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Received 19 October 1997; received in revised form 24 May 1998; accepted 28 September 1998
Abstract
A new approach using a back-propagation neural network for life prediction was developed and demonstrated for predicting the
elevated temperature (0.70.8 Tm) creepfatigue behavior of Ni-base alloy INCONEL 690. The neural network was trained with
five extrinsic parameters, characterized via a 251 fractional factorial design methodology, and an intrinsic parameter (final grain
size). The back-propagation network training error, prediction error and training time were minimized using a second fractional
factorial design. Life prediction accuracy using only 11 training sets, few training iterations ( 20,000) and a simple network
architecture (6-2-2-1) showed significant improvement, for sets not previously used for training, when compared to CoffinManson,
linear life fraction and hysteresis energy prediction techniques. 1999 Elsevier Science Ltd. All rights reserved.
* Corresponding author. TIMETTechnical Labs, Henderson, NV where f is the damage due to fatigue, c the damage
89015, USA; Tel.: 1-702-566-4435; Fax: 1-702-564-9038; E- due to creep, n the number of cycles applied during a
mail: vasisht.venkatesh@timet.com given loading condition, Nf the corresponding fatigue
0142-1123/99/$ - see front matter 1999 Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 2 - 1 1 2 3 ( 9 8 ) 0 0 0 7 1 - 1
226 V. Venkatesh, H.J. Rack / International Journal of Fatigue 21 (1999) 225234
life for this loading condition, t the time of creep load- ive cycle [5]. Additionally, while Ostergrens wavesh-
ing, tR the rupture time under load and D the total allow- ape-dependent method separates tensile and compressive
able damage. Typically a total allowable damage of 1.0 hold times, it only considers a tensile hold time to be
is possible only when failure is ascribed to either pure damaging, overriding possible damage caused by com-
creep or fatigue damage. When creep and fatigue inter- pressive holds that result in mean tensile stresses
act, the damage value falls below 1.0, the exact design [2,5,27].
value of D then being defined from experimental data A possible alternative approach entails artificial neural
for each material under specified extrinsic conditions networks (ANN), which has emerged as a powerful
[2,5,14,15,24,26]. problem solving tool in signal processing, non-destruc-
Ostergren [2,4,5,27] recognized that mean stress tive testing, process control, corrosion life prediction and
effects had to be included in any successful high tem- materials science [2832]. The architecture of an ANN
perature life prediction approach. These mean stress is based on the human nervous system which has over
effects arise from time-dependent relaxation. This a billion interconnected neurons that receive and process
approach assumed the damage measure to be the net ten- information (Fig. 1) [33,34]. Each processing element
sile hysteretic energy corresponding to the area in the (PE) receives input signals, xi, from the environment or
hysteresis loop between the mean stress and ultimate from other PEs and processes the weighted, wij, sum of
stress. This physical measure was related to be the all the inputs through a threshold function:
energy associated with crack propagation and was
approximated as Tp [27], where T was the 1
yij (7)
maximum tensile stress, i.e. 1 eWijxi
in the final layer. In a BP network the knowledge, i.e.
1 1 the relationship between input and output factors, is
(O T C) stored as the interconnection strength (i.e. the weights)
between processing elements. In order for the network
where , C, k are constants, is the frequency, O the to be able to learn the relationship between input and
continuous cycling period, T the tensile dwell time and output factors a training set consisting of known input
C the compressive dwell time. For materials whose life- and corresponding output sets is compiled. For each
time is dependent on waveshape, i.e., when the amount input in the training set the network computes an output,
of relaxation is different in tension and compression, the
waveshape dependence is accounted for by
1
for T > C (6)
(O T C)
1
O
for T C.
the error between the computed and actual output then major impact on the deformation mechanisms observed
being calculated by the error function: during constant stress loading, a transition in primary
deformation mechanism from matrix controlled dislo-
o(1 o)(d o) (8) cation motion to grain boundary sliding and migration
being observed [22,23].
where o is the calculated network output and d is the This material is therefore an excellent candidate for
actual output in the training set. Next the error function examining the potential applicability and limitations of
is minimized using the gradient descent approach, and the neural network approach for creepfatigue life pre-
the weights between PEs are adjusted by: diction. The objective of this research was aimed at
examining this new method and comparing its predictive
wijk wijk(n 1) wijk(n 1) Z wijk(n) (9) capability with those of the CoffinManson, linear life
fraction and the hysteresis energy techniques for the
where wijk is the connection strength between the jth neu- design of components operating at high temperatures
ron in the (k 1) layer and the ith neuron in the kth (0.70.9 Tm).
layer, w is the weight change that reduces the error,
is the momentum term that is added after the first 100
iterations and Z is the learning rate. 2. Experimental procedure
These steps are repeated for all the training patterns,
until an acceptable error between the calculated and The experimental tasks undertaken in this investi-
observed output, or a preset number of iterations, both gation utilized solution annealed INCONEL 690 plate
of which are defined by the user prior to training, is achi- (wt% 61.01% Ni, 28.05% Cr, 10.24% Fe, 0.016% C,
eved. Successful application of neural networks does 0.22% Mn, 0.22% Si and 0.24% Cu). Optical metal-
however require that model inputs (based on physical lography of the solution treated alloy revealed an equi-
process), network architecture (number of hidden neu- axed grain size of 39 m, with discrete (M23C6) carbides
rons and layers), the learning rate, momentum term and and larger rectangular titanium carbonitrides Ti(C,N)
the number of iterations be adjusted to develop an accur- distributed non-uniformly along bands (Fig. 2).
ate BP model [2837]. The influence of the five extrinsic factors, i.e. strain
Optimization of the back-propagation network per- range, tensile strain rate, compressive strain rate, tensile
formance can be accomplished using a statistical design hold and compressive hold, on the fatigue life, Nf of
approach. Improved network performance (prediction INCONEL 690, were considered. High temperature low
capability) can be judged by minimizing the standard cycle creepfatigue lifetimes were determined per
deviation, M, evaluated from: ASTM E606-80 [38] at 1000 and 1100C, where prior
investigations have revealed microstructural instabilities
n [1921]. A 251 fractional factorial design, for each tem-
1
M 10 (logNmf logNex
f ) (10) perature, was utilized over a range of extrinsic con-
n 1 ditions within typical creepfatigue conditions, each
having two levels (i.e. a high level (+) and a low level
where Nmf is the predicted fatigue life, Nexf is the exper-
imentally observed fatigue life and n is the number of
test points. A linear correlation between predicted and
experimental values in the training set can also be used
as an indicator of the level of network training; the
higher the correlation value, the better the training, reco-
gnizing that over training of the network can occur lead-
ing to high correlation values (r 0.9) and poor network
predictions [37]. This has been attributed to the network
memorizing the training sets, i.e. the weights are over-
adjusted to yield good correlation with the training set,
but are unable to generalize on a test set.
Recently, increased interest has been shown in utiliz-
ing INCONEL 690 for nuclear waste vitrification
components operating at temperatures above 0.75 Tm
where INCONEL 690 is metallurgically unstable, both
carbide dissolution and extensive grain growth having
been observed [1921]. These latter studies have also Fig. 2. Micrograph showing solution annealed microstructure in
shown that such microstructural instabilities have a INCONEL 690.
228 V. Venkatesh, H.J. Rack / International Journal of Fatigue 21 (1999) 225234
Table 1
251 factorial design containing five extrinsic parameters at two levels carried out at 1000 and 1100C
Tensile strain rate, t Compressive strain Tensile hold time, tt Compressive hold
Test Strain range,
(s1) rate, c (s1) (s) time, th (s)
3. Results
Fig. 5. Frequency versus fatigue life at constant plastic strain ranges
out at (a) 1000C and (b) 1100C.
The creepfatigue lifetimes of INCONEL 690 at 1000
and 1100C can be classified into four broad groups
(Table 3). Group A consisted of sets 2, 3, 5 and 8 with Table 2
no hold times, Group B with sets 9, 12, 14 and 15 having Neural network parameters
a tensile hold, Group C with sets 1, 4, 6 and 7 having
Parameter Levels ( )
a compressive hold and finally Group D including sets
10, 11, 13 and 16 with both tensile and compressive Hidden neurons 26
hold times. Hidden layers 13
Statistical analysis confirmed that 98% of the Learning rate 0.10.5
Momentum term 0.30.9
observed variation in fatigue life, Nf, can be explained
Iterations 500020,000
by the five extrinsic factors, either acting alone or inter-
acting with other factors. For example, this analysis
showed that at 1000C the significant factors on fatigue
lifetime, at 1% significance level, were strain range, ten- level. The effect of increasing the temperature from 1000
silecompressive strain rate, tensilecompressive hold to 1100C resulted in increasing average fatigue life
times, tensile hold and strain rangecompressive strain within each group (Table 3).
rate, tensile strain rate being significant at 2.5% signifi- Specific single factor interactions at 1000 and 1100C
cance level. At 1100C the same factors with an showed that a decrease in strain range increased fatigue
additional two factor interaction between strain range life. This can be observed in Table 3 where test sets with
tensile strain rate were observed at a 1% significance a high strain range (even numbered test sets) have the
230 V. Venkatesh, H.J. Rack / International Journal of Fatigue 21 (1999) 225234
Table 3
Comparison of fatigue life for the different groups and temperatures
Group Set Fatigue life at 1000C, N, cycles Fatigue life at 1100C, N, cycles
A 2 443 600
3 2518 3550
5 1300 1500
8 600 850
B 9 850 1307
12 600 1135
14 375 630
15 1406 1760
C 1 1003 950
4 480 650
6 550 764
7 800 1550
D 10 480 1230
11 1970 4662
13 2050 4000
16 1500 1332
lowest fatigue lives in each group. At both temperatures with increasing tensile strain rate. In each of these cases
the tensilecompressive hold time interaction suggests a change in significant factor levels at 1100C resulted
that asymmetric cycles, i.e. with hold times in either ten- in a larger effect or change in average fatigue life than
sion or compression, have a negative effect on fatigue at 1000C.
life, whereas symmetric cycles with either hold times in
both tension and compression or no hold times yield the 4. Discussion
longest lives. This interaction effect can be observed in
Table 3 where groups A and D have larger average lives The life prediction capability of individual design
than groups B and C, which have asymmetric cycles. methodologies was assessed utilizing sets that had a
The two factor interactions between strain rangecom- combination of extrinsic parameters not used to
pressive strain rate at the two temperatures and low calibrate/train the life prediction methods. These
strain ranges resulted in decreasing fatigue life with prediction/test sets included group D having both tensile
increasing compressive rate (Table 3, sets 3 and 5 in and compressive hold times and set 4 having a com-
group A). However, at a high strain range the fatigue pressive hold (Fig. 3). The other sets consisting of sym-
life increased with increasing compressive rate, observed metric and asymmetric cycles with different combi-
in sets 8 and 2 in group A. The tensilecompressive nations of tensile/compressive strain rates were used in
strain rate interaction at both 1000 and 1100C and low the training/calibration stage at each temperature.
compressive rate indicated an increase in fatigue life, The modified CoffinManson predicted set 4 accu-
with increasing tensile strain rate. In contrast, at 1000C rately at both temperatures, but was unable to satisfac-
and a high compressive rate the fatigue life increased torily predict any of group D (Fig. 6). This indicates
with increasing tensile rate, whereas at 1100C the that, although the interpolative capability of the Coffin
fatigue life decreased with increasing tensile rate. For Manson methodology is satisfactory, its prediction capa-
example, the influence of strain amplitudes on fatigue bility for combined tensile and compressive hold times
life, at constant frequency in group A (test sets 3, 5, 8), is unsatisfactory. Furthermore, the modified method does
showed a decrease in fatigue life with increasing strain not account for different waveshapes, hold time effects
range (Fig. 4). However, at the low strain range (test sets and mean stress effects. Although a frequency term has
3 and 5) large variations in fatigue life (2000 cycles) due been introduced in this method, it still does not consider
to interaction between tensilecompressive strain rates cases possessing differing tensile and compressive strain
was observed. This interaction effect between extrinsic rates. For example, sets 11, 13 and 16 have the same
parameters can be further visualized in Fig. 5, which frequency of 0.03 Hz, but considerably different cycles
shows a large variation in fatigue life at like and unlike to failure. Similar interaction effects between extrinsic
frequencies. The additional two factor interaction, at parameters have been reported by other investigators
1100C, between strain rangetensile strain rate showed [3,4,10,11,43,44]. For example, asymmetric cycles were
that there was a negligible effect of increasing tensile observed to result in a lower fatigue life vis-a-vis sym-
strain rate on fatigue life when the strain range is high; metric cycles for 1CrMoV steel and CrNi alloy HK-
however, at low strain ranges the fatigue life increased 40 [3,4,10,11].
V. Venkatesh, H.J. Rack / International Journal of Fatigue 21 (1999) 225234 231
5. Conclusions
Acknowledgements
Fig. 10. Neural network fatigue life prediction results at (a) 1000C This research was partially funded by Westinghouse
and (b) 1100C. Savannah River Company and monitored by Dr. Charles
F. Jenkins. The high temperature grip material (MA 754)
Table 4
Final back-propagation neural network parameters and errors
Network
Temperature, C Learning rate Momentum term Iterations Training correlation Deviation, M
architecture
Table 5
Range of back-propagation neural network parameters used in a 251 fractional factorial design to enhance prediction capability
Number of hidden
Temperature, C Number of neurons Learning rate Momentum term Number iterations
layers
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