Overview of High Temperature and Thermo-mechanical Fatigue ... · Overview of High Temperature and...

Huseyin Sehitoglu

Department of Mechanical and Industrial Engineering1

University of Illinois at Urbana-Champaign

Overview of High Temperature and Thermo-mechanical

Fatigue (TMF)

Overview of High Temperature and Thermo-mechanical

Fatigue (TMF)

Huseyin SehitogluMechanical and Industrial Engineering,University of Illinois, Urbana, Il. 61801

Tel : 217 333 4112 Fax: 217 244 6534e-mail: [email protected]

Huseyin Sehitoglu



Talk OutlineTalk Outline

• Examples of High Temperature Problems• Basic Terminology at High Temperatures• Introduction to Constraint : Plasticity and ratchetting,

Out of Phase and In phase TMF• Experimental Techniques at High Temperatures• Fatigue Lives of Selected Materials under IF and TMF• Mechanics- Stress-strain Models• Life Models-Fatigue-Oxidation and Fatigue-Creep

Modeling• Future Directions

Huseyin Sehitoglu



• Railroad Wheels undergoing Friction Braking• Brake Rotors • Pistons, Valves and Cylinder Heads of Spark-

ignition and Diesel Engines• Turbine Blades and Turbine Disks• Pressure Vessel and Piping

Examples of Components Experiencing High

Temperatures

Examples of Components Experiencing High

Temperatures

Huseyin Sehitoglu



Mechanical Strain

-2x10 -3 -3 -3-10 10

.

.

.

..

.

.

..

......

.

..

.. ....

.

2x10 -3-3x10 -3

-100

-200

-300

Stre

ss (M

Pa)

100

200

60 min, 615 C°°

°°

°°°

50 min, 589 C

55 min, 603 C45 min, 572 C

40 min, 552 C 35 min, 527 C

°° °

°°

°

°°°

°°

30 min, 497 C25 min, 459 C

20 min, 438 C 15 min, 362 C

10 min, 295 C

5 min, 210 C

65 min, 462 C

70 min, 401 C75 min, 354 C80 min, 314 C

85 min, 279 C

°°

°

°°

°

90 min, 249 C95 min, 223 C

100 min, 200 C110 min, 162 C

120 min, 133 C

122.5 min, 78 C125 min, 24 C

Railroad Wheels under Friction Braking

Railroad Wheels under Friction Braking

Huseyin Sehitoglu



Schematic of a Railroad Wheel,Strain-Temperature-Stress Changes on the B1 location under brake shoe heating (laboratory simulation based

on strain temperature measurements on wheels)

-400

-200

0

200

400

Stre

ss (

MPa

), T

empe

ratu

re (

°C)

6005004003002001000

Time (minutes)

Laboratory Simulation of Stress at B1 Location in Railroad Wheel

Stress

Temperature

Huseyin Sehitoglu



cold

hot-200

-100

0

100

200

stre

ss (

MP

a)

-0.3 -0.2 -0.1 0.0 0.1 0.2 0.3

mechanical strain (%)

cycle 1 cycle 20 cycle 36

Cast IronOP TMFMinimum Temperature = 150 °CMaximum Temperature = 500 °CCycle Time = 4 mintues∆εm = 0.6%Nf = 37 cycles

Brake Rotor Cracking

Huseyin Sehitoglu



Design-Manufacturing-Life Prediction Methodology for Cylinder Heads and BlocksDesign-Manufacturing-Life Prediction Methodology for Cylinder Heads and Blocks

Huseyin Sehitoglu



Percentage of Vehicles with Aluminum Engine Blocks and Heads(*)

(*) Delphi VIII Study, 1996

20%10%5%Light trucks

50%30%13%Passenger cars

Blocks

60%40%20%Light trucks

95%85%78%Passenger cars

Heads

200520001994

Huseyin Sehitoglu



Cylinder Heads (FEM and Fatigue Life Contours)

Inlet Valve

Exhaust Valve

Spark Plug

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Turbine Blades

TF

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Turbine Blades( Thermo-mechanical fatigue failure)Turbine Blades( Thermo-mechanical fatigue failure)

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Turbine Blades (strain-temperature variation)

Huseyin Sehitoglu



Basic Terminology at High Temperatures

• What is a high temperature problem? Deformation under Constant or Variable Stress at homologous temperatures above 0.35 ( T/Tm >0.35 where Tmis melting temperature).

• Stress Relaxation: Decrease in Stress at Constant Strain

• Creep: Increase in Strain at Constant Stress

Huseyin Sehitoglu



High temperaturefatigue testing or modeling

TMFexternal stresses

TFinternal stresses

HCF∆εin ≈ 0

LCF∆εin > 0

Isothermal fatigue Non-isothermal fatigue

Isothermal vs. Thermo-mechanical fatigue

Huseyin Sehitoglu



Disk Specimen under TF loading (Simovich)

Huseyin Sehitoglu



Limitations in our Understanding of High

Temperature Material Behavior

Limitations in our Understanding of High

Temperature Material Behavior

•Experiments on TMF are missing (difficult, expensive).•Microstructural damage mechanisms are not well understood.

•Stress-strain (constitutive) models havenot been established

•Proposed failure models have severe drawbacks.

Huseyin Sehitoglu



ControlTower

LABWIEV

MACINTOSH IICi

LOAD CELL

Loading History

High TemperatureExtensometer Induction

Coil

TemperatureController

ACTUATOR

GPIB

InductionHeater

RF

C/L

THERMOCOUPLEC/L

Strain, load,position control

Test Frame

Experimental Techniques at High Temperatures

Experimental Techniques at High Temperatures

Huseyin Sehitoglu



Total Constraint Total Constraint

T

Tot BD A

O

C

E

α (T-To)

σο

σο−

Mechanical Strain

Stre

ss

T

ε net = 0

Huseyin Sehitoglu



The compatibility equation

εnet = εth+εmech = α (T-T o ) + εmech

When the net strain is zero and all of the thermal strain is converted to

mechanical strain. Then,

εmech = - α (T-T o )

Total Constraint (ctd.)

Total Constraint (ctd.)

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Two-Bar Model(ctd.)Two-Bar Model(ctd.)

A , l 1 1

A , l 22

P

∆T

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Simple RelationsSimple Relations

• Equilibrium : A1 σ1 + A2 σ2 = P• Compatability : l1 ε1 = l2 ε2

• Strain : ε1 = ε1 e + ε 1 in + ε1 th

ε2 = ε2 e

ε 1 th = α ( T- T0 )

ε 1 in = inelastic (plastic) strain

ε1 e = elastic strain

Huseyin Sehitoglu



The Concepts of Total, Partial, Over and Notch Constraint

The Concepts of Total, Partial, Over and Notch Constraint

ε1=-σ1E2C

, C = A2.l1A1.l2

C→∞ ; Total ConstraintC→ finite ; Partial Constraint

A , l 1 1

A , l 22

P

∆T

Huseyin Sehitoglu



The Stress-strain Response under Total and Partial Constraint

The Stress-strain Response under Total and Partial Constraint

Huseyin Sehitoglu



The Stress-strain Response under Total and Partial Constraint (ctd.)

The Stress-strain Response under Total and Partial Constraint (ctd.)

Huseyin Sehitoglu



Out-of-Phase TMF Response

Mechanical Strain

Tmax

Str

ess

Tmin

In-Phase TMF Response

Mechanical Strain

Str

ess

T

minT

max

Stress-strain Behavior under Out-of-Phase versus In-Phase Stress-strain Behavior under Out-of-Phase versus In-Phase

Huseyin Sehitoglu



Mechanical StrainTmax

Stre

ss

Tmin

∆σ

σmin

σmax

∆εm

AB

C

Some DefinitionsSome Definitions

Inelastic St rain range:

∆εin ≅ ∆εm - σBEB

+ σCEC

Huseyin Sehitoglu



Comparison of TMF IP and TMF OP Tests on 1010 Steel (Jaske’s Data)

Huseyin Sehitoglu



TMF experiments of Coffin

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Thermal Block Histories on Steels under Total Constraint

Huseyin Sehitoglu



• Metallurgical Studies : (a) Damage Mechanisms (Crack nucleation from slip bands,

precipitates, porosities, surface and internal oxidation, grain boundary cavitation)(b) Alloy Development

• Mechanistic Studies : (a) Constitutive Modeling ( phenomenological:non-unified

and unified models for stress-strain prediction)(b) Life Prediction Modeling (Crack nucleation (stress,

strain, time), Crack Growth (Mean stress, crack length)

Classification of IF and TMF StudiesClassification of IF and TMF Studies

Huseyin Sehitoglu



• Engineering Application : (a) Material Selection(b) Early Design(c) Residual Life Assesment

Classification of IF and TMF Studies (ctd.)Classification of IF and TMF Studies (ctd.)

Huseyin Sehitoglu



1015

1010

105

100

10-5

εin/A

0.012 3 4 5 6 7

0.12 3 4 5 6 7

12 3 4 5 6 7

10σ/Κο

Al319- Solutionized Small SDAS

Power Law Creep

Plasticityn2=7.96

n1=3.12

Constitutive Modeling-Experimentally Determined Flow Rule

Constitutive Modeling-Experimentally Determined Flow Rule

Huseyin Sehitoglu



TMF OP 100-300°C 1.0%

100°C

300°C

200°C

-200

-100

0

100

200

Str

ess

(MP

a)

-6x10 -3 -4 -2 0 2 4 6Strain

STRESS1-2fea Stress1-2 STRESS300fea Stress300

Huseyin Sehitoglu



Hysteresis loops for the tests performed at 5x10-3 s-1

-240

-180

-120

-60

0

60

120

180

240

Str

ess

(MP

a)

-6x10-3

-4 -3 -2 -1 0 1 2 3 4 5 6Strain

experimental TNET

20oC

250oC

130oC

300oC

Huseyin Sehitoglu



Drag stress recoveryHyteresis loops at 20°C for the material pre-exposed at 300°C

-300

-200

-100

0

100

200

300

Str

ess

(MP

a)

-0.6 -0.4 -0.2 0.0 0.2 0.4 0.6Strain (%)

0 h

1 h10 h

100 h

Huseyin Sehitoglu



Coarsening of the PrecipitatesCoarsening of the Precipitates

Huseyin Sehitoglu



300

200

100

0

-100

-200

Stre

ss (M

Pa)

-0.4 -0.2 0.0 0.2 0.4Mechanical strain, (%)

TMF OP ∆T=100-300°C, ∆ε=0.6%, 5x10-5s-1

Al 319-T7B Small SDAS

Experiment Simulation

Cycle 1

Cycle 350

TMF OP Stress-Strain PredictionTMF OP Stress-Strain Prediction

Huseyin Sehitoglu



Constitutive Modeling:

Mechanistic Studies

Requirements for a good model:• Incorporate strain rate, temperature and mean

stress effect on stress-strain response• Incorporate temperature-strain induced

changes on material’s stress-strain response

Huseyin Sehitoglu



Constitutive Modeling:• Non-unified Plasticity (stress-strain) Models:

Plastic strains (time-independent) and creep strains are added.

• Unified Creep-Plasticity Models: Plastic strain and creep srain is combined as inelastic strain.

Mechanistic Studies

Huseyin Sehitoglu



Requirements for a good model:• Incorporate stress,strain, thermal expansion,

mean stress, stress state effect on life• Predict the effect of temperature, strain rate,

metallurgical changes on life.

Life Prediction ModelingLife Prediction Modeling

Huseyin Sehitoglu



Coffin’s ApproachCoffin’s Approach

Huseyin Sehitoglu



Coffin’s Approach (Frequency Modified Life)

Coffin’s Approach (Frequency Modified Life)

Huseyin Sehitoglu



Coffin’s ApproachCoffin’s Approach

Advantages:

(1) Simple to use; accounts for frequency effects

Disadvantages;

(1) Not sensitive to location of hold time within the cycle (tension or compression).

(2) Does not account for creep damage effects

(3) TMF life prediction not explicitly handled.

(4) No stress-strain model

Advantages:

(1) Simple to use; accounts for frequency effects

Disadvantages;

(1) Not sensitive to location of hold time within the cycle (tension or compression).

(2) Does not account for creep damage effects

(3) TMF life prediction not explicitly handled.

(4) No stress-strain model

Huseyin Sehitoglu



Strain Range Partitioning Method(SRP)

∆ε∆ε

∆ε

∆ε∆ε

∆ε

pp

cp

cppc

pc

cc

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SRP Data on Two Class of Steels(Manson et al.)

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SRP ApproachSRP Approach

Advantages:

(1) Accounts for location of hold time within a cycle

Disadvantages;

(1) Life curves are often too close, expensive to generate all these curves

(2) Does not account for oxidation/environment effects

(3) TMF Life prediction not explicitly handled.

Advantages:

(1) Accounts for location of hold time within a cycle

Disadvantages;

(1) Life curves are often too close, expensive to generate all these curves

(2) Does not account for oxidation/environment effects

(3) TMF Life prediction not explicitly handled.

Huseyin Sehitoglu



• Damage per cycle is sum of the dominant mechanisms Dfat, Dox , Dcreep.

• The terms in the damage equations should be physically based, specifically, they should be linked to specific experiments, stress-strain behavior and microstructural observations.

Development of a Mechanism Based Failure Model (Sehitoglu et al.)

Development of a Mechanism Based Failure Model (Sehitoglu et al.)

Huseyin Sehitoglu



• Neu, Sehitoglu, Boismier, Kadioglu, 1987-

1Nf

ox = hcr δo

BΦox Kpeff

-1β 2 ∆εmech

ox 2β +1

ε (1-a' /β)

This equation accounts for the strain range at the oxide tip hence the oxide-metal properties the shapeof the oxide are included.

depends on the temperature strain history

and the temperature- time variation in the cycle.

Fatigue - Oxidation Models (ctd.)

Fatigue - Oxidation Models (ctd.)

Φ ox Kpeff

Huseyin Sehitoglu



Combined Damage Model Predictions

Combined Damage Model Predictions

10-4

10-3

10-2

10-1

Mec

hani

cal S

trai

n R

ange

101

102

103

104

105

106

107

108

Nf

WAP319-T7B Small SDAS All Fatigue Results

RT 40Hz 250?C 0.5Hz

250?C 5 x10-5s-1

300?C 5 x10-5s-1

TMF OP 100-300?C TMF IP 100-300?C

300?C Dox=0

300?C Dox

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Combined Damage Model Predictions (1070 Steel)


Huseyin Sehitoglu





Huseyin Sehitoglu



Combined Damage ModelCombined Damage Model

Advantages:

(1) Accounts for TMF loading.

(2) Damage due to oxidation and creep are included.

Disadvantages:

(1) Requires some time to understand how it all works.

Advantages:

(1) Accounts for TMF loading.

(2) Damage due to oxidation and creep are included.

Disadvantages:

(1) Requires some time to understand how it all works.

Huseyin Sehitoglu



• Modified Strain-Life Relation

- initial pore size– fatigue strength coefficient– fatigue strength exponent– fatigue ductility coefficient– fatigue ductility exponent

C'b

ε f'

c

Fatigue Damage Equation

a0

∆εmech

2= C'a0

2−b2b (2N f

fat )−1b +ε f

' (2N ffat )c

Huseyin Sehitoglu



- empirical constants- activation energy

- universal gas constant- hydrostatic stress- effective stress

- initial pore size

Cc,mc

σσ H

H∆R

Creep Damage Equation

a0

Dcr = Cc(mc − 1)a0mc −1 σ H

σ H

σ n+1 exp −∆HRT

dt

0

tc

∫m c

Huseyin Sehitoglu



TMF IP versus TMF OP Comparison- Al 319

2

3

4

5

6

7

8

90.01

2

3

4

5

101

2 3 4 5 6 7 8 9

102

2 3 4 5 6 7 8 9

103

2 3 4 5 6 7 8 9

104

Nf

WAP EAP PredictionTMF-IPTMF-OP a0 = 70 µm

300 µm

Huseyin Sehitoglu



Initial Voids and after TMF IP

Huseyin Sehitoglu



Future DirectionsFuture Directions

• A simple model is developed to predict lifefor a given mechanical strain range, maximumtemperature, and material.

• Given a strain and temperature field in a component,the model can predict the most critical location wherecrack nucleation will occur.

Huseyin Sehitoglu



• Given an elastic strain, temperature history from FEM, the model is able to predict the stresses and plastic strains assuming the mechanical strain is equal to the elastic strain from FEM. This is known as the ‘ strain invariance method’.

• To predict component behavior the model accounts for the initial defect size.

Future Directions (ctd.)Future Directions (ctd.)

Overview of High Temperature and Thermo-mechanical Fatigue ... · Overview of High Temperature and...

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