Mazin Mahmood Yahya is currently pursuing Ph.D degree program in theThe research paper published by IJSER journal is about Low Cycle Fatigue Failuer of Composite Materials/Aluminium Alloys At Different Heat Treatments Prossece – A review 1
ISSN 2229-5518
Low Cycle Fatigue Failuer of Composite Materials/Aluminium Alloys At Different Heat Treatments Prossece – A review
Mr. Mazin Mahmood Yahya, Dr. Nilanjan Mallik
Abstract -Aluminum alloys and composite materials are of great technological importance. One of the essential goals in the fatigue process study is the prediction of the fatigue life of a structure or machine component subjected to a given stress —time history, it is subjected to repeated loading and un- loading or alternating stresses, over a long period of time. Several parameters influence fatigue life of a component like grain size, corrosion, fr equency of loading, vacuum, average mean stress, ductility, surface finish, microstructure, temperature, alloying element etc.
The shape of the structure will significantly affect the fatigue life, square holes or sharp corners will lead to elevated local stresses where fati-
gue cracks can initiate. Round holes and smooth transitions or fillets are therefore important to increase the fatigue streng th of the structure. Examples of where Fatigue may occur are: springs, turbine blades, airplane wings, bridges and bones. Mechanical properties and the micro structure of material is affected under cyclic loading.. Heat treatment processes for increasing the strengt h and hardness of aluminium/composite materials utilize the mechan- ism of precipitation hardening. The micro structural and mechanical characterization of heat treatable for composite materials/aluminum alloys are very much affected by the fatigue. For fatigue failure of a material a heat treatment process or any nano fluids can be used for heat treatment and Temper a- ture dependents on heat transfer co-efficient and the wet ability of the medium that are the two important parameters that can be used to charac terize a nano quenchant to assess its suitability for industrial heat treatment. Metal matrix composites (MMCs) are promising material s for lightweight, high strength structural applications. In particulate MMCs non-metallic particles are incorporated in metallic alloys to improve their elastic modulus and strength. However, introducing reinforcement particles with high modulus to the matrix alloy can reduce the fracture toughnes s and change the fatigue resistance of the material. The effects of reinforcement on cyclic fatigue damage and crack initiation, its role on constraining matrix plastic flow during cyclic deformation and the response of the material are important aspects in low cycle fatigue (LCF) of MMCs.
The present work gives a broad review of the available literature on low cycle fatigue Failure of aluminium alloys and composite materials analysis and effects were investigated in terms of microstructure analysis and mechanical properties by tensile tests and hardness measurements under different heat treatment process.
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ll materials have different properties that result in advan- tages and disadvantages. Study and understanding of these properties is critical to the design of a mechanical
system and the selection of the correct materials for a given part. One crucial failure mode is fatigue. Fatigue is the wea- kening or failure of a material resulting from prolonged stress. However, it is understood that when a mass is repeatedly cyc- lically loaded at a location on the material, cracks begin to form. These cracks spread enough to eventually cause failure and break the piece at the location. Consequently, when de- signing a mechanical system, it is important to know these limits. Not only could catastrophic fatigue failure cause a large loss in money due to a poor design but it could result in a loss of lives as well. Critical examples of fatigue failure range from
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Mazin Mahmood Yahya is currently pursuing Ph.D degree program in the
Department of Mechanical Engineering , IIT-BHU ,Varanasi, India , PH-
00919559646277. E-mail: mmyitbhu@gmial.com
Nilanjan Mallik is currently Senior Assistant Professor in the Department of Mechanical Engineering ,IIT-BHU ,Varanasi, India , PH-
0091973682244. E-mail: get_nilu@yahoo.com
train axles to wing cracking on airplanes [1].
The damage evolution mechanism is one of the im-
portant focuses of fatigue behavior investigation of composite
materials and also is the foundation to predict fatigue life of composite structures for engineering applications [2].
The classical way to describe fatigue consists of split- ting the domain of the numbers of cycles to rupture into three parts corresponding to different strain behaviors and also dif-
ferent fields of applications. Elasticity corresponds to relative- ly small stress amplitudes, which induce large numbers of cycles to failure (larger than iü cycles); this is “high cycle fati- gue HCF”. Elasto-plasticity corresponds to stresses above the yield stress, which induce lower numbers of cycles to failure (smaller than io4 cycles); this is “low cycle fatigue LCF”. Elas- to-visco-plasticity also corresponds to small number of cycles to failure (smaller than 10” cycles), but with time effects in- duced by creep, it is generally called “creep fatigue interac- tion” [3].
The cyclic stress - strain path are dependent on the ma- terial microstructure [4]. Fatigue cracks frequently initiated
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The research paper published by IJSER journal is about Low Cycle Fatigue Failuer of Composite Materials/Aluminium Alloys At Different Heat Treatments Prossece – A review 2
ISSN 2229-5518
from intensively stress concentration regions, increasing vo- lume fraction and particulate sizes result in early crack initia- tion [5]. Aging resulted in the formation of second phase with associated reduction in the toughness and LCF lives of the alloy [6]. Fatigue life was found to decrease with increase in the duration of hold time in both tension and compression and it is increased and decreased according the type of heat treat- ments [7,8]. Alloying can increase the strength; hardness; elec- trical and thermal conductivities; corrosion resistance or change the color of a metal. The addition of a substance to im- prove one property may have unintended effects on other properties e. g. the best way to increase the electrical and thermal conductivity of copper is to decrease the impurity levels [9 - 11].
Cyclic fatigue involves the microstructural damage and failure of materials under cyclically varying loads. Structural materials, however, are rarely designed with compositions and microstructures optimized for fatigue resistance. Metallic alloys are generally designed for strength, intermetallics for ductility, and ceramics for toughness; yet, if any of these mate- rials see engineering service, their structural integrity is often limited by their mechanical performance under cyclic, loads [12].
S. Khan et al. [13] studied the Detection of cracks in A12024
T351 specimens subjected to low cycle fatigue loading by a
certain nondestructive inspection technique is demonstrated.
I. A. Volkov et al. [14] introduced a „mathematical model that
describes the processes of fatigue damage accumulation in structural materials (metals and alloys) under rnultiaxial dis- proportionate combined thermomechanical loading is ad- vanced from the standpoint of the damaged medium mechan- ics, and founded the long-term experimental and theoretical investigations of fatigue damage accumulation in structural materials have demonstrated that fatigue covers three essen- tially different regions of cyclic loading.
J. Szusta, A. Seweryn [15] states that the fatigue damage ac- cumulation model created to analyse fatigue life of structure
elements operating in conditions of multiaxial, non- proportional low-cycle loadings. And they used the approach connected with the critical plane in the presented model. These were preceded by uniaxial loading state tests (cyclic tension—compression or torsion) on the basis of which para- meters of the calculation model should be calculated.
U. Sánchez-Santana et al [161 studied the dynamic response of fatigue damaged 6061-T6 aluminum alloy and AISI 4140T steel specimens subjected to impact loading was investigated. And they founded the quasi-static mechanical properties of alumi- num are not affected by the way the fatigue damage is in- duced. The dynamic properties, however, are sensitive to the previous fatigue damage, but are not affected by the strain rate, and showing how the previous fatigue damage can modi- fy the quasi-static and dynamic mechanical properties of the tested materials.
Zhi Yong Huang et al [17] while Continuum Damage Mechan- ics model is employed to estimate the fatigue damage of LCF
and is extended to VHCF regime. The VHCF damage is ob- tained from varying test resonance frequency of specimen. Moreover, the effect of LCF load on VHCF is studied by an improved cumulative damage model they investigated the low carbon—manganese steel LCF and VHCF behavior, re- spectively. Then, cumulative fatigue damage tests, with first LCF level followed by VHCF loading have been executed. Fa- tigue damage models based on CDM are applied to describe the LCF, VHCF damage evolution and their cumulative fati- gue behavior.
M. Naderi, M.M. Khonsari [18] Introduced an experimental
approach to fatigue damage in metals based on thermody- namic theory of irreversible process. And an irreversible Fati- gue damage is progression of cyclic plastic strain energy that reaches its critical value at the onset of fracture. And irreversi- ble cyclic plastic energy in terms of entropy generation is uti- lized to experimentally determine the degradation of different specimens subjected to low cyclic bending, tension- compres- sion, and torsional fatigue. Experimental results show that the cyclic energy dissipation in the form of thermodynamic entro- py can be effectively utilized to determine the fatigue damage evolution. An experimental relation between entropy genera- tion and damage variable is developed.
A. Seweryn, A. Buczynski, J. Szusta [19] description of damage
accumulation for analysis of fatigue life of structural elements
under non-proportional loading states. Damage accumulation
rule has been formulated incrementally and connected with a
monotonic work-hardening curve, and They proposed model of damage accumulation enables to define the number of cycles or the time of safe application of complex fatigue loads to arbitrarily shaped machine components.
Fuqiang Wu , WeiXing Yao [2] studied The characteristics of
damage development and accumulation of composite mate- rials subjected to variable loading, when The mechanical properties of composite materials degrade progressively with the increasing of the number of cyclic loadings.
K. Narayan Prabhu and Peter Fernades[20] expressed The out- lines the possibility of using nanofluids for industrial heat treatment. Development of nanoquenchants having (i) high quench severity for enhancement of heat transfer for thick sec- tions with low quench sensitivity and (ii) low cooling severity for thin sections with high quench sensitivity would be ex- tremely useful to the heat treating community. The tempera- ture dependent heat transfer coefficient and the wettability of the medium are the two important parameters that can be used to characterize a nanoquenchant to assess its suitability for industrial heat treatment.
D. Ortiz et al. [21] evaluated the tensile properties, conductivi-
ty, hardness, and grain size measurements and were heat
treated Aluminum alloys 6061, 2024, and 7075 to various tem-
pers and then subjected to a range of plastic strain (stretching) in order to determine their strain limits. They found the effects of the plastic strain on these properties are discussed and
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strain limits are suggested.
Yalin Lu, Miaoquan Li, Yong Niu, and Xingcheng Li [22]
showed The effects of the isothermal temperature and holding
time on the microstructure and element distribution have been
investigated during partial remelting of the semisolid Al-4Cu-
Mg alloy. The experimental results show that the optimal
process parameter should be chosen at isothermal temperature of 540-5 80 °C with the holding time of less than 10 mm. Meanwhile, the higher the isothermal temperature and the longer the holding time, the more segregation of Cu at the grain boundary would be, which conform to the theory of element distribution affected by heating condition.
N. Stefansson and S,L. Serniatin [23] They observation the Mi- crostructural suggested that the process of globularization can be divided into two stages. The first includes microstructural changes during deformation and the initial stages of static heat
treatment; the second occurs during prolonged static anneal- ing. The initial stage consists of segmentation of the lamellae via boundary splitting, whereas microstructural coarsening characterizes the latter stage. And the mechanisms controlling static globularization of Ti-6Al-4V after deformation and an- nealing at 900 C and 955 C were established. Thus, the process of static globularization is only moderately dependent on the formation and evolution of dislocation substructure; the addi- tional driving force is provided by the reduction in interface energy. The duration of the initial stage of static globulariza- tion was calculated by estimating the time required for the completion of the boundary splitting process. and calculated in excellent agreement with microstructural observations and showed that the duration of the initial stage at 900 C and 955 C lasted approximately 10 hours and 1 hour, respectively. Abdulwahab, M., Zaria, Nigeria [24] introduced The made on the mechanical properties upon age- hardening treatment to Al-Si-Fe-Mn (Aluminium- Silicon- Iron- Manganese) alloy. The produced alloys consist of varying manganese content from 0.l to 0.5 percent with constant Si-Fe composition and Al as the dominant constituent. As-cast alloys were produced and also age-hardened. There mechanical properties; Tensile properties, Hardness and Impact strength were investigated according to standard procedures. From the results, addition of Mn to the alloy increased the tensile properties and hard- ness subject to 0.4 percent for both the as-cast and age- har- dened conditions. While the impact energies upon addition of Mn decreased with the age- hardened samples having better mechanical properties than the as-cast one.
YY Zhao et al. [25] Found the relationship between strength
and hardness was reasonably linear, whereas the relationship
between hardness and strength with electrical conductivity
was non-linear for Al alloy 7010 under different temper and ageing conditions. The ageing conditions and therefore the mechanical properties of the components can be predicted more accurately by the simultaneous combination of hardness and conductivity values.
M.N. Cavalli, V. Mandava [26] Studied the Effect of Tempera- ture and Aging Time on 2024 Aluminum Behavior, similar changes in the fracture behavior of 2024-T4 aluminum as the processing conditions are varied. Above about 490°C, 2024
aluminum becomes a solid solution which is frozen in place by a subsequent quench to room temperature. The structure of the material changes over time even if it is left at room tem- perature (natural aging). Heating to an intermediate tempera- ture (490°C) can result in the formation of precipitates. The evolution of the microstructure tends to lead to an increase in both strength and fracture toughness of the alloy.
Evren TAN and Bilgehan [27] Showed that the initial characte-
rizations of Mg2 Si and (Fe,Mn,Cu)3 SiA112 (AA6066 Alloy)
were the primary particles observed in the cc-Al matrix. Near-
ly 14OHB hardness was obtained with solutionizing at 530 ° C
and aging at 175 ° C for 8 h, which was the optimum treatment for obtaining peak hardness.
Chih-Ting Wu et al. [28] Explained How Mg content affects the microstructure and mechanical properties of Al-14.5Si-
4.5Cu alloy by adding 0.45 and 0.90 wt pet Mg. Primary sili- con, eutectic silicon, acicular b-A15FeSi, Al2Cu, and A15Cu2IVIg8Si6 phases were observed under the as-cast con- dition in low-Mg alloy. In high-Mg alloy, a large proportion of the acicular b-Al5FeSi phase was converted to Chinese script Al8Mg3FeSi6 phase.
Ilyas Uygur, Mustafa Kemal Kulekci [29]Tested powder metal- lurgy processed metal matrix composites under the strain con-
trol loading conditions. The influence of volume fraction (17 and 25 vol%), particulate size (2.5 and 15 tim) of reinforcement particles and strain ratio (R0, R0.5 and R= -1) are examined for
2124 Al-alloy-T4 composites, Increasing the content of SiCp results in the degradation of strain control fatigue properties.
The monotonic and cyclic stress-strain response of the 2124A1
— (25 vol% 2.5 jim) SiCp composite was significantly altered
by strain ratio values. Fatigue cracks frequently initiated from
intensively stress concentrated regions, increasing volume
fraction and particle sizes result in early crack initiation.
Huai-Wen Wang, Yi-Lan Kang , Zhi-Feng Zhang and Qing- Hua Qin [30] Investigated the size effects on fracture behavior of Cu foil by a new optical technique, the digital speckle corre- lation method (DSCM). Displacement and strain fields around a crack tip are analyzed for different thicknesses of Cu foil. Then, the J integral and fracture toughness JC are evaluated directly from the strain fields around the crack tip. The frac- ture toughness JC is obtained as a function of foil thickness. The results indicate that JC indeed depends on foil thickness within a certain range of thickness.
M. J. Hadianfard, Yiu-Wing Mai [3 1]They found the low cycle
fatigue (LCF) resistance of two different 6061 Al/20 vol% alumina particulate metal matrix composites (MMCs) in a peaked-aged condition has been evaluated under fully re- versed strain control testing. Test results were combined with scanning electron and optical microscopy investigations to determine the effects of reinforcement particles and strain am- plitude on the LCF behaviour of these MMCs, Both materials show three stages of response to LCF: initial fast hardening or
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The research paper published by IJSER journal is about Low Cycle Fatigue Failuer of Composite Materials/Aluminium Alloys At Different Heat Treatments Prossece – A review 4
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softening in the first few cycles, gradual softening for most of the fatigue life, and a rapid drop in the stress carrying capabil- ity prior to failure, Both MMCs exhibit short LCF life which follows a Coffin-Manson relationship. All tested specimens demonstrate ductile fracture morphology at final failure.
Amir Pakdela, R. Rahmanifarda, H. Farhangia and M. Emamya [32] Showed that the reinforcement particles (oxi- dized SiC) were refined by the extrusion process and increas- ing the extrusion temperature (extruded at 45 0°C, 5 00°C and
550°C ) decreased the extent of the fragmentation.
P. Poza and J. Llorca [33] They showed the deformation and
failure mechanisms under cyclic deformation in an 8090 Al-Li alloy reinforced with 15 vol pct SiC particles.
Many researches [34-37] Studied the initiation and growth of surface cracks during low-cycle fatigue of an AA6061 alloy composite containing (a) 15 vol% of SiC particles and (b) 20
vol% of Saffil short fibres, For both of the composites, cracks are initiated very early in the fatigue life irrespective of the cyclic strain amplitude, (fig. 1, 2, 3).
The study of the previous work, previews that the rein- forcement of aluminium alloy and composite opens up the possibility of application of these materials in areas where weight reduction has first priority. The precondition is the improvement of the component properties. The metal matrix composites fabrication technology allows obtaining locally reinforced elements and nearing net shape products.
Some researchers showed the possibility of obtaining the new aluminium matrix composite materials being the cheaper alternative for other materials based on the ceramic fibers. Some researchers proved that developed technology of manu- facturing of composite materials based on the porous ceramic performs infiltrated by liquid aluminium, alloy ensures ex- pected structure and strength Hardness increased about twice compared to the matrix, and some researchers described who to use micromechanical element models to simulate both the static and cyclic mechanical behaviour of a metal matrix com- posite, whereas some others researchers observed that the in- creasing volume fraction and particle size of reinforcements decreased the strain controlled fatigue life response of the composites, for example a higher volume fraction and finer particulate sizes of the SiCp resulted in an increase in harden- ing behaviour with fatigue lives, some researches showed the increasing of stress ratio increased the crack growth rates of the composite.
Other researchers recommended for the heat treatment processes to increasing the strength and hardness of either wrought or cast aluminium alloys utilize the mechanism of
precipitation hardening, the different properties were ob- tained with various amounts of alloying elements. Hence, the studies were to optimize the heat treatment and to investigate the effect of initial deformation (shaping) process on the me- chanical properties of Aluminium alloy and composite mate- rials.
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