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A frequency domain enhanced multi-view neural network approach to multiaxial fatigue life prediction for various metal materials 频域增强型多视角神经网络方法用于预测各种金属材料的多轴疲劳寿命
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-20 DOI: 10.1016/j.ijfatigue.2024.108620
Shuonan Chen , Xuhong Zhou , Yongtao Bai
Fatigue damages and failure widely exist in engineering structures, particularly in industries such as aerospace, automotive, and construction, where components are often subjected to complex multiaxial loading conditions. Accurate prediction of fatigue life is critical for ensuring the safety and longevity of these structures. In this study, a novel multi-view deep learning model incorporating frequency domain analysis for fatigue life prediction is proposed. The proposed model integrates a Convolutional Neural Network (CNN), a Long Short-Term Memory Network (LSTM), and FNet that combines frequency domain analysis, in a parallel structure to extract features from the loading paths of materials. These extracted features are then connected to a fully connected neural network to predict fatigue life. The model was validated using fatigue data collected from 6 different materials, encompassing 17 loading paths and 336 samples. Additionally, ablation experiments were conducted, and the extrapolation capabilities were evaluated using specifically designed test sets. The results demonstrate that the proposed model exhibits excellent predictive performance and extrapolation capabilities. We anticipate that the multi-view approach, along with its accuracy and applicability, can offer potential applications in engineering fields that require reliable, data-driven models to assess material durability under complex loading scenarios.
疲劳破坏和失效广泛存在于工程结构中,尤其是在航空航天、汽车和建筑等行业中,这些行业中的部件通常要承受复杂的多轴载荷条件。准确预测疲劳寿命对于确保这些结构的安全性和使用寿命至关重要。本研究提出了一种新颖的多视角深度学习模型,该模型结合了用于疲劳寿命预测的频域分析。该模型将卷积神经网络(CNN)、长短期记忆网络(LSTM)和结合频域分析的 FNet 集成在一个并行结构中,以从材料的加载路径中提取特征。然后将这些提取的特征连接到全连接神经网络,以预测疲劳寿命。该模型使用从 6 种不同材料中收集的疲劳数据进行了验证,包括 17 种加载路径和 336 个样本。此外,还进行了烧蚀实验,并使用专门设计的测试集评估了外推能力。结果表明,所提出的模型具有出色的预测性能和外推能力。我们预计,多视角方法及其准确性和适用性可为工程领域提供潜在应用,这些领域需要可靠的数据驱动模型来评估复杂加载情况下的材料耐久性。
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引用次数: 0
Observation and modeling of potential sub-threshold damage growth mechanism for nitinol in ultra-high cycle fatigue 超高循环疲劳中镍钛诺潜在阈下损伤增长机制的观测与建模
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-18 DOI: 10.1016/j.ijfatigue.2024.108613
Andrew Roiko , Scott Cook , Brian Berg , Wayne Falk , Jason D. Weaver
Fatigue fracture of small nitinol components commonly used in medical devices is currently dominated by the initiation and/or growth of small cracks at non-metallic inclusions preceding conventional fatigue crack growth. Therefore, an understanding of the threshold and growth of small cracks is critical to inform fatigue performance of devices. In this paper, we conduct rotary bend fatigue experiments of nitinol wire to 2 billion cycles, measure the inclusion from which the crack initiated, and calculate the stress intensity threshold. Inclusion size is compared to the size of a unique feature observable with a scanning electron microscope which appears as a smooth area surrounding the inclusion and only on specimens that fractured after > 10 million cycles. The hypothesis presented is that the smooth feature around the inclusion is the growth of a small crack which continues until it reaches a size large enough to cause conventional fatigue crack growth. Relating inclusion size to that of the smooth feature creates a damage curve that can be written as a function of cycles to fracture. This damage curve may be useful to estimate the critical size of the largest allowable defect based on the design life and applied loading of the nitinol component.
目前,医疗设备中常用的小型镍钛诺部件的疲劳断裂主要是在非金属夹杂物上的小裂纹在常规疲劳裂纹生长之前产生和/或生长。因此,了解小裂纹的阈值和生长情况对设备的疲劳性能至关重要。在本文中,我们对镍钛诺丝进行了 20 亿次旋转弯曲疲劳实验,测量了裂纹产生的夹杂物,并计算了应力强度阈值。夹杂物的大小与扫描电子显微镜观察到的独特特征的大小进行了比较,该特征表现为夹杂物周围的光滑区域,且仅出现在 1000 万次循环后断裂的试样上。提出的假设是,夹杂物周围的光滑特征是小裂纹的生长过程,这种生长过程一直持续到其尺寸大到足以导致常规疲劳裂纹生长为止。将内含物的尺寸与光滑特征的尺寸联系起来,可以绘制出一条损伤曲线,该曲线可以写成断裂周期的函数。根据镍钛诺部件的设计寿命和应用载荷,该损伤曲线可用于估算最大允许缺陷的临界尺寸。
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引用次数: 0
Effect of over-ageing on the tensile and torsional fatigue properties of the AlSi7Cu0.5 Mg0.3 precipitation-hardened cast aluminium alloy 超时效对 AlSi7Cu0.5 Mg0.3 沉淀硬化铸铝合金拉伸和扭转疲劳性能的影响
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-18 DOI: 10.1016/j.ijfatigue.2024.108615
Pierre Osmond , Daniel Bellett , Viet Duc Le , Franck Morel
The objective of this work is to evaluate the influence of over-ageing on the high cycle fatigue behaviour of the AlSi7Cu0.5Mg0.3 cast aluminium alloy. It is generally accepted that over-ageing has a large influence on the behaviour of these materials, however its effect on the fatigue strength is less understood. This work provides an experimental investigation of the effect of over-ageing on high cycle fatigue strength in both tensile and torsional loading conditions. It is shown that the torsional fatigue strength is more sensitive to over-ageing when compared to the tensile fatigue strength and that the fatigue defect sensitivity is negligible for torsional loads, in contrast to tensile loading conditions. The experimental results indicate that this is due to a change in the crack initiation mechanism, going from initiation in the matrix for torsion loads to initiation from casting defects for tensile loads. An original two-steps approach is proposed to rationalise the effect of over-ageing on the fatigue strength, with particular emphasis on decoupling the respective contributions from defects and the mechanical properties. This approach is used to build normalised Kitagawa-Takahashi diagrams that highlights the reduced defect sensitivity under tensile loads for the most severe over-ageing condition.
这项工作的目的是评估过时效对 AlSi7Cu0.5Mg0.3 铸造铝合金高循环疲劳性能的影响。人们普遍认为过时效对这些材料的性能有很大影响,但对其疲劳强度的影响却不甚了解。这项研究对拉伸和扭转加载条件下超时效对高循环疲劳强度的影响进行了实验研究。实验结果表明,与拉伸疲劳强度相比,扭转疲劳强度对超龄更敏感,而与拉伸载荷条件相比,扭转载荷的疲劳缺陷敏感性可以忽略不计。实验结果表明,这是由于裂纹萌发机制发生了变化,从扭转载荷下的基体萌发变为拉伸载荷下的铸造缺陷萌发。为了合理解释超时效对疲劳强度的影响,我们提出了一种新颖的两步法,特别强调将缺陷和机械性能各自的贡献分离开来。这种方法用于建立归一化的北川-高桥图表,突出了在最严重的超时效条件下,拉伸载荷下缺陷敏感性的降低。
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引用次数: 0
Surface integrity and high-cycle fatigue life of direct laser metal deposited AISI 431 alloys modified by plasticity ball burnishing 直接激光金属沉积 AISI 431 合金经塑性球烧蚀改性后的表面完整性和高循环疲劳寿命
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-18 DOI: 10.1016/j.ijfatigue.2024.108614
Mya Thit , Anthony Rocissano , Andre Hatem , Mohammad Uddin , Colin Hall , Thomas Schlaefer
Laser metal deposition (LMD) as an additive manufacturing (AM) is widely used to repair and extend wear and fatigue life of the critical components. This paper has investigated the application of ball burnishing (BB) to improve surface integrity and high-cycle fatigue resistance of LMDed AISI 431 alloys. Results showed that the BB treated samples exhibited significant surface finish improvement by lowering roughness by 91 %. Microhardness increased from 490 to 530 HV0.1, an increase by 10 % with a modified depth of 400 µm from the top surface. XRD results showed a peak shift and increase in FWHM by up to 17 %. This had been corroborated by EBSD exhibiting a 20 % increase in dislocation density and 24 % increase in localised misorientation within microstructure. As a result, the overall high cycle fatigue strength of the burnished sample increased by 50 %, and the cracks initiated from sub-surface level defects at a depth of 350 μm below the top surface, delaying the crack propagation and fracture failure. The findings clearly highlight that the burnishing treatment can be a plausible approach in improving the dynamic fatigue resistance and the overall service life of LMDed AISI 431 steel alloys components in engineering applications.
激光金属沉积(LMD)作为一种增材制造(AM)技术,被广泛用于修复和延长关键部件的磨损和疲劳寿命。本文研究了如何应用球形灼烧(BB)技术来改善经 LMD 处理的 AISI 431 合金的表面完整性和高循环抗疲劳性。结果表明,经过 BB 处理的样品表面光洁度显著提高,粗糙度降低了 91%。显微硬度从 490 HV0.1 提高到 530 HV0.1,提高了 10%,改性深度从顶面开始为 400 µm。X 射线衍射结果表明,峰值发生了移动,全宽域增加了 17%。EBSD 也证实了这一点,显示微结构中的位错密度增加了 20%,局部错向增加了 24%。因此,抛光样品的整体高循环疲劳强度提高了 50%,裂纹从顶面以下 350 μm 深度的次表层缺陷开始,延迟了裂纹扩展和断裂失效。研究结果清楚地表明,在工程应用中,烧钝处理是提高 LMDed AISI 431 钢合金部件动态抗疲劳性能和整体使用寿命的一种可行方法。
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引用次数: 0
Peridynamic analysis of rolling contact fatigue crack propagation in rail welding joints with pore defects 具有孔隙缺陷的轨道焊接接头中滚动接触疲劳裂纹扩展的周动态分析
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-18 DOI: 10.1016/j.ijfatigue.2024.108612
Shirui Li , Xiaoming Wang , Weijia Dong , Qing He , Boyang An , Ping Wang , Bing Yang
Pore defects are prevalent in rail welding joints and significantly contribute to the propagation of fatigue cracks. This study develops a peridynamic (PD) model that incorporates the characteristics of pore defects to analyze their impact on rolling contact fatigue behavior. Initially, compact tension (CT) fatigue tests were performed to derive and validate the bond fatigue failure model specific to rail weld materials. Subsequently, pore defects were modeled as holes in the CT specimens, with experimental results being compared to PD simulation outcomes for validation. Finally, a wheel-rail contact PD model was constructed to investigate the mechanisms of fatigue crack propagation in rail welding joints affected by pore defects.
孔隙缺陷在钢轨焊接接头中非常普遍,对疲劳裂纹的扩展起着重要作用。本研究开发了一种结合孔隙缺陷特征的周动态 (PD) 模型,以分析其对滚动接触疲劳行为的影响。首先,进行了紧凑拉伸(CT)疲劳试验,以推导和验证轨道焊接材料特有的结合疲劳失效模型。随后,将孔隙缺陷建模为 CT 试样中的孔,并将实验结果与 PD 模拟结果进行比较,以进行验证。最后,构建了轮轨接触 PD 模型,以研究受孔隙缺陷影响的钢轨焊接接头中疲劳裂纹的扩展机制。
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引用次数: 0
Effect of microstructure on small fatigue crack initiation and early propagation behavior in super martensite stainless steel 微观结构对超级马氏体不锈钢中细小疲劳裂纹萌生和早期扩展行为的影响
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-17 DOI: 10.1016/j.ijfatigue.2024.108604
Xue Li , Tian Ye , Yaohan Du , Min Zhan , Xiangyu Wang , Yajun Dai , Yongjie Liu , Chong Wang , Kun Yang , Chao He , Qingyuan Wang

The objective of this study is to investigate the influence mechanism of martensite multi-scale interfaces on the fatigue small cracks propagation behavior in super martensite stainless steel. The findings revealed that crack propagation slows during the transition from early to steady stages. Multiscale martensite interfaces can cause varying degrees of crack deflection, and cracks tend to propagate along-boundaries during the early propagation stage. Martensite lath is the basic unit that affects the fatigue performance and the behavior of small crack propagation.

本研究旨在探讨马氏体多尺度界面对超级马氏体不锈钢疲劳小裂纹扩展行为的影响机制。研究结果表明,在从早期向稳定阶段过渡的过程中,裂纹扩展速度减慢。多尺度马氏体界面会导致不同程度的裂纹偏转,裂纹在早期扩展阶段倾向于沿边界扩展。马氏体板条是影响疲劳性能和小裂纹扩展行为的基本单元。
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引用次数: 0
Analysis of high temperature and strain amplitude effects on low cycle fatigue behavior of pitting corroded killed E350 BR structural steel 高温和应变振幅对点蚀致死 E350 BR 结构钢低循环疲劳行为的影响分析
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-17 DOI: 10.1016/j.ijfatigue.2024.108611
Siddharth Chauhan , S. Muthulingam , Samir Chandra Roy

High-tension structural steels are prone to accelerated fatigue damage from pitting corrosion and high-temperature. Despite adverse effects, research on their low cycle fatigue (LCF) behavior is limited. Specifically, studies analyzing temperature-dependent pit sensitivity effects, considering pit-related material’s susceptibility to surface topographic features variation and stress concentration are lacking. This study conducts LCF tests on pitting corroded killed E350 BR structural steel at multiple strain amplitudes and high temperatures. It develops temperature-dependent parameters, such as the cyclic softening pit sensitivity factor, suitable for integration into existing approaches like total cyclic plastic strain energy density (CPSED), power-law, average strain energy density (SED), Coffin-Manson, and pit stress intensity factor (pit-SIF). Further, it proposes multiple linear regression-based prediction models relating total CPSED and average SED with strain amplitude and temperature. Corroded specimens show higher plastic deformation and reduced peak stress, fatigue life, and total CPSED compared to uncorroded ones. The developed parameters, integrated with average SED approach, predicts LCF life within an error band of ±1.5, while power-law relationship reduces it to ±1.2. Moreover, pit-SIF approach estimates fatigue life within an error band of ±1.5. The findings provide critical knowledge for enhanced component design, leading to structural safety, performance, and fire resilience.

高压结构钢容易因点蚀和高温而加速疲劳损伤。尽管存在不利影响,但对其低循环疲劳(LCF)行为的研究却十分有限。具体来说,缺乏对温度相关点蚀敏感性效应的分析研究,也没有考虑到与点蚀相关的材料对表面形貌特征变化和应力集中的敏感性。本研究在多种应变振幅和高温条件下,对被点蚀腐蚀的 E350 BR 结构钢进行了 LCF 试验。它开发了与温度相关的参数,如循环软化凹坑敏感系数,适合集成到现有方法中,如总循环塑性应变能量密度 (CPSED)、幂律、平均应变能量密度 (SED)、Coffin-Manson 和凹坑应力强度系数 (pit-SIF)。此外,它还提出了基于多元线性回归的预测模型,将总 CPSED 和平均 SED 与应变振幅和温度联系起来。与未腐蚀的试样相比,腐蚀试样的塑性变形更大,峰值应力、疲劳寿命和总 CPSED 均有所降低。所开发的参数与平均 SED 方法相结合,可在 ±1.5 的误差范围内预测 LCF 寿命,而幂律关系则将误差缩小到 ±1.2。此外,凹坑-SIF 方法估计的疲劳寿命误差在 ±1.5 范围内。这些发现为加强部件设计提供了重要知识,从而提高了结构的安全性、性能和耐火性。
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引用次数: 0
α-lamella orientation dependence of fatigue crack propagation in as-forged TiB/near α-Ti composite 锻造钛B/近似α-钛复合材料疲劳裂纹扩展的α-拉美拉取向依赖性
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-16 DOI: 10.1016/j.ijfatigue.2024.108610
Fanchao Meng , Rui Zhang , Shuai Wang , Fengbo Sun , Ming Ji , Cunyu Wang , Lujun Huang , Lin Geng

The influence of microstructural attributes on fatigue crack propagation in titanium matrix composite remains largely unexplored. The impact of α-lamella crystallographic and spatial orientations on fatigue crack propagation in an as-forged TiB/near α-Ti composite was investigated using innovative quantitative tilt fractography and electron backscattered diffraction techniques. Crack initiation was observed from TiB cluster defects, followed by faceted fatigue crack propagation across α lamellae. In long-life failure, facet formation appears to be driven by a combination of slip and resolved normal stress across the facet plane, with facet angles relative to the loading direction (LD) predominantly ranging between 30.0° and 50.0°. In contrast, short-life failure exhibited shear deformation as the primary mode, with facet angles relative to LD mainly between 40.0° and 50.0°. Crystallographic orientation analysis revealed that facets predominantly formed near the basal plane in both long-life and short-life failures. Crack-initiation microstructural neighborhoods favoring basal slip increased effective slip length over α lamellae, reducing resistance to crack propagation. This led to a rise in basal geometrically necessary dislocation (GND) density from 1.2 × 1013 m−2 in long-life to 3.6 × 1013 m−2 in short-life failures. These observations highlight the dominance of spatial and crystallographic orientations of α lamellae in controlling fatigue crack propagation.

微结构属性对钛基复合材料疲劳裂纹扩展的影响在很大程度上仍未得到研究。我们采用创新的定量倾斜分形和电子反向散射衍射技术,研究了α-拉梅拉晶体学和空间取向对锻造钛B/近α-钛复合材料疲劳裂纹扩展的影响。观察到裂纹从 TiB 簇缺陷处开始,随后在 α 薄片上出现刻面疲劳裂纹扩展。在长寿命失效中,刻面的形成似乎是由滑移和跨刻面平面的解析法向应力共同驱动的,刻面相对于加载方向(LD)的角度主要在 30.0° 和 50.0° 之间。相反,短寿命失效的主要模式是剪切变形,相对于 LD 的面角主要在 40.0° 和 50.0° 之间。晶体取向分析表明,在长寿命和短寿命失效中,刻面主要在基底面附近形成。有利于基面滑移的裂纹引发微结构邻域增加了α薄片的有效滑移长度,降低了裂纹扩展的阻力。这导致基底几何必要位错(GND)密度从长寿命故障的 1.2 × 1013 m-2 上升到短寿命故障的 3.6 × 1013 m-2。这些观察结果突显了α薄片的空间和晶体取向在控制疲劳裂纹扩展中的主导作用。
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引用次数: 0
Exploring the strengthening mechanisms of additive manufactured metals treated by ultrasonic nanocrystal surface modification 探索经超声波纳米晶表面改性处理的增材制造金属的强化机制
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-16 DOI: 10.1016/j.ijfatigue.2024.108609
Yu Zhang , Lan Peng , Yixuan Ye , Yuanqing Chi , Le Gao , Xuming Zha , Tao Huang , Yongkang Zhang , Han Ding , Chang Ye
This study investigates the use of ultrasonic nanocrystal surface modification (UNSM) to enhance the surface integrity and mechanical properties of stainless steel fabricated using selective laser melting (SLM). The improved yield strength is primarily obtained from grain refinement, deformation-induced martensitic, and high density of dislocations and deformation twins. The superior fatigue resistance is attributed to the synergistic effect of a reduction in surface and subsurface defects, dense dislocation substructure, high-strength martensitic phase, and a high amplitude of compressive residual stress (CRS) within the gradient deformation layer, collectively suppressing crack initiation. Microstructure evolution and CRS relaxation behavior of UNSM-treated samples during cyclic loading were examined. The results revealed that the benefits of CRS are relatively constrained due to its rapid relaxation under cyclic loading at a moderate stress level (550 MPa). In contrast, the gradient nanostructure remained stable under cyclic loading at the same stress level, exhibiting limited plastic deformation and grain coarsening. This indicates that the gradient nanostructure plays a more significant role than the CRS in delaying fatigue crack initiation and propagation at high stress levels. These findings provide valuable insights for identifying the dominant factor responsible for the improvement in fatigue resistance of SLM components after surface-strengthening treatment.
本研究探讨了如何使用超声波纳米晶表面改性(UNSM)来提高使用选择性激光熔化(SLM)制造的不锈钢的表面完整性和机械性能。屈服强度的提高主要得益于晶粒细化、形变诱导马氏体以及高密度位错和形变孪晶。优异的抗疲劳性能归功于表面和次表面缺陷的减少、密集的位错子结构、高强度马氏体相以及梯度变形层内高幅度的压缩残余应力(CRS)的协同作用,这些因素共同抑制了裂纹的产生。研究人员考察了经过 UNSM 处理的样品在循环加载过程中的微观结构演变和 CRS 松弛行为。结果表明,在中等应力水平(550 兆帕)的循环加载下,CRS 会迅速松弛,因此其益处相对有限。相反,梯度纳米结构在相同应力水平的循环加载下保持稳定,表现出有限的塑性变形和晶粒粗化。这表明在高应力水平下,梯度纳米结构在延迟疲劳裂纹的产生和扩展方面比 CRS 起到了更重要的作用。这些发现为确定表面强化处理后 SLM 部件耐疲劳性改善的主导因素提供了宝贵的见解。
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引用次数: 0
Evaluating the damage tolerant behavior of cold spray repaired aluminum alloys 评估冷喷修复铝合金的损伤容限行为
IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-09-12 DOI: 10.1016/j.ijfatigue.2024.108607
Patrick E. Morrison, Krzysztof S. Stopka, John I. Ferguson, Michael D. Sangid

Cold spray presents a promising solution for repair of damaged material within high-value components. However, before employing cold spray for component repair, it is crucial to assess its damage tolerance and durability. This study focuses on evaluating the fatigue behavior of helium-sprayed AA6061 applied to an A356-T6 cast substrate compared to the same specimen geometry made entirely of the A356-T6 material. Fatigue testing was conducted using a marker band schedule to analyze fatigue crack growth rates in the cold spray and substrate materials. To complement the fatigue testing, experimental uncertainties and variabilities were incorporated into a crack growth model using a Monte Carlo approach to probabilistically assess reliability. The results indicate that the AA6061 cold spray material exhibited faster crack growth, resulting in a ∼25% lower life compared to the baseline A356-T6 material. Given the cost effectiveness of the cold spray repair process, it appears to be a viable approach, with the caveats that the residual life is expected to be less than the pristine substrate material and the cold spray interface is prone to delamination during crack impingement.

冷喷技术为修复高价值部件内的受损材料提供了一种前景广阔的解决方案。不过,在使用冷喷技术修复部件之前,评估其损伤容限和耐久性至关重要。本研究的重点是评估与完全由 A356-T6 材料制成的相同几何形状试样相比,在 A356-T6 铸造基体上喷氦气的 AA6061 的疲劳行为。疲劳测试采用标记带计划来分析冷喷材料和基体材料的疲劳裂纹生长率。作为疲劳测试的补充,使用蒙特卡罗方法将实验不确定性和变异性纳入裂纹增长模型,以从概率上评估可靠性。结果表明,与基准 A356-T6 材料相比,AA6061 冷喷材料的裂纹生长速度更快,导致寿命缩短了 25%。鉴于冷喷修复工艺的成本效益,它似乎是一种可行的方法,但需要注意的是,残余寿命预计低于原始基体材料,而且冷喷界面在裂纹撞击过程中容易分层。
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引用次数: 0
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International Journal of Fatigue
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