Short-Time Fatigue Life Estimation for Heat Treated Low Carbon Steels by Applying Electrical Resistance and Magnetic Barkhausen Noise
<p>Micrographs of the investigated steels in different heat-treated conditions. SAE 1020: (<b>a</b>) +N; (<b>c</b>) +QT650; (<b>e</b>) +QT250. SAE 5120: (<b>b</b>) +N; (<b>d</b>) +QT650; (<b>f</b>) +QT250.</p> "> Figure 2
<p>Dimensions of the applied (<b>a</b>) tensile specimen; (<b>b</b>) fatigue specimen.</p> "> Figure 3
<p>Applied tensile testing system with measuring techniques and related devices: 1. PC for DAQ (data acquisition) of the IR camera and ER; 2. PC for the MBN measurement; 3. PC for tensile test machine control; 4. DC power supply for ER; 5. IR camera; 6. Tactile extensometer; 7. MBN sensor mounted on a sliding rail; 8. Electrodes and sensing wires of the four-point DC resistance measurement with DAQ device.</p> "> Figure 4
<p>Applied fatigue testing system with measuring techniques and related devices: 1. IR camera; 2. MBN sensor; 3. Electrodes and sensing wires of the four-point DC resistance measurement device; 4. Cooled clamps; 5. DAQ device for electrical resistance measurement; 6. Pre-amplifier for MBN sensor.</p> "> Figure 5
<p>Schematic procedures of MaRePLife for measuring techniques with continuous data acquisition (e.g., thermometry or electrical resistometry). (<b>a</b>) Tensile test for <span class="html-italic">R<sub>m</sub></span> and <span class="html-italic">R<sub>p0.2</sub></span> determination. (<b>b</b>) First LIT (plastic portion: white round dots, solid line) and second LIT (plastic portion: yellow triangles) for the determination of the stress amplitude of both upcoming CATs (selected in the red and blue areas). The elastic response <span class="html-italic">M<sub>e</sub></span> of the first LIT (white round dots, dotted line) for the determination of the elastic modulus (blue straight line). (<b>c</b>) Both CATs and their plastic response <span class="html-italic">M<sub>p</sub></span>. (<b>d</b>) Elastic (round dots with dotted line) and plastic (round dots with solid line) portion calculated following Basquin and Coffin–Manson laws to find the partitioning point (round dot, black solid line). (<b>e</b>) Allometric regression of the plastic responses for obtaining <span class="html-italic">K’<sub>CAT</sub></span> and <span class="html-italic">n’<sub>CAT</sub></span>. (<b>f</b>) Calculated S–N curve with both CATs used and more CATs for verification.</p> "> Figure 6
<p>Schematic procedures of MaRePLife for measuring techniques with discrete data acquisition (e.g., magnetic Barkhausen noise). (<b>a</b>) Tensile test for <span class="html-italic">R<sub>m</sub></span> and <span class="html-italic">R<sub>p0.2</sub></span> determination. The slope (blue straight line) of the material response (round dots with dotted line) in the elastic region is used for the determination of the elastic modulus. (<b>b</b>) First LIT (plastic portion: white round dots, solid line) and second LIT (plastic portion: yellow triangles) for the determination of the stress amplitude of both upcoming CATs (selected in the red and blue areas); (<b>c</b>) Both CATs and their plastic response <span class="html-italic">M<sub>p</sub></span>. (<b>d</b>) Elastic (round dots with dotted line) and plastic (round dots with solid line) portion calculated following Basquin and Coffin–Manson laws to find the partitioning point (round dot, black solid line). (<b>e</b>) Allometric regression of the plastic responses for obtaining <span class="html-italic">K’<sub>CAT</sub></span> and <span class="html-italic">n’<sub>CAT</sub></span>. (<b>f</b>) Calculated S–N curve with both CATs used and more CATs for verification.</p> "> Figure 7
<p>Flowchart of obtaining the S–N curve according to the principles described in <a href="#materials-16-00032-f005" class="html-fig">Figure 5</a> and <a href="#materials-16-00032-f006" class="html-fig">Figure 6</a>.</p> "> Figure 8
<p>Results of tensile test on SAE 1020 steel in normalized conditions. The change in temperature, the engineering strain, the nominal stress and the change in MBN signal rate are shown as material responses.</p> "> Figure 9
<p>MBN signal responses in terms of Δ<span class="html-italic">φ<sub>MBN</sub></span> caused by elastic deformation during tensile tests on (<b>a</b>) SAE 1020 and (<b>b</b>) SAE 5120 in the differently heat-treated (+N: normalized, +QT650: quenched and tempered at 650 °C and +QT250: quenched and tempered at 250 °C) conditions. The slopes are interpreted as the elastic modulus for the MBN signal <span class="html-italic">E<sub>MBN</sub></span>, which has MPa as its unit.</p> "> Figure 10
<p>Development of the measured and calculated quantities plotted against the number of load cycles during (<b>a</b>) the first LIT and (<b>b</b>) the second LIT on SAE 1020 in normalized conditions. Mean values from each load step are shown as dots with different shapes.</p> "> Figure 11
<p>Mean plastic material response from each load step of (<b>a</b>) Δ<span class="html-italic">φ<sub>MBN</sub></span> and (<b>b</b>) Δ<span class="html-italic">φ<sub>R</sub></span> during both LITs, and their relation to the applied stress amplitudes for normalized SAE 1020.</p> "> Figure 12
<p>Cyclic material response in terms of (a) the change in temperature Δ<span class="html-italic">T</span> and (b) the change in electrical resistance Δ<span class="html-italic">R</span>. The amplitude in the elastic region is used to calculate the elastic portion. The mean value of each load cycle is calculated as the plastic portion.</p> "> Figure 13
<p>Calculation of the elastic modulus with the example of normalized SAE 1020 for (<b>a</b>) the change in temperature, Δ<span class="html-italic">T</span> and (<b>b</b>) the change in the electrical resistance ratio, Δ<span class="html-italic">φ<sub>R</sub></span>, by performing linear regression on <span class="html-italic">σ<sub>a</sub>–M<sub>e</sub></span> data points in the elastic zone.</p> "> Figure 14
<p>Development of single data points with trend curves during CATs on SAE 1020 of (<b>a</b>) Δ<span class="html-italic">φ<sub>MBN</sub></span> and (<b>b</b>) Δ<span class="html-italic">φ<sub>R</sub></span>, as well as on SAE 5120 of (<b>c</b>) Δ<span class="html-italic">φ<sub>MBN</sub></span> and (<b>d</b>) Δ<span class="html-italic">φ<sub>R</sub></span>. Both plastic values calculated from CATs (big square points) are later used for the fatigue life calculation.</p> "> Figure 14 Cont.
<p>Development of single data points with trend curves during CATs on SAE 1020 of (<b>a</b>) Δ<span class="html-italic">φ<sub>MBN</sub></span> and (<b>b</b>) Δ<span class="html-italic">φ<sub>R</sub></span>, as well as on SAE 5120 of (<b>c</b>) Δ<span class="html-italic">φ<sub>MBN</sub></span> and (<b>d</b>) Δ<span class="html-italic">φ<sub>R</sub></span>. Both plastic values calculated from CATs (big square points) are later used for the fatigue life calculation.</p> "> Figure 15
<p>Stress amplitude of CATs as a function of plastic material response for the case of: (<b>a</b>) SAE 1020 +N; (<b>b</b>) SAE 5120 +QT650; (<b>c</b>) SAE 1020 +QT650; (<b>d</b>) SAE 5120 +N. The square data points represent the plastic portion from single CATs. The dash-dotted curves represent the calculated <span class="html-italic">σ<sub>a</sub>–M<sub>p</sub></span> relation.</p> "> Figure 15 Cont.
<p>Stress amplitude of CATs as a function of plastic material response for the case of: (<b>a</b>) SAE 1020 +N; (<b>b</b>) SAE 5120 +QT650; (<b>c</b>) SAE 1020 +QT650; (<b>d</b>) SAE 5120 +N. The square data points represent the plastic portion from single CATs. The dash-dotted curves represent the calculated <span class="html-italic">σ<sub>a</sub>–M<sub>p</sub></span> relation.</p> "> Figure 16
<p>Calculated S–N curves using MaRePLife for (<b>a</b>) SAE 1020 normalized; (<b>b</b>) SAE 5120 normalized; (<b>c</b>) SAE 1020 quenched and tempered at 650 °C; (<b>d</b>) SAE 5120 quenched and tempered at 650 °C. The magenta dash-dot-dot-dash line is the S–N curve calculated by applying a change in the electrical resistance ratio, Δ<span class="html-italic">φ<sub>R</sub></span>. The brown dash-dot-dash line represents the S–N curve calculated by applying a change in the MBN signal ratio, Δ<span class="html-italic">φ<sub>MBN</sub></span>.</p> ">
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material and Machining of Specimens
2.2. Test Setup
2.3. MaRePLife: Principles
3. Results
3.1. Tensile Tests
3.2. Load Increase Tests
3.3. Constant Amplitude Tests
3.4. MaRePLife
4. Discussion
5. Conclusions
- It is essential to perform tensile and load increase tests (LIT) in order to determine the parameters of constant amplitude tests (CAT), which is the key to conduct short-time fatigue calculations. A method depending on Rm, Rp0.2 and the values from the first LIT (σY,f1 and σY,m1) has been proposed, which is suitable for the common materials to be investigated.
- The elastic modulus of material responses is defined by calculating the slopes of σa–Me data points in the elastic region from a single LIT or a tensile test. The latter is ideal for measurands acquired with discrete measuring methods, such as MBN.
- By applying the idea of material response partitioning for MBN and ER, we could maximize the information we acquired from single fatigue tests and use this as input to calculate the S–N curve in the HCF regime, so that the total cost of time can be reduced.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Symbol or Abbreviation | Meaning | Symbol or Abbreviation | Meaning |
---|---|---|---|
CAT | Constant amplitude test | E | E-modulus |
DAQ | Data acquisition | Imax | Maximum MBN signal intensity |
ER | Electrical resistometry | Imax,0 | Initial maximum MBN signal intensity |
HCF | High cycle fatigue | K’ | Cyclic strength coefficient |
IR | Infrared | L0 | Measuring length at tensile specimen |
LCF | Low cycle fatigue | Me(Me,1/Me,2) | Elastic material response (of first/second CAT) |
LIT | Load increase test | Mp(Mp,1/Mp,2) | Plastic material response (of first/second CAT) |
MaRePLife | Material response partitioning fatigue life evaluation | Mpop | Material response at point of partitioning |
MBN | Magnetic Barkhausen noise | Nf | Fatigue life/number of cycles to failure |
NDT | Non-destructive testing | Npop | Number of load cycle at point of partitioning |
+N | Normalized state | n’ | Cyclic strain hardening exponent |
+QT | Quenched and tempered state | R0 | Initial electrical resistance |
αf | Ratio between the stress increases of both LITs | Rm | Tensile strength |
b | Fatigue strength exponent | Rp0.2 | Yield strength |
c | Fatigue ductility exponent | σ’f | Cyclic strength |
Δεt/Δεe/Δεp | Change in total/elastic/plastic strain | Taust. | Austenitization temperature |
ΔφMBN | Change in MBN signal ratio | Ttemp. | Tempering temperature |
ΔφR | Change in ER ratio | vc | Crosshead speed |
Δσa1 | Stress increase of the first LIT | σa/σa,t | (Total) stress amplitude |
Δσa2 | Stress increase of the second LIT | σa,start1 | Initial stress amplitude of the first LIT |
ΔT | Change in temperature | σa,start2 | Initial stress amplitude of the second LIT |
ε a,t/ε a,e/εa,p | Total/elastic/plastic strain amplitude | σm,f1 | Stress amplitude at which the specimen breaks during LIT |
ε’f | Cyclic ductility | σY,f1 | Stress amplitude at which the first obvious increment of material response is observed during LIT |
EM/EMBN/ER | E-modulus regarding material response/MBN/R |
Material | Fe | C | Si | Mn | P | S | Cr | Mo | Ni | |
---|---|---|---|---|---|---|---|---|---|---|
1.1149 SAE 1020 | DIN EN 10083-2 | - | 0.17–0.24 | ≤0.4 | 0.40–0.70 | ≤0.030 | 0.020–0.040 | ≤0.40 | ≤0.10 | ≤0.40 |
Producer | - | 0.21 | 0.24 | 0.46 | 0.013 | 0.023 | 0.12 | 0.013 | 0.12 | |
* +N | bal. | 0.234 | 0.286 | 0.481 | 0.014 | 0.018 | 0.118 | 0.014 | 0.112 | |
* +QT650 | bal. | 0.237 | 0.288 | 0.478 | 0.014 | 0.019 | 0.118 | 0.014 | 0.114 | |
* +QT250 | bal. | 0.236 | 0.286 | 0.479 | 0.014 | 0.019 | 0.119 | 0.016 | 0.115 | |
1.7149 SAE 5120 | DIN EN 10084 | - | 0.17–0.22 | ≤0.4 | 1.10–1.40 | ≤0.025 | 0.020–0.040 | 1.00–1.30 | - | - |
Producer | - | 0.18 | 0.24 | 1.23 | 0.015 | 0.026 | 1.05 | 0.022 | 0.10 | |
* +N | bal. | 0.196 | 0.274 | 1.324 | 0.017 | 0.023 | 1.065 | 0.025 | 0.093 | |
* +QT650 | bal. | 0.194 | 0.274 | 1.309 | 0.016 | 0.024 | 1.056 | 0.022 | 0.093 | |
* +QT250 | bal. | 0.195 | 0.271 | 1.310 | 0.016 | 0.024 | 1.060 | 0.024 | 0.094 |
Material Number after EN/SAE | Heat Treatment | Rm [MPa] | [MPa] | [MPa] | [MPa] | [-] | [MPa] | [MPa] |
---|---|---|---|---|---|---|---|---|
1.1149SAE 1020 | +N | 460 | 290 | 260 | 220 | 0.2 | 180 | 4 |
+QT650 | 580 | 440 | 340 | 300 | 0.3 | 260 | 6 | |
+QT250 | 470 | 595 | 360 | 300 | 0.5 | 240 | 10 | |
1.7149SAE 5120 | +N | 540 | 340 | 300 | 240 | 0.3 | 180 | 6 |
+QT650 | 700 | 600 | 460 | 440 | 0.2 | 420 | 4 | |
+QT250 | 1200 | 905 | 760 | 580 | 0.6 | 400 | 12 |
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Wu, H.; Ziman, J.A.; Raghuraman, S.R.; Nebel, J.-E.; Weber, F.; Starke, P. Short-Time Fatigue Life Estimation for Heat Treated Low Carbon Steels by Applying Electrical Resistance and Magnetic Barkhausen Noise. Materials 2023, 16, 32. https://doi.org/10.3390/ma16010032
Wu H, Ziman JA, Raghuraman SR, Nebel J-E, Weber F, Starke P. Short-Time Fatigue Life Estimation for Heat Treated Low Carbon Steels by Applying Electrical Resistance and Magnetic Barkhausen Noise. Materials. 2023; 16(1):32. https://doi.org/10.3390/ma16010032
Chicago/Turabian StyleWu, Haoran, Jonas Anton Ziman, Srinivasa Raghavan Raghuraman, Jan-Erik Nebel, Fabian Weber, and Peter Starke. 2023. "Short-Time Fatigue Life Estimation for Heat Treated Low Carbon Steels by Applying Electrical Resistance and Magnetic Barkhausen Noise" Materials 16, no. 1: 32. https://doi.org/10.3390/ma16010032