and undermatched portion. Specimens with a pre-crack in the symmetry plane of each joint are examined. In double mismatched joints, the pre-crack front passes through both weld metals. Micromechanical approach (complete Gurson model) is used for ductile damage development modelling. Influence of joint width, crack length, as well as size and formulation of finite elements, is examined. The constraint effect caused by the different joint geometry is predicted and the effect of material inhomogeneity along the crack front of the double mismatched joint is assessed by transferring the parameters from the joints with one weld metal.

The subject of this study was the application of local approach to ductile fracture in order to estimate the integrity of damaged seam casing pipes for oil and gas drilling rigs. The experimental testing included tensile testing of specimens and a pressure test of a pipe with different levels of damage simulated by machined notches. In exploitation, such structures (i.e., pipes with local thin areas) can fail by the ductile fracture mechanism or by plastic collapse in the ligament. However, the majority of the procedures for determining their integrity are based on limit loads, i.e., plastic collapse criteria. In this work, a pipe subjected to internal pressure was modelled using the finite element method and local approach to fracture (the Complete Gurson Model - CGM), with the aim of determining damage development in the material (i.e., at the bottom of a machined defect) and of establishing the criteria for the maximum pressure that a damaged pipe can withstand. The results obtained using the micromechanical model are discussed and compared with several often used limit load expressions from the literature and a stress-based finite element criterion. It is shown that local approach can give appropriate results and represent failure criterion for pipes with local thin areas. [doi:10.2320/matertrans.M2011210]

Seam casing pipe used in an oil drilling rig, manufactured by high frequency (HF) contact welding of API J55 steel, is tested. The influence of an initial defect (machined surface crack) is analysed, by performing pressure test of a pipe segment closed at both ends. Besides the damages at the internal surface, casing pipes are exposed to damage at the external surface, which is why such configuration is analysed here. Measurement of strains and crack mouth opening displacement (CMOD) enabled the application of direct method for J integral evaluation. This procedure is based on the path independence of the J integral and can be applied both in laboratory conditions (on specimens) and on structures. However, it requires a demanding experimental - computational procedure, which is accomplished here using the developed routine. Additionally, the behaviour of the pipe under internal pressure, including fracture mechanics parameters determination, is modelled numerically (by finite element method) in software package Abaqus. The pressure is applied as distributed load acting on the inner surface of the three-dimensional model, and axial tension is applied at the end of the pipe to simulate the closed end. J integral values determined numerically and using direct method are used for estimation of the critical pressure corresponding to the crack growth initiation. Additionally, plastic limit load, i.e. pressure which causes yielding of the ligament, is determined. Based on the results, criteria for pipe integrity assessment are discussed

The paper deals with the integrity assessment of API J55 steel casing pipes for drilling rigs, manufactured by high frequency contact welding procedure. The influence of corrosion defects on the pipeline load carrying capacity is determined through pressure test of a pipe with corrosion damages simulated by machining the circular holes. Finite element analysis of the damaged pipe subjected to internal pressure is used for determining the stress/strain conditions in the damaged area of the pipe. Also, numerical model was used for establishing the load carrying capacity of the pipe with different damage levels (i.e. defect depth and length). Several expressions from the literature are used for estimation of the maximum pressure in the damaged section of the pipe, and the solutions are compared with the predictions of finite element models and experimental results.

U ovom radu su istraženi efekti ograničenja na inicijaciju i propagaciju žilavog loma. Trodimenzionalna analiza konačnim elementima zavarenih spojeva nejednake čvrstoće, izrađenih od visokočvrstog čelika, pokazana je na primjeru CCT uzoraka sa središnjom pukotinom opterećenih na rastezanje. Razmatrane su različite širine zavara i omjeri nejednakosti čvrstoće. Parametar žilavog loma, pomak otvaranja vrška pukotine pri inicijaciji rasta pukotine (CTODi), dobiven je za CCT uzorak sa zarezom u sredini opterećenim na vlak koristeći lokalni pristup lomu, uz usporedbu s eksperimentalnim rezultatima određenim na uzorku na savijanje zarezanim s jedne strane. Mikromehanički cjeloviti Gursonov model primijenjen je kako bi se istražilo lomno ponašanje zavarenih spojeva s pukotinom. Ograničenja tečenja oko vrška pukotine analizirani su kroz troosnost naprezanja, kako bi se istražila prenosivost parametara loma s jedne geometrije na drugu., In this paper, constraint effect on ductile fracture initiation and propagation has been studied. Three-dimensional finite element analyses of mismatched welded joints made of high strength steel, have been performed for centre-cracked tensile (CCT) specimens. Different weld widths and material mismatching ratios have been considered. Ductile fracture parameter, crack tip opening displacement at crack growth initiation (CTODi), has been obtained for centre-cracked tensile (CCT) specimens using local approach to fracture and compared with experimental results of single edge bend specimens. Micromechanical complete Gurson model has been applied to investigate fracture behaviour of cracked welded joints. Crack tip constraint has been analysed through stress triaxiality in order to study transferability of fracture parameters from one geometry to another.

The behavior of the plates with a surface notch under tensile external loading is experimentally and numerically analyzed. The specimens were made of micro-alloyed steel NIOMOL 490 K, welded by MAG (CO2) welding method. Surface notches were machined by the spark erosion method in the weld metal and heat affected zone. A finite element analysis of the specimens subjected to the tensile external loading is performed, with a simplified treatment of the heat affected zone mechanical properties. Obtained results are compared with the results of the experimental investigation, and a satisfactory agreement for the specimens containing the weld metal notch is observed. However, results for the specimen containing a notch in the heat affected zone require further investigation, including the analysis of the effects of micro structural heterogeneity.

This paper gives an overview of the development of a new software solution for project management, intended mainly to use in industrial environment. The main concern of the proposed solution is application in everyday engineering practice in various, mainly distributed industrial companies. Having this in mind, special care has been devoted to development of appropriate tools for tracking, storing and analysis of the information about the project, and in-time delivering to the right team members or other responsible persons. The proposed solution is Internet-based and uses LAMP/WAMP (Linux or Windows - Apache - MySQL - PHP) platform, because of its stability, versatility, open source technology and simple maintenance. Modular structure of the software makes it easy for customization according to client specific needs, with a very short implementation period. Its main advantages are simple usage, quick implementation, easy system maintenance, short training and only basic computer skills needed for operators.

The aim of this paper is prediction of ductile fracture initiation in mismatched and double mismatched welded joints. The micromechanical approach is very well-suited for this purpose, because it describes the process of fracture in a way close to the actual phenomena in the material. Micromechanical models based on the Gurson plastic flow criterion are often used for ductile fracture analysis. One of these models, the Complete Gurson Model (CGM) is used here, because the critical value of the damage parameter can be calculated during the analysis. In many other models, the value of this parameter must be predefined. Experimental and numerical analysis of ductile fracture of pre-cracked single-edge notched bend (SENB) specimens is presented. These specimens contain mismatched or double mismatched (undermatched - OM, and overmatched - UM) welded joints. The crack is located in the weld metal (WM), and in case of double mismatched joints it runs through both weld metals. Numerical analysis is conducted using ABAQUS, with user material subroutine for the CGM created by Z.L. Zhang. Three-dimensional models of double mismatched welded joints are analysed, because they cannot be regarded as plane strain or plane stress. To attain the best possible computational efficiency, the submodelling technique is used in the crack front region. With submodelling, it is possible to have sufficiently refined mesh around the crack front (which is very important, as will be discussed in the paper), without excessive computational cost. Microstructural observation is used to quantify the volume fractions of non-metallic inclusions in base metal (BM) and overmatched and undermatched weld metals. Based on these data, initial void volume fractions and mean free paths between the inclusions for all materials are determined. Crack tip opening displacement (CTOD) at the crack growth initiation is measured experimentally and calculated using the CGM, and different values are obtained in overmatched weld metal in comparison with the undermatched weld metal (for double mismatched joints). The size of the elements near the crack tip strongly influences the prediction of the crack growth initiation, and the best results are obtained for the size of the element similar to the mean free path between non-metallic inclusions. The results are also sensitive to the change of the initial void volume fraction, and the best agreement with the experimental data is obtained for the value determined by quantitative microstructural analysis. It is concluded that the CGM enables determination of the crack growth initiation in analysed welded joints and successfully captures the effect of the inhomogeneity.Copyright © 2009 by ASME

In the paper, the level of damage of steam pipeline steel after about 100,000 hours at 540°C (1004 °F) under pressure of 42 bars (609 PSI) is analyzed. Material degradation is estimated using a combined experimental and numerical procedure based on micromechanical or local approach to fracture. Detailed analysis is conducted on the samples taken from exploited – used steel and from unused – new steel of the same designation. Damage parameter – void growth ratio – is determined using round notched specimens, (including various notch radii). A comparison of the values for critical void growth ratio, computed for tested steels is made. Based on the values obtained, the possibility of prolongation of the operating life of used steel is discussed.Copyright © 2008 by ASME

A new reliable primal–mixed finite element approach for the heat transfer analysis in solids, is examined in detail. The essential contribution is that both variables of interest, temperature and heat flux, are calculated simultaneously from the same system of finite element equations. In addition, as a novelty, continuity of the trial and test heat flux functions is enforced, to avoid the need for some a posteriori heat flux smoothing technique. In order to minimize the accuracy error and enable introduction of the flux constraints, tensorial character of the present finite element equations is fully respected. The proposed finite element is subjected to low and high order convergence and efficiency tests in steady state and transient heat transfer analysis, which enlighten its solvability, stability, accuracy and effectiveness, i.e. its reliability.

Local approach is applied to analysis of ductile fracture in steel welded joints. Welded single-edge notched bend (SENBspecimens with joints containing one or two weld metals are investigated. The Gurson plastic flow criterion is used, and the crack growth is modelled by observing damage in elements in front of the crack tip. The effect of various factors: microstructural parameters, joint width, initial crack length, as well as size and formulation of finite elements in the ligament, is examined. Special consideration is given to the connection between material microstructure and fracture behaviour, and it is found that initial porosity and finite element size that correspond to the microstructural quantities (volume fraction of non-metallic inclusions and mean free path between them, determined using quantitative microstructural analysisgive the most appropriate results. It is concluded that local approach enables estimation of ductile fracture initiation in analysed welded joints, also capturing the constraint effect caused by the different joint widths and effect of material inhomogeneity along the crack front of the joints with two different weld metals.