PHYBAL—A new method for lifetime prediction based on strain, temperature and electrical measurements

Starke, Peter; Eifler, Dietmar

doi:10.1016/j.ijfatigue.2005.07.050

Cited by 68 publications

(77 citation statements)

References 11 publications

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“…It can be done in exactly the same manner by using the plastic strain amplitude or the change in temperature, cf. [11][12] . In Figure 8(a) the cyclic stress-resistance (s a -DR) curve for the load levels of the load increase test (Figure 7 As can be seen in Figure 8(b), the experimentally determined lifetimes N f, exp.…”

Section: Resultsmentioning

confidence: 99%

“…[14,16] Furthermore, the ''PHYBAL'' approach was successfully applied on fatigue tests with random and service load spectra. [12,13] Conclusions Plastic strain amplitude, change in temperature and change in electrical resistance measurements are suitable techniques to characterise the fatigue behaviour of metallic materials. Load increase tests allow to estimate the endurance limit of different metals or heat treatment conditions with one single specimen.…”

Section: Resultsmentioning

confidence: 99%

“…For electrical resistance measurements a DC-power supply was fixed at both shafts and DR was measured with two wires spot welded at the transition of the gauge length and the shafts (Figure 3), cf. [11][12][13][14] .…”

Section: Methodsmentioning

confidence: 99%

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“PHYBAL” a Short‐Time Procedure for a Reliable Fatigue Life Calculation

Starke

Eifler

2010

Adv Eng Mater

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The reliable calculation of the fatigue life of high‐strength steels and components requires the systematic investigation of the cyclic deformation behaviour and the comprehensive evaluation of proceeding fatigue damage. Besides mechanical stress‐strain hysteresis measurements, temperature and electrical resistance measurements were used for the detailed characterisation of the fatigue behaviour of the steel SAE 4140 in one quenched and tempered, one normalised, one bainitic and one martensitic condition. To guarantee optimal operation conditions the new fatigue life calculation method “PHYBAL” on the basis of generalised Morrow and Basquin equations was developed. It is a short‐time procedure which requires the data of only three fatigue tests for a rapid and nevertheless precise determination of S‐N (Woehler) curves. Consequently, “PHYBAL” provides the opportunity to reduce significantly experimental time and costs compared to conventional test methods.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

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“PHYBAL” a Short‐Time Procedure for a Reliable Fatigue Life Calculation

Starke

Eifler

2010

Adv Eng Mater

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“…That said, the spatial resolution of the infrared camera limits the detection of micro crack formation. These two methods, infrared thermography and electrical resistance measurement, could also be combined to determine a new lifetime calculation [31]. Another mechanical method, which can be implemented as a non-contact in-situ measurement of non-linear behavior was introduced by Kumar et al and Funk et al [32,33].…”

Section: Comparison Of Crack Initiation Detection Methodsmentioning

confidence: 99%

Small-Scale Multiaxial Setup for Damage Detection Into the Very High Cycle Fatigue Regime

et al. 2015

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Micro electro mechanical systems, coatings, and thin films contain materials that are often subjected to complex loading conditions and high frequencies. Therefore, the implementation of a resonant multiaxial fatigue setup for small-scale samples is of high interest. Finite Element simulations have been used to design small-scale samples which possess very close bending and torsional resonant frequencies.The bending and torsional modes are excited by two piezo actuators working either in or out of phase with one another. The bending and torsional amplitudes are measured independently by a laser and the actuator amplitudes are controlled by a Field Programmable Gate Array. The fatigue setup can be used with a varying range of sample sizes from centimeters down to tens of micrometers. The novel multiaxial resonant micro fatigue setup as well as results (fatigue damage for Ni and lifetime for Cu) from bending small-scale fatigue tests are shown and discussed.

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“…Temperature and electrical resistance measurements are suitable for online monitoring of components in service. Related to a reference value of the virgin material state, the electrical resistance enables the detection of proceeding fatigue damage also during load-free inspections [14,15] .…”

Section: Methodsmentioning

confidence: 99%

Influences of the Process Chain on the Fatigue Behavior of Samples with Tension Screw Geometry

Klein

Eifler

2010

Adv Eng Mater

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To analyze the influence of the material batch, the structure of the manufacturing process chain, and the process parameters, four different material batches of the quenched and tempered steel SAE 4140 were used to manufacture samples with tension screw geometry. Five different, manufacturing process chains, consisting of the process steps heat treatment, turning, and grinding, were applied. After selected process steps, light and SEM micrographs as well as fatigue experiments were performed. The process itself as well as the process parameters influences the properties of the surface layers and the fatigue behavior in a characteristic manner. For example the variation of the feed rate and cutting speed in the hard‐turning process leads to significantly different mechanical properties of the surface layers and residual stress states, which could be correlated with the fatigue behavior. The cyclic deformation behavior of the investigated components can be benchmarked equivalently with stress–strain hysteresis as well as high precision temperature and electrical resistance measurements. The temperature and electrical resistance measurements are suitable for component applications and provide an enormous advantage of information about the fatigue behavior. The temperature changes of the failed areas of the samples with tension screw geometry were significantly higher, a reliable identification of endangered areas is thereby possible. A new test procedure, developed at the Institute of Materials Science and Engineering of the University of Kaiserslautern, with inserted load‐free‐states during constant amplitude loading, provides the opportunity to detect proceeding fatigue damage in components during inspections.

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PHYBAL—A new method for lifetime prediction based on strain, temperature and electrical measurements

Cited by 68 publications

References 11 publications

“PHYBAL” a Short‐Time Procedure for a Reliable Fatigue Life Calculation

“PHYBAL” a Short‐Time Procedure for a Reliable Fatigue Life Calculation

Small-Scale Multiaxial Setup for Damage Detection Into the Very High Cycle Fatigue Regime

Influences of the Process Chain on the Fatigue Behavior of Samples with Tension Screw Geometry

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