Fatigue life analysis in the residual stress field due to resistance spot welding process considering different sheet thicknesses and dissimilar electrode geometries

Kashyzadeh, Kazem Reza; Farrahi, G.H.; Ahmadi, Alireza; Minaei, Mohammad; Rahimi, Mojtaba Ostad; Barforoushan, Sohrab

doi:10.1177/14644207221101069

Cited by 6 publications

(3 citation statements)

References 32 publications

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“…A crack's "lifecycle", which culminates in fatigue failure of a cyclically loaded component, is divided into five stages: crack initiation, microstructurally short crack propagation, mechanically/physically short crack propagation, protracted crack propagation, and final structure fracture [122]. Since most industrial parts are under the effect of dynamic and repeating loads, the occurrence of fatigue phenomenon in the industry is inevitable [123][124][125][126][127][128]. In this regard, large industries such as petrochemical and power plants are not excluded.…”

Section: Fatigue Failurementioning

confidence: 99%

Common Failures in Hydraulic Kaplan Turbine Blades and Practical Solutions

2023

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Kaplan turbines, as one of the well-known hydraulic turbines, are generally utilized worldwide for low-head and high-flow conditions. Any failure in each of the turbine components can result in long-term downtime and high repair costs. In a particular case, if other parts are damaged due to the impact of the broken blades (e.g., the main shaft of the turbine), the whole power plant may be shut down. On the other hand, further research on the primary causes of failures in turbines can help improve the present failure evaluation methodologies in power plants. Hence, the main objective of this paper is to present the major causes of Kaplan turbine failures to prevent excessive damage to the equipment and provide practical solutions for them. In general, turbines are mainly subjected to both Internal Object Damage (IOD) and Foreign Object Damage (FOD). Accordingly, this paper presents a state-of-the-art review of Kaplan turbine failures related to material and physical defects, deficiencies in design, deficits in manufacturing and assembly processes, corrosion failures, fatigue failure, cavitation wear, types of cavitation in hydro turbines, hydro-abrasive problems, and hydro-erosion problems. Eventually, the authors have attempted to discuss practical hints (e.g., nanostructured coatings) to prevent damages and improve the performance of Kaplan turbines.

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Section: Fatigue Failurementioning

confidence: 99%

Common Failures in Hydraulic Kaplan Turbine Blades and Practical Solutions

2023

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“…In addition, at high temperature the stress properties decrease. Tensile residual stresses make the material weaker and shortens the life cycle of fatigue leading to corrosion cracking, distortion, stress fatigue cracking, and premature component failures [15][16]. Gajalappa et al [5] applied thermo-mechanical deformation technique to analyze the flow behaviour of Inconel 600 in the temperature range of 950 ºC to 1100 ºC and strain rate range of 10 -3 to 1 s -1 .…”

Section: Introductionmentioning

confidence: 99%

Experimental research on mechanical, material, and metallurgical properties of Inconel 600: Application in elevated temperature environment

Moradi,

Ghorbani,

Chizari

2024

JDAF

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Du to high strength and toughness, high oxidation resistance, and high ductility, the Inconel 600 alloy is an ideal choice for the components used in combined heat and power turbines. Therefore, in this paper, the authors conducted experimental tests to better underestand the mechanical behavior of superalloys Inconel 600. The experiments included tensile, fatigue, and creep tests. The material deformation and stress-strain behavior were measured. In addition the yield strength, ultimate tensile strength, elongation, and modulus of elasticity were captured. By illustrating the engineering and true stress-strain curves the Ramberg-Osgood relation were extracted. As a result of fatigue test, the relationship between strain amplitude and the number of cycles to failure for specimens were obtained. The creep tests were conducted at a constant temperature of 650℃. The strain-time data were collected, and the resulting creep strain-time curve were plotted for smooth samples under their respective stress conditions. REFERENCES G. Becerra, M.R.B. Alvarez, V.H.L Morelos, A. Ruiz. Creep behavior and microstructural characterization of Inconel-625/Inconel-600 welded joint. MRS Adv. 8, (2023) 1217–1223, https://doi.org/10.1557/s43580-023-00662-7. Baig, S.H.I. Jaffery, M.A. Khan, M. Alruqi, Statistical analysis of surface roughness, burr formation and tool wear in high speed micro milling of Inconel 600 alloy under cryogenic, wet and dry conditions. Micromachines 14(1) 2023, 13. https://doi.org/10.3390/mi14010013. Nanaware, S. Pawar, M. Ramachandran. Mechanical characterization of nickel alloys on turbine blades. REST J.E.M.M., 1(1) (2015), 15–19. D. Kwon, D.K. Park, S.W. Woo, D.H. Yoon, I. Chung. A study on fretting fatigue life for the Inconel alloy 600 at high temperature. Nucl. Eng. Des. 240 (2010) 2521–2527. https://doi.org/10.1016/j.nucengdes.2010.05.013. Gajalappa, A. Krishnaiah, K.B. Kumar, Eswaranna, K.K. Saxena, P. Goyal. Flow behaviour kinetics of Inconel 600 superalloy under hot deformation using gleeble 3800. Mater. Today: Proc. 45 (2021) 5320–5322. https://doi.org/10.1016/j.matpr.2021.01.909. Y. Wu, P.H. Sun, F.J. Zhu, S.C. Wang, W.R. Wang, C.C. Wang, C.H. Chiu. Tensile flow behavior in Inconel 600 alloy sheet at elevated temperatures. Procedia Eng. 36 (2012) 114–120. https://doi.org/10.1016/j.proeng.2012.03.018. Xu, S. Wang, X. Tang, Y. Li, J. Yang, J. Li, Y. Zhang. Corrosion mechanism of Inconel 600 in oxidizing supercritical aqueous systems containing multiple salts. Eng. Chem. Res. 58(51) (2019) 23046–23056. https://doi.org/10.1021/acs.iecr.9b04527. S. Al-Rubaie, L.B. Godefroid, J.A.M. Lopes. Statistical modeling of fatigue crack growth rate in Inconel alloy 600. Int. J. Fatigue 29 (2007) 931–940. https://doi.org/10.1016/j.ijfatigue.2006.07.013. Y. Wu, F.J. Zhu, S.C. Wang, W.R. Wang, C.C. Wang, C.H. Chiu. Hot deformation characteristics and strain-dependent constitutive analysis of Inconel 600 superalloy. J. Mater. Sci. 47 (2012) 3971–3981. https://doi.org/10.1007/s10853-012-6250-4. A. Khafri, N. Golarzi. Forming behavior and workability of Hastelloy X superalloy during hot deformation. Mater. Sci. Eng. A 486 (2008) 641–647. https://dx.doi.org/10.1016/j.msea.2007.11.059. T.W.K. Fahmi, K.R. Kashyzadeh, S. Ghorbani. A comprehensive review on mechanical failures cause vibration in the gas turbine of combined cycle power plants. Engineering Failure Analysis 134 (2022) 106094.‏ https://doi.org/10.1016/j.engfailanal.2022.106094. J. Li, K.L. Lin. Strengthening of Inconel 600 alloy with electric current stressing. MTLA 27 (2023) 101666. https://doi.org/10.1016/j.mtla.2022.101666. T. Kim, Y.S. Kim. The effect of the static load in the UNSM process on the corrosion properties of alloy 600. Materials 12 (2019) 3165. https://doi.org/10.3390/ma12193165. Kuzmanov, B. Borisov, I. Muhtarov. Tensile testing of Inconel 600 wire at high temperatures. IOP Conf. Ser.: Mater. Sci. Eng. 878 (2020) 012057.https://doi.org/10.1088/1757-899X/878/1/012057. V.C.S. Rao, A. Manoj, B.R. Swathi. Residual stress measurement of Inconel 600 on different welding techniques by using conventional and XRD methods. Mater. Today: Proc. 41 (2021) 1160–1163. https://doi.org/10.1016/j.matpr.2020.09.403. Reza Kashyzadeh, G.H. Farrahi, A. Ahmadi, M. Minaei, M. Ostad Rahimi, S. Barforoushan. Fatigue life analysis in the residual stress field due to resistance spot welding process considering different sheet thicknesses and dissimilar electrode geometries. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 237(1) (2023) 33-51. ‏ https://doi.org/10.1177/14644207221101069. A. Monteiro, S.L.V. Silva, L.V. Silva, A.H.P. Andrade, L.C.E. Silva. Characterization of nickel alloy 600 with ultra-fine structure processed by severe plastic deformation technique (SPD). J. Mater. Sci. Chem. Eng. 5 (2017) 33–44. https://doi.org/10.4236/msce.2017.54004. Yi, G.S. Was. Stress and temperature dependence of creep in alloy 600 in primary water. Metall. Mater. Trans. A 32, (2001) 2553–2560. https://doi.org/10.1007/s11661-001-0045-6ю Karthik, S. Swaroop. Laser shock peening enhanced corrosion properties in a nickel based nconel 600 superalloy. J. Alloys Compd. 694 (2017) 1309–1319. https://doi.org/10.1016/j.jallcom.2016.10.093. Makuch, M. Kulka. Microstructural characterization and some mechanical properties of gas-borided Inconel 600-alloy. Appl. Surf. Sci., 314 (2014) 1007–1018. https://doi.org/10.1016/j.apsusc.2014.06.109. ASTM E8-04: Standard Test Methods for Tension Testing of Metallic Materials, ASTM, https://doi.org/10.1520/E0008-04. ASTM E466-21: Standard Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials, ASTM, https://doi.org/10.1520/E0466-21. P. Skelton. H.J. Maier, H.J. Christ. The Bauschinger effect, Masing model and the Ramberg– Osgood relation for cyclic deformation in metals. Mater. Sci. Eng. A, 238 (1997) 377–390. https://doi.org/10.1016/S0921-5093(97)00465-6. Niesłony, C. Dsoki, H. Kaufmann, P. Krug. New method for evaluation of the Manson–Coffin–Basquin and Ramberg– Osgood equations with respect to compatibility. Int. J. Fatigue 30 (2008) 1967–1977. https://doi.org/10.1016/j.ijfatigue.2008.01.012. Weixing, X. Kaiquan, G. Yi. On the fatigue notch factor, Kf. Int. J. Fatigue 17(4) (1995) 245–251. https://doi.org/10.1016/0142-1123(95)93538-D. E. Dowling. Mechanical behavior of materials, engineering methods for deformation, fracture, and fatigue. fourth ed., Pearson, 2013. Zhang. C. Zhang, S. Mu, S. Wang, H. Li. Characterization of mechanical properties of in-service nickel-based alloy by continuous indentation. Structures 48 (2023) 1346–1355. https://doi.org/10.1016/j.istruc.2023.01.053.

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“…To improve the fatigue life of metallic materials, scientists proved that the two factors of compressive residual stress on the surface and an ultrafine grain in the surface are very effective. This conclusion is due to the fact that the initial damages caused by cyclic loading always appear as surface cracks [17][18][19][20][21]. As a result, fatigue properties can be improved by increasing the surface strength.…”

Section: Introductionmentioning

confidence: 99%

Influence of Conventional Shot Peening Treatment on the Service Life Improvement of Bridge Steel Piles Subjected to Sea Wave Impact

Reza Kashyzadeh,

Chizari

2023

JMSE

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The first goal of the current study is to estimate the fatigue life of the middle steel piles of an integrated bridge installed in water and subject to the impact of sea waves. In the following, the authors have tried to improve the service life of this critical part of the bridge, which is also the main purpose of the study. To this end, conventional shot peening, as one of the most well-known surface treatments, was used. Axial fatigue tests were performed on samples fabricated from IPE-220 steel piles in two states without and with shot peening surface treatment. Next, the modified S-N curve was entered into the finite element software to define the effect of shot peening treatment. Different analysis, including thermal, thermal-structural coupled, and transient dynamic, were performed and various outputs were extracted for the entire structure. In all these analyses, changes in air temperature have been neglected. The most important achievement of this research is the discovery that motionless water cannot cause serious damage to steel piles. Moreover, application of conventional shot peening can increase the fatigue life of steel piles, or in other words the service life of the bridge, subjected to the impact of sea waves by about 22%.

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Fatigue life analysis in the residual stress field due to resistance spot welding process considering different sheet thicknesses and dissimilar electrode geometries

Cited by 6 publications

References 32 publications

Common Failures in Hydraulic Kaplan Turbine Blades and Practical Solutions

Common Failures in Hydraulic Kaplan Turbine Blades and Practical Solutions

Experimental research on mechanical, material, and metallurgical properties of Inconel 600: Application in elevated temperature environment

Influence of Conventional Shot Peening Treatment on the Service Life Improvement of Bridge Steel Piles Subjected to Sea Wave Impact

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