Escolar Documentos
Profissional Documentos
Cultura Documentos
Abstract
The aim of this research is to develop an experimental approach for corrosion fatigue behaviour of welded structures subjected to
simultaneous biaxial, rotating-bending and torsional loading, results of which could be used in railway bridges, ship, offshore structures,
ground vehicles etc. The experimental program developed here considers stress field information due to the variations of applied stress
conditions, surface treatments and corrosive environment using simulated heat-affected-zone (HAZ) and base materials. This is aimed at
providing a procedure for improved design of new welded structures subjected to biaxial loading. The experimental data have been collected
and compared with standard theoretical stresslife curves generated by earlier researchers (Juvinall, Shigley and Collins method).
Experimental data in dry and corrosive environment (3.5% NaCl solutions) for rotating-bendingtorsional thrust have been collected.
This initial investigation suggests that the effects of secondary thrust is more severe than the effects due to corrosive environment, as it
accelerates the initiation of the cracks; and consequently, the fatigue life reduces significantly. Design-engineers must consider reducing
the effects of secondary thrust and minimising the environmental effect to improve on crack initiation properties of the structures.
2003 Elsevier Science B.V. All rights reserved.
Keywords: Biaxial and corrosion fatigue; Rotating-bending and torsional fatigue; Fatigue strength reduction; Air and corrosive environment
1. Introduction
General fatigue assessment only considers axial fatigue
loading but real structures are always subjected to multiaxial
loads. The procedure developed in this study was aimed at
providing an increased understanding of the failure mechanisms in biaxial loading. The problem of multiaxial fatigue
loading becomes more complex for welded structures under dynamic cyclic load. It has been found by several researchers that generally fatigue cracks originate either in the
heat-affected-zone (HAZ) or in the weld materials due to
fatigue loading and could be the potential source of catastrophic failures in some unfortunate situations. Even though
the applied load could be completely rotating-bending or
purely cyclic axial, there is always induced shear and principal stresses present on the structures and therefore, biaxial
loading invariably is being present in most real life loading
situations. However, most reported experimental work only
considers uniaxial loading, even though the effect of secondary loading could reduce the fatigue life of any structure
significantly.
In addition to biaxial fatigue loading, it is well documented that corrosion environment and welding of structural
Corresponding author.
E-mail address: wahab@me.lsu.edu (M.A. Wahab).
0924-0136/$ see front matter 2003 Elsevier Science B.V. All rights reserved.
doi:10.1016/S0924-0136(03)00412-6
M.A. Wahab, M. Sakano / Journal of Materials Processing Technology 143144 (2003) 410415
411
lags. McDiarmid [8] found that the behaviour of ductile materials under reversals of combined bending and twisting fatigue stress can be predicted by a non-linear equation which
takes into account of fatigue limits under reversal bending
and torsional and applied normal and shear stresses.
Fig. 1. Estimating completely reversed SN curves for a smooth and notched members suggested by (a) Collins and (b) Juvinall and Shigley.
412
M.A. Wahab, M. Sakano / Journal of Materials Processing Technology 143144 (2003) 410415
4. Experimental program
4.1. Rotating-bending fatigue testing machine
In rotating-bending machine the region of the rotating
beam between the inboard bearings is subjected to a constant bending moment all along its length. The segment of
the machine with a corrosion chamber is shown in Fig. 2.
While under the influence of constant moment, the specimen rotates with the drive spindles about its longitudinal
axis. Any point on the surface is subjected to a completely
reversed stress time pattern. The machine is designed to shut
down automatically when the specimen fractured and the
shaft connected to the drive motor drops and activate the
micro-switch.
4.2. Experimental corrosion system
A 4 A, 12 V DC Shurflo Diaphragm Pump capable of
circulating 10.6 l of corrosive fluid per minute at 310 kPa is
attached on an accumulator and produces a mist through the
top of the chamber and onto the rotating specimen.
The corrosion chamber was designed as a removable attachment for the rotating-bending machine (Fig. 2). The
3.5% of sodium chloride (NaCl) solution are stored in a tank
for continuous supply during the experiment.
4.3. Weld thermal simulation
M.A. Wahab, M. Sakano / Journal of Materials Processing Technology 143144 (2003) 410415
413
Fig. 6. (a) Obtained microstructures 200 and (b) required microstructures 500.
414
M.A. Wahab, M. Sakano / Journal of Materials Processing Technology 143144 (2003) 410415
5. Experimental results
5.1. Discussions of results
Four different types of experiments have been conducted
and these are summarised in the SN curves which is shown
in Figs. 79. Under medium stresses (360 MPa), the fatigue life for a specimen subjected to bending load alone is
marginally higher than the fatigue life for a specimen subjected to biaxial and corrosion fatigue. At a lower stress level
(320 MPa), the bending fatigue life is much higher than the
biaxial and biaxial corrosion fatigue lives. Specimens that
did not fail at 10 million revolutions were stopped and it
was assumed that the specimens were run-out.
It was noted that the biaxial fatigue life drops 53.63% from
the rotating-bending fatigue life at a stress level of 360 MPa.
Fig. 8. Estimating SN curves for C1020 mild steel using procedure by Juvinall and Shigley.
Fig. 9. Stresslife (SN) curves for C1020 mild steel using procedure by Collins.
M.A. Wahab, M. Sakano / Journal of Materials Processing Technology 143144 (2003) 410415
415
Fig. 10. Estimating SN curves for heat-treated C1020 mild steel using procedure by Collins, and Juvinall and Shigley.
6. Conclusions
From experimental results, it can be concluded that a secondary thrust reduces the fatigue life of a structure drastically. From the results shown, the fatigue life for a specimen
under biaxial loading failed at much lower life compared
to a specimen that subjected to bending loading. Moreover,
corrosive environment further reduces the life but not as
drastically as compared to biaxial loading does to bending
fatigue. It is thus can be concluded that biaxial is an important and serious reduction factor for steel structures, more
severe than corrosion.
Acknowledgements
Authors acknowledge with great appreciation the contribution made in the experimental program by their research
students Ben Abraham, Marc Gardner, Lee K. Onn and Soo
Y. Haw. Contributions made by Mr. I. Brown during the
design stage of the experimental research program are acknowledged with gratitude.
References
[1] P.L. Andersen, Corrosion fatigue testing, fatigue and fracture, in:
ASM International, The Materials Information Society of USA, vol.
2, 1997.
[2] P.S. Pao, Mechanisms of corrosion fatigue, fatigue and fracture, in:
ASM International, The Materials Information Society of USA, vol.
2, 1997.
[3] M.A. Wahab, M. Sakano, Experimental study of corrosion fatigue
behaviour of welded steel structures, J. Mater. Process. Technol. 118
(13) (2001) 116121.
[4] D. Radaj, Heat Effects of WeldingTemperature Field, Residual
Stress, Distortion, Springer, Berlin, September 1992.
[5] W.N. Findley, Effects of extremes of hardness and mean stress on
fatigue of AISI 4340 steel in bending and torsion, J. Eng. Mater.
Technol. 111 (2) (1989), ASME.
[6] Z. Hashin, Fatigue failure criteria for combined cyclic stress, Int. J.
Fract. 17 (2), Sijthoff & Noordhoff, Alphen a/d Rijn, April 1981.
[7] G. Sines, G. Ohgi, Fatigue criteria under combined stresses or strains,
J. Eng. Mater. Technol. 103 (2) (1991), ASME.
[8] D.L. McDiarmid, A new analysis of fatigue under combined bending
and twisting, Aeronaut. J. 78 (752), Royal Aeronautical Society,
London, 1974.
[9] J.A. Collins, Failure of Materials in Mechanical Design, Wiley, New
York, 1993.
[10] R.C. Juvinall, K.M. Marshek, Fundamentals of Machine Component
Design, Wiley, New York, 1983.
[11] J.E. Shigley, C.R. Mischke, Mechanical Engineering Design,
McGraw-Hill, New York, 1989.