A Robust Numerical Methodology for Fatigue Damage Evolution Simulation in Composites

Composite materials, like metals, are subject to fatigue effects, representing one of the main causes for component collapse in carbon fiber-reinforced polymers. Indeed, when subject to low stress cyclic loading, carbon fiber-reinforced polymers exhibit gradual degradation of the mechanical properties. The numerical simulation of this phenomenon, which can strongly reduce time and costs to market, can be extremely expensive in terms of computational effort since a very high number of static analyses need to be run to take into account the real damage propagation due the fatigue effects. In this paper, a novel cycle jump strategy, named Smart Cycle strategy, is introduced in the numerical model to avoid the simulation of every single cycle and save computational resources. This cycle jump strategy can be seen as an enhancement of the empirical model proposed by Shokrieh and Lessard for the evaluation of the fatigue-induced strength and stiffness degradation. Indeed, the Smart Cycle allows quickly obtaining a preliminary assessment of the fatigue behavior of composite structures. It is based on the hypothesis that the stress redistribution, due to the fatigue-induced gradual degradation of the material properties, can be neglected until sudden fiber and/or matrix damage is verified at element/lamina level. The numerical procedure has been implemented in the commercial finite element code ANSYS MECHANICAL, by means of Ansys Parametric Design Languages (APDL). Briefly, the Smart Cycle routine is able to predict cycles where fatigue failure criteria are likely to be satisfied and to limit the numerical simulation to these cycles where a consistent damage propagation in terms of fiber and matrix breakage is expected. The proposed numerical strategy was preliminarily validated, in the frame of this research study, on 30° fiber-oriented unidirectional coupons subjected to tensile–tensile fatigue loading conditions. The numerical results were compared with literature experimental data in terms of number of cycles at failure for different percentage of the static strength. Lastly, in order to assess its potential in terms of computational time saving on more complex structures and different loading conditions, the proposed numerical approach was used to investigate the fatigue behavior of a cross-ply open-hole composite panel under tension–tension fatigue loading conditions.     

Evaluation of Fatigue Strength Improvement by CFRP Laminates and Shot Peening onto the Tension Flanges Joining Corrugated Steel Webs

Corrugated steel web with inherent high out-of-plane stiffness has a promising application in configuring large span highway bridge girders. Due to the irregularity of the configuration details, the local stress concentration poses a major fatigue problem for the welded flange plates of high strength low alloy structural steels. In this work, the methods of applying CFRP laminate and shot peening onto the surfaces of the tension flanges were employed with the purpose of improving the fatigue strength of such configuration details. The effectiveness of this method in the improvement of fatigue strength has been examined experimentally. Test results show that the shot peening significantly increases hardness and roughness in contrast to these without treatment. Also, it has beneficial effects on the fatigue strength enhancement when compared against the test data of the joints with CFRP strengthening. The stiffness degradation during the loading progress is compared with each treatment. Incorporating the stress acting on the constituent parts of the CFRP laminates, a discussion is made regarding the mechanism of the retrofit and related influencing factors such as corrosion and economic cost. This work could enhance the understanding of the CFRP and shot peening in repairing such welded details and shed light on the reinforcement design of welded joints between corrugated steel webs and flange plates.     

Numerical Study of the Effects of Residual Stress on Fretting Fatigue Using XFEM

Residual compressive stress can improve fretting fatigue strength. In this paper, the effects of residual stress on fretting fatigue of Al 2024-T351 alloy specimens are studied using a numerical approach. The extended finite element method combined with the cyclic cohesive zone model is adopted to model fretting fatigue crack growth behavior. It is shown that residual stress changes the fretting fatigue crack growth path and enhances fretting fatigue life. Crack initiation angle, depth of knee point, crack initiation life, crack propagation life and total life are greater for specimens with residual stress compared to specimens without residual stress. The effects of residual stress are more remarkable for specimens with a high intensity of residual stress. However, the effects of residual stress reduce at a high bulk load level.     

Testing Procedure for Fatigue Characterization of Steel-CFRP Hybrid Laminate Considering Material Dependent Self-Heating

Combining carbon fiber reinforced polymers (CFRP) with steel offers the potential of utilizing the desired characteristics of both materials, such as specific strength/stiffness and fatigue strength of fiber reinforced polymers (FRP) and impact resistance of metals. Since in such hybrid laminates multiple material layers are combined, a gradual failure is likely that can lead to changes in mechanical properties. A failure of the metal partner leads to an increase in stress on the FRP, which under fatigue load results in increased self-heating of the FRP. Therefore, a suitable testing procedure is required and developed in this study, to enable a reproducible characterization of the mechanical properties under fatigue load. The resulting testing procedure, containing multiple frequency tests as well as load increase and constant amplitude tests, enabled characterization of the fatigue performance while never exceeding a testing induced change in temperature of 4 K. In addition to the development of the testing procedure, an insight into the manufacturing induced residual stresses occurring in such hybrid laminates, which impacts the load-bearing capacity, was established using finite element simulation. The gathered data and knowledge represents a basis for future in-depth investigations in the area of residual stress influence on the performance of hybrid laminates and highlights its importance, since not only the used testing procedure determines the measured fatigue performance.     

Residual Strength Prediction of Aluminum Panels with Multiple Site Damage Using Artificial Neural Networks

Multiple site damage (MSD) cracks are small fatigue cracks that may accumulate at the sides of highly loaded holes in aging aircraft structures. The presence of MSD cracks can drastically reduce the residual strength of fuselage panels. In this paper, artificial neural networks (ANN) modeling is used for predicting the residual strength of aluminum panels with MSD cracks. Experimental data that include 147 unique configurations of aluminum panels with MSD cracks are used. The experimental dataset includes three different aluminum alloys (2024-T3, 2524-T3, and 7075-T6), four different test panel configurations (unstiffened, stiffened, stiffened with a broken middle stiffener, and bolted lap-joints), many different panel widths and thicknesses, and the sizes of the lead and MSD cracks. The results presented in this paper demonstrate that a single ANN model can predict the residual strength for all materials and configurations with high accuracy. Specifically, the overall mean absolute error for the ANN model predictions is 3.82%. Furthermore, the ANN model residual strength predictions are compared to those obtained using the most accurate semi-analytical and computational approaches from the literature. The ANN model predictions are found to be at the same accuracy level of these approaches, and they even outperform the other approaches for many configurations.     

Fatigue Behavior of Heavy-Haul Railway Prestressed Concrete Beams Based on Vehicle-Bridge Coupling Vibration

Due to the demand for increasing trainload and enhancing some existing heavy-haul railways, the low reserve value of bearing capacity is a problem for the 32 m-span simply supported beam. The fatigue behavior of prestressed concrete beams in a heavy-haul railway loaded by 33 t and larger axle weight of trains was experimentally investigated. The experimental results of the fatigue behaviors, including fatigue deformation, crack propagation behavior, and strains of classical materials were obtained and analyzed. A fatigue behavior assessment model was established to investigate the residual stiffness and yield point degradation of the beams loaded by the trainload. The effects of train fatigue cycles and prestress loss on the residual stiffness and yield point degradation models of the beams were analyzed. The results indicated that the crack development process had three stages during the fatigue process: the derivative stage, gradual development stage, and fatigue failure stage. Trainload was the main external factor influencing the fatigue behavior of prestressed concrete beams. The increase in trainload accelerated the degradation rate of the residual stiffness of the beams and yield point, reducing the fatigue life. The prestressing strand was primarily used to delay the concrete cracking in the tension zone. When the beam was not cracked, the prestressed concrete beam showed good fatigue performance, and the degree of prestressing did not affect the fatigue life of the beams. When the maximum fatigue load exceeded the cracking load of the beam, prestress loss in beams became a critical issue that accelerated the degradation rate of fatigue strength and reduced fatigue life. The higher the fatigue damage degree, the more pronounced the effect of prestress loss on the fatigue strength of the beams. The fatigue failure of prestressed concrete beams occurred in the bottom tensile steel bar. Therefore, when the trainload of a heavy-haul railway is greater than the cracking load of the beam, it is recommended to strengthen the beam by prestressing and strictly control the trainload to avoid yield failure.     

Influence of the Arrangement of Mechanical Fasteners on the Static Strength and Fatigue Life of Hybrid Joints

This paper presents the results of experimental research and numerical calculations regarding the static strength and fatigue life of hybrid joints. In the experiments, specimens built as single-lap adhesive–mechanical joints (hybrid joints) were tested. In a two-stage process of the failure of the hybrid joints, the adhesive joint was damaged first. Therefore, it was assumed that the assembly of fasteners closer to the edge of the overlap (beyond the ranges recommended for mechanical joints) limits the negative impact of the peeling phenomenon on the strength and performance properties of hybrid joints. The specimens used in the experiments were prepared from composite elements (i.e., carbon fiber-reinforced polymer (CFRP)), as well as from the aluminum alloy 2024T4. Because the detection of fatigue damage in composite materials is a complex problem, computed tomography was used to evaluate the degradation of the composite material. Experimental and numerical comparative analyses of the static strength and fatigue life of hybrid joints with adhesive and mechanical joints confirmed the assumptions made.     

Fatigue Models for Airfield Concrete Pavement: Literature Review and Discussion

The fatigue model plays an important role in the mechanistic–empirical design procedure of airfield pavement. As for cement concrete pavement, the fatigue model represents the relationship between the stress and the number of load repetitions. To further understand the fatigue model, a literature review was performed in this paper along with the discussion. In this paper, the developed fatigue models available now were classified as the full-scale testing-based fatigue model and the concrete beam testing-based fatigue model, according to the data source. Then, the regression analysis process and stress calculation method of each fatigue model were summarized. Besides, the fatigue model proposed by the Federal Aviation Administration (FAA) was compared with the fatigue model of the Civil Aviation Administration of China (CAAC). The design thicknesses using the two models were obtained based on the finite element analysis. The results show that the designed slab using the fatigue model of FAA is thicker than that of CAAC, meaning that the fatigue model of FAA is comparatively conservative. Moreover, it can be concluded that the differences in the slab thickness become more significant with the increase in the wheel load and the foundation strength. Finally, the recommendation was proposed to refine the fatigue model in the future study from three aspects: data source, stress calculation method, and regression analysis process.     

Fatigue Life Assessment of Welded Joints by Combined Measurements Using DIC and XRD

The existing methods of assessing the fatigue life of welded joints fail to consider local strain ranges and mean stress at the weld toe. The present work proposes a novel approach to assessing the fatigue life of welded joints by conducting measurements with digital image correlation (DIC) and X-ray diffraction (XRD) in combination. Local strain ranges at the weld toe of gusset welded joints were measured by DIC. Hammer peening was conducted on the welded joints to introduce different initial stresses. The influence of mean stress was investigated by considering initial residual stress measured by XRD and a perfect plastic material model. The fatigue experiment was carried out on specimens with and without hammer peening. The results showed that hammer peening could offset adverse welding deformation effectively, and introduce significant residual compressive stress. The fatigue failure life increased by more than 15 times due to hammer peening. The fatigue initiation life assessed by the proposed method was close to that based on nominal stress, indicating that the proposed method is reliable for predicting the fatigue initiation life of welded joints.     

Assessment of the Impact of Shot-Peening on the Fatigue Life of a Compressor Blade Subjected to Resonance Vibrations

This publication presents an assessment of the influence of a surface treatment such as shot-peening on the fatigue life of a compressor blade exposed to resonant vibrations. As part of the work, a geometric model of the blade was developed, and a numerical modal and fatigue analysis were performed. The fatigue analysis was based on the Manson–Coffin–Basquin and Ramberg–Osgood models. Additionally, the location of the highest equivalent stresses was established. Based on the results of the strength analysis, two points were identified where a fatigue crack may potentially occur. As part of the work, the influence of different values of residual stresses on the results of the fatigue life was determined. The obtained results were compared to the literature values of fatigue life for this blade. A secondary objective of the study was to determine the size of the grains at various points of the blade, as well as the thickness of the layer plasticized as a result of peening. The relationship between the location of the highest values of the equivalent stresses and the thickness of the plasticized layer was determined. An explanation of the effect of shot-peening on the increase in the fatigue life of the blade was proposed.     

An Investigation of the Contact Fatigue Characteristics of an RV Reducer Crankshaft,Considering the Hardness Gradients and Initial Residual Stress

The crankshaft is one of the core components of a Rotate Vector (RV) reducer. The fatigue life of the RV reducer is severely hindered by fatigue failure on the eccentric cylindrical surface of the crankshaft. The hardness gradients and residual stress in the crankshaft, associated with machining operations, exert an enormous impact on the rolling contact fatigue (RCF). In this work, a finite element method (FEM)-based three-dimensional elasto-plastic contact model is established to calculate the stress–strain field by taking hardness gradients and initial residual stress into account. The RCF characteristics of an RV reducer crankshaft is investigated by applying modified Fatemi–Socie (FS) multiaxial fatigue criterion. The results indicate that initial residual stress plays an influential role in the fatigue damage by altering the distribution of the maximum normal stress near the contact surface. The modified FS fatigue criterion could better consider the effect of initial residual stress and the shear stress, which significantly improves the prediction accuracy of the contact fatigue life model. The contact fatigue performance could be considerably improved by designing appropriate shot peening parameters to obtain optimized residual stress distribution. Therefore, the technique presented may serve as an important guideline for the anti-fatigue design of an RV reducer crankshaft.     

Experimental Study on Bond Performance of Carbon- and Glass-Fiber Reinforced Polymer (CFRP/GFRP) Bars and Steel Strands to Concrete

FRP bars and steel strands are widely used in civil engineering. In this study, three different types of high-strength reinforcement materials, carbon fiber reinforced polymer (CFRP) bar, glass fiber reinforced polymer (GFRP) bar, and steel strand, were investigated for their interfacial bond performance with concrete. A total of 90 sets of specimens were conducted to analyze the effects of various parameters such as the diameter of reinforcement, bond length, the grade of concrete and stirrup on the bond strength and residual bond strength. The results show that CFRP bars possess a higher bond strength retention rate than steel bars in the residual section. In addition, with the increase in bond length and diameter of the CFRP bar, the residual bond strength decreases, and the bond strength retention rate decreases. Furthermore, the bond strength retention rate of GFRP bars was found to be higher than that of CFRP bars. With the increase in grade of concrete, the bond strength and residual bond strength between GFRP bars and concrete increases, but the bond strength retention rate decreases. With an increase in bond length and diameter of the GFRP bar, the bond strength starts to decrease. Further, stirrup can also increase the bond strength and reduce the slip at the free end of GFRP bars. Moreover, the bond strength retention rate of the steel strand was found to be lower than CFRP and GFRP bar.     

Numerical Simulation and Analytical Prediction of Residual Strength for Elbow Pipes with Erosion Defects

It is well known that the safety and reliability of pipeline transportation are crucial. We are aiming at the problem that the residual life and residual strength of the defective elbow pipes are difficult to predict and usually need to be obtained through experiments. Consequently, a combined method of numerical simulation technology combined with a genetic algorithm to optimize neural network extreme learning machine (GA-ELM) is proposed. Firstly, the erosion characteristics of elbow pipes with different defects under the conditions of different impurity particle flow rates, particle sizes, and mass flow rates are analyzed by numerical simulation. At the same time, the effects of erosion defects of different sizes on the equivalent stress and residual strength of elbow pipes are also studied. Based on numerical simulation data, the extreme learning machine prediction model optimized by a genetic algorithm is used to predict the erosion rate, residual life, and residual strength and compared with the traditional ELM network model. The results show that residual strength of the elbow pipes with the increase of the depth and length of the defect, and increases with the increase of the width of the defect; the GA-ELM model can not only effectively predict the erosion rate, residual life and residual strength of defective elbow pipes, moreover its prediction accuracy is better than the traditional ELM model.     

A Two-Dimensional Model for Pin-Load Distribution and Failure Analysis of Composite Bolted Joints

Multibolt composite joints are widely used in aircraft structures. The determination of the pin-load distribution among the bolts is a critical step in the failure prediction of bolted joints. In this paper, a two-dimensional model of the multibolt composite structure is established for the pin-load distribution analysis. Its accuracy is validated by experimental results and the results from a 3D finite element model. Based on the determined pin-load distribution, FE models for a laminated plate with three-row fastener joints are built for failure prediction. Hashin stress criteria and the degradation guidelines of the material stiffness with respect to the different failure modes proposed by Tserpes are applied for the failure evaluation and the material degradation, respectively. The failure location and ultimate load are well predicted, which further validates the effectiveness and applicability of the proposed model for the pin-load distribution analysis.     

High-Temperature Effect on the Tensile Mechanical Properties of Unidirectional Carbon Fiber-Reinforced Polymer Plates

Carbon fiber-reinforced polymer (CFRP) has the advantages of a high strength-weight ratio and excellent fatigue resistance and has been widely used in aerospace, automotive, civil infrastructure, and other fields. The properties of CFRP materials under high temperatures are a key design issue. This paper presents the quasi-static tensile mechanical properties of unidirectional CFRP plates at temperatures ranging from 20 to 600 °C experimentally. The laser displacement transducer was adopted to capture the in situ displacement of the tested specimen. The results showed that the tensile strength of the CFRP specimen was affected by the high-temperature effect significantly, which dropped 68% and 16% for the 200 and 600 °C, respectively, compared with that of the room temperature. The degradation measured by the laser transducer system was more intensive compared with previous studies. The elastic modulus decreased to about 29% of the room temperature value at 200 °C. With the evaporation of the resin, the failure modes of the CFRP experienced brittle fracture to pullout of the fiber tow. The study provides accurate tensile performance of the CFRP plate under high-temperature exposure, which is helpful for the engineering application.     

Optimization of Residual Stress Measurement Conditions for a 2D Method Using X-ray Diffraction and Its Application for Stainless Steel Treated by Laser Cavitation Peening

As the fatigue strength of metallic components may be affected by residual stress variation at small length scales, an evaluation method for studying residual stress at sub-mm scale is needed. The sin²ψ method using X-ray diffraction (XRD) is a common method to measure residual stress. However, this method has a lower limit on length scale. In the present study, a method using at a 2D XRD detector with ω-oscillation is proposed, and the measured residual stress obtained by the 2D method is compared to results obtained from the sin²ψ method and the slitting method. The results show that the 2D method can evaluate residual stress in areas with a diameter of 0.2 mm or less in a stainless steel with average grain size of 7 μm. The 2D method was further applied to assess residual stress in the stainless steel after treatment by laser cavitation peening (LCP). The diameter of the laser spot used for LCP was about 0.5 mm, and the stainless steel was treated with evenly spaced laser spots at 4 pulses/mm². The 2D method revealed fluctuations of LCP-induced residual stress at sub-mm scale that are consistent with fluctuations in the height of the peened surface.     

Numerical and Experimental Studies for Fatigue Damage Accumulation of CFRP Cross-Ply Laminates Based on Entropy Failure Criterion

The transverse cracking behavior of a carbon-fiber-reinforced plastic (CFRP) cross-ply laminate is investigated using a fatigue test and an entropy-based failure criterion in this study. The results of fatigue experiments show that the crack accumulation behavior depends on the cyclic number level and frequency, in which two obvious transverse cracks are observed after 10⁴ cyclic loads and 37 transverse cracks occur after 10⁵ cycles. The final numbers of transverse cracks decrease from 29 to 11 when the load frequency increases from 5 Hz to 10 Hz. An entropy-based failure criterion is proposed to predict the long-term lifetime of laminates under cyclic loadings. The transverse strength of 90° ply is approximated by the Weibull distribution for a realistic simulation. Progressive damage and transverse cracking behavior in CFRP ply can be reproduced due to entropy generation and strength degradation. The effects of stress level and load frequency on the transverse cracking behavior are investigated. It is discovered that, at the edge, the stress σ₂₂ + σ₃₃ that is a dominant factor for matrix tensile failure mode is greater than the interior at the first cycle load, and as stress levels rise, a transverse initial crack forms sooner. However, the initial transverse crack initiation is delayed as load frequencies increase. In addition, transverse crack density increases quickly after initial crack formation and then increases slowly with the number of load cycles. The proposed method’s results agree well with those of the existing experimental method qualitatively. In addition, the proposed entropy-based failure criterion can account for the effect of load frequency on transverse crack growth rate, which cannot be addressed by the well-known Paris law.     

Effects of High Temperatures on the Performance of Carbon Fiber Reinforced Polymer (CFRP) Composite Cables Protected with Fire-Retardant Materials

In this study, the safe critical temperature that can be tolerated by CFRP tendons under normal working conditions was derived through tensile tests at room and high temperatures. Next, the times required to reach a safe critical temperature for CFRP cables protected with different types of fire-retardant materials of various thicknesses were determined through fire resistance tests, Finally, fitting the surface of the finite element simulation results allowed the establishment of the temperature rise calculation model of CFRP tendons under the protection of fire-retardant materials. The results showed that 300 °C can be regarded as the safe critical temperature. Both high-silica needled felt and ceramic fiber felt exhibited high fireproof performance. With an increase in the thickness of the fire-retardant material, the time for the CFRP tendon to reach the inflection point of the heating rate increased, and the safe fire resistance time increased exponentially. According to the HC temperature rise curve, the fire resistance time of CFRP tendons protected by 24 mm thick high-silica needled felt was 45 min, and that for CFRP tendons protected by 24 mm thick ceramic fiber felt was 39.5 min. Under the action of fire corresponding to the hydrocarbon temperature rise model, the safe fire resistance time of CFRP tendons protected by 45 mm high-silica needled felt or 50 mm ceramic fiber felt was more than 2 h, sufficient to meet the specification. The proposed model of fire resistance performance enables the determination of the thickness of the fire resistance material required to obtain different degrees of fire resistance for CFRP cables for structural use.     

Tension-Tension Fatigue Behavior of Unidirectional C/Sic Ceramic-Matrix Composite at Room Temperature and 800 °C in Air Atmosphere

The tension-tension fatigue behavior of unidirectional C/SiC ceramic-matrix composite at room temperature and 800 °C under air has been investigated. The fatigue hysteresis modulus and fatigue hysteresis loss energy corresponding to different number of applied cycles have been analyzed. The fatigue hysteresis loops models for different interface slip cases have been derived based on the fatigue damage mechanism of fiber slipping relative to matrix in the interface debonded region upon unloading and subsequent reloading. The fiber/matrix interface shear stress has been estimated for different numbers of applied cycles. By combining the interface shear stress degradation model and fibers strength degradation model with fibers failure model, the tension-tension fatigue life S-N curves of unidirectional C/SiC composite at room temperature and 800 °C under air have been predicted.     

Residual Compressive Behavior of Self-Compacting Concrete after High Temperature Exposure—Influence of Binder Materials

This paper presents an experimental investigation of the compressive behavior of high-strength self-compacting concrete exposed to temperatures up to 600 °C. Ten different concrete compositions were tested, in which part of the cement (by weight) was replaced by three different mineral additives (5–15% metakaolin, 20–40% fly ash and 5–15% limestone). The stress–strain curves, compressive strength, modulus of elasticity and strain at peak stress were evaluated from uniaxial compression tests. Scanning electron microscope micrographs were also taken to evaluate the damage caused by the high temperatures. A sharp decrease in mechanical properties and an increase in peak strain were observed already after 200 °C for all mixes tested. The different mineral additives used in this study affected the variations of residual compressive strength by 24% and peak strain by 38%, while the variations of residual modulus elasticity were 14%. Comparing the obtained results with the recommendations for compressive strength given in regulatory code EN 1992-1-2 for high strength concrete, it can be concluded that the strength loss observed in EN 1992-1-2 at temperatures up to 400 °C is too conservative. The Popovics model for the relationship between stress and strain provided a good approximation for the experimentally determined stress–strain curves at different temperatures.