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S-N CURVE AND NDT EXPERIMENTS ON ALUMINIUM ALLOYS

 

 

 

Sr. No.

Parameters

Pg. No.

1.

Introduction

4

1.1

Report Objectives

5

1.2

Significance

5

2.

Literature Review

5

2.1

Chemical Composition of Aluminum Alloys

5

2.2

Procedure of Fatigue testing

8

3.

Theory

9

3.1

Definition of S-N curve

10

3.2

Definition of NDT

10

3.3

Ultrasonic Testing

11

3.4

Magnetic Particle Inspection

13

4.

Undertaking Experiments

14

4.1

S-N curve Plotting

15

4.2

NDT test by Ultrasonic Testing

16

4.3

NDT test by Magnetic Particle Inspection

16

5

Results and Analysis

18

5.1

Fatigue tests results

18

5.2

S-n curve plotting

19

5.3

Fractography aspects

21

5.4

Ultrasonic test results

23

6

Conclusions and Summary

24

7

References

25

 

 

 

 

 

ABSTRACT

 

Different kind of automobile and other engineering component were made up of alloys like aluminium. Because of its unique property like light in weight etc.. A method of fatigued image accumulation based upon application of energy parameters of the fatigue process is proposed in this paper. This paper consists of mainly fatigue test (S-N Curve) and NDT experiment of the aluminum alloys grade 2011-T3 and grade 6082-T6. To study its behavior the S-N curve is plotted. The ultrasonic and magnetic particle testing was done on the mild steel plate and their test results were noted. All the experiments were carried out on the fatigue testing equipment servo-hydraulic ZwickRoell 25kN.

 

1. INTRODUCTION

 

 Machine parts which subjected to a repeated reversal or removal of an applied load, fail at a stress much lower than the ultimate strength of material. A cyclic fatigue failure is a type of time dependent failure.From centuries, Fatigue become the major concern in engineering. On this fatigue problem, huge number of literature review is available. The importance of data of fatigue in engineering design is emphasized by one estimation that 90 percent of all service failures of machines are caused by fatigue.

 Fatigue failure results from improper design. And because of the case with which complex shapes can be manufactured, the complete rethinking of an established design in terms of composite can often lead to both cheaper and better solution. Below, a review for some of researches deals with the fatigue life for aluminum alloy and composite materials for the last five years. They predicted the low cycle fatigue life of 316L (N) stainless steel based on cyclic elasto-plastic response (Roy et al.). They studied the fatigue life of woven carbon-epoxy and compared it with the finite element modeling (Satrio and Chai). They investigated the damage of composite materials under two block loading cycle fatigue conditions (Bendouba et al.). Also they studied the effect of loading sequence and the influence of the cycle ratio of the first stage on the cumulative fatigue life. Two loading sequences included high-to-low and low-to-high cases are considered.  They presented a survey paper deals with aluminum alloy metal matrix composite and their mechanical properties (Vengatesh and Chandramohan). They predicted S-N curves for different stress ratios under variable amplitude loading from the constant life diagram by using limited fatigue experimental data (Park et al.). They presented a useful survey study to design engineer’s deals with aluminum and its alloys and their application in automobile engine components such as engine block, piston and connecting rod (Nair Sarath et al.). The current research investigates the mechanical properties for aluminum alloys and composite material under tensile load to find static properties and fatigue test to find dynamic properties.

Fatigue lives of material represent the time for a flaw to initiate and propagate tofailure. The most frequent method used to evaluate the fatigue life of a material is to plot a Wohler curve also called the S -N curve. An n S-N curve is where; cyclic stress amplitude is plotted against the log number of cycles to fractures for a material.

S-N curve is normally used to predict the fatigue limit or fatigue life of the structural components. It is also called a stress-life method, based upon plotting nominal stress value vs. the number of cycles during a test. There are many ways to generate data for plotting S-N curve of the materials which is usually plot on the Log-log scale (Dowling,1972).Endurance limit or fatigue limit is the value below which material can bear an infinite number of cycles without failure (Papadopoulos,1997). Some materials have well-defined endurance limits like steel and titanium but most of the non-ferrous materials do not have well-defined endurance limit i.e. Aluminum and magnesium etc. These materials have continuously decreasing S-N curve during fatigue testing, it is important to specify the fatigue strength for a given number of cycles (Niesłony, 2012)

  • RESEARCH OBJECTIVES

The primary objectives of this report are as given below:-

  • Done Experiment on servo-hydraulic ZwickRoell 25kN
  • Generate test reports and plot S-N curve
  • NDT on Sample Specimen by Ultrasonic test
  • NDT on Sample Specimen by magnetic particle
  • Analysis of results
    • SIGNIFICANCE

The report carries two main sections. In first section, the fatigue analysis of alluminium alloys was done. Based upon that the test report was made. The fractography aspects were studied as per the test. With the help of echo-pulse method, the ultrasonic and magnetic particle testing have been done.

 

2. LITERATURE REVIEW

 

Aluminum alloys and other lightweight materials have growing applications within the automotive industry, with relation to reducing the fuel utilization and shielding the environment, where they will successfully reinstate steel and forged iron parts. These alloys are extensively utilized in buildings and constructions, containers and packaging, marine, aviation, 12 aerospace and electrical industries thanks to their lightweight, corrosion resistance in most environments or a mixture of these properties (Allen 1983).

Aluminum alloys have higher electrical and thermal conductivities than most other metals and they are usually cheaper than the alloys which are superior conductors like copper, silver, gold, and so on (Kenneth and Michael 2006). Al-alloy provides good combination of strength, corrosion resistance, together with fluidity and freedom from hot shortness (ASM Hand book 1979).

 

2.1PHYSICAL AND CHEMICAL PROPERTIES OF ALLUMINIUM ALLOYS

 

For carrying out the fatigue test and NDT experiments, we have selected two aluminum alloys grades. The grades of alloys are 2011-T3 and 6082-T6. The physical and chemical plays vital role here to understand the behavior of the material

The specifications of aluminium alloy 2011-T3 rod and bar is given below:-

The mechanical strength of the Al alloy is high and on this machining can be done very easily. Often called a Free Machining Alloy or ‘FMA’ it is well suited to use in automatic lathes. (Sources: aalco.co.uk)

Machining al alloys at high speeds produces fine chips that are easily removed. In some circumstances 2011 can replace free machining brass without the requirement for alterations to tooling. Its poor corrosion resistance, which implies parts made up of All alloy 2011-T3 tend to be anodized to produce additional surface protection. (Sources: aalco.co.uk)

When higher levels of corrosion resistance are required, 6262 T9 may be a suitable replacement. (Sources: aalco.co.uk)

Applications

2011-T3 is typically used in applications that require parts manufactured by repetition machining.

These applications may include:

  • Appliance parts & trim
  • Automotive trim
  • Fasteners and fittings
  • Ordnance

The chemical composition of the aluminium alloy 2011-T3 rod and bar as per BS EN 573-3:2009 are:-

 

Table 1: Chemical Properties of Al Alloys  2011-T3

(Sources: aalco.co.uk)

 

The specifications of aluminium alloy 6082-T6 plate is given below:-

Aluminium alloy 6082 could be a medium strength alloy with excellent corrosion resistance. It’s the very best strength of the 6000 series alloys. Alloy 6082 is understood as a structural alloy. In plate form, 6082 is that the alloy most ordinarily used for machining. As a comparatively new alloy, the upper strength of 6082 has seen it replace 6061 in many applications. The addition of an oversized amount of manganese controls the grain structure which successively leads to a stronger alloy. (Sources: aalco.co.uk)

It is difficult to provide thin walled, complicated extrusion shapes in alloy 6082. The extruded surface finish isn’t as smooth as other similar strength alloys within the 6000 series. (Sources: aalco.co.uk)

Application

6082 is typically used in:

  • Highly stressed applications
  • Trusses
  • Bridges
  • Cranes
  • Transport applications
  • Ore skips
  • Beer barrels
  • Milk churns

The chemical composition of the aluminium alloy 6082-T6 plate as per BS EN 573-3:2009 are:-

 

Table 2: Chemical Properties of Al Alloys 6082-T6

 (Sources: aalco.co.uk)

 

2.2ABOUT FATIGUE TESTING EQUIPMENT

 

The fatigue-testing machines consist of the same basic components: a load train, controller, sensors and monitors. Normally, the test specimen is loaded on the test system through the load train and gripping has been done. Then the test is controlled by controller. The sensors feed data back to the controller, and finally communicate with the investigator by means of the read-out devices. E.g.: monitors (L C D).

The present fatigue testing of the aluminum alloys 2011-T3 and 6082-T6 will be done on servo-hydraulic ZwickRoell 25kN. Fig.1 show Servo-hydraulic testing machine. It have universal application for materials and component testing under pulsating or alternating loads, with periodic or random signals. Quasi-static and dynamic loads are also easily achieved. 

ZwickRoell’s product portfolio includes a spread of testing machines for determining the fatigue limit of components or complete products. Also available from ZwickRoell are Vibrophores for determination of fatigue strength. Fatigue limit are often determined for the tensile and compression limits of the component, moreover as for the torsion limit. (Source:-zwickroell.com)

 

Fig.1 Servo-hydraulic fatigue testing machine 25KN

 

3. THEORY

 

The continuous progressive, permanent structural change that happens in materials subjected to fluctuating stresses and strains which will end in cracks or fracture is called as fatigue [ASM, 1985 Metal Handbook]. A fatigue fracture happens due to continuous action of cyclic stress, tensile stress and plastic strain. If anyone of those three isn’t present, fatigue cracking won’t initiate and propagate. A cleft is started by cyclic stress, whereas crack propagation is produced by tensile stress. In general, this phenomenon has attracted attention because progressively more and more is demanded from machine parts in term of speeds of operation and loads to be sustained.

The process of fatigue failure consists of three stages [You C.P., 1990]:

  1. Initial fatigue damage resulting in crack nucleation.
  2. Progressive cyclic growth of a crack (crack propagation) until the remaining uncracked portion of a component becomes too weak to sustain the masses imposed.
  • At last the sudden fracture happens on the remaining portion.

 

3.1 DEFINITION OF S-N CURVE

 

The fatigue properties of materials are very well explained using the fatigue limit or the S-N curve (fatigue curve, Wöhler curve). The S-N curve shows the relation between cyclic stress amplitude in MPa and number of cycles to failure. The figure below shows a typical S-N curve. On the horizontal axis the quantity of cycles to failure is given on scale of measurement. On the vertical axis (either linear or logarithmic) the strain amplitude (sometimes the most stress) of the cycle is given. (Source:fatec engg.)

S-N curves are derived from fatigue tests. Tests are performed by applying a cyclic stress with constant amplitude (CA) on specimens until failure of the specimen. In some cases the test is stopped after a awfully sizable amount of cycles (N>10^6). The results are then interpreted as infinite life. (Source: fatec engg.)

for Kt=1 (unnotched specimens), Fatigue curves are given Those curves describe the fatigue properties of a cloth. With S-N curves, the actual structures are well described for Kt>1 (notched specimens). (Source:fatecengg.)

 

Fig 2. S-N Curve

(Source:fatec engg.)

 

3.2 DEFINITION OF NDT TEST

 

Non-Destructive Testing (NDT) is that the examination of an object or material with technology that doesn’t affect its future usefulness. NDT techniques don’t harm or destroy the thing under test. NDT can provide a superb balance of internal control and cost-effectiveness without affecting manufacturing yield.

The term “NDT” includes many methods that can:

  • Detect internal or external defects
  • Determine structure, composition or material properties
  • Measure geometric characteristics

NDT can and will be employed in any phase of a product’s design and manufacturing process, including materials selection, research and development, quality assurance and production.

Non-Destructive Testing is additionally referred to as Non-Destructive Evaluation (NDE) or Non-Destructive Inspection (NDI).Different Types of NDT Methods are as:

  • Resonant Inspection (RI)
  • Radiography X-ray (RT)
  • Computed Tomography (CT)
  • Magnetic Particle Testing (MT)
  • Ultrasonic Testing (UT)
  • Electromagnetic Eddy Current (ET)
  • Acoustic Emission Testing (AE)
  • Liquid Penetrant Testing (PT)
  • Optical Testing
  • Visual Inspection

(Source: MTS)

 

3.3 ULTRASONIC TESTING

 

Ultrasonic testing (UT) may be a non-destructive testing technique supported the propagation of ultrasonic waves within the object or material tested.

A common example is ultrasonic thickness measurement, which tests the thickness of the test object, for instance, to observe pipe work corrosion.

Ultrasonic testing is usually performed on steel and other metals and alloys, though it may be used on concrete, wood and composites, albeit with less resolution. In many industries like steel and aluminium construction, manufacturing, aerospace, automotive and other transportation sectors, UT is used.

Principle of Ultrasonic Testing

As shown in below figure (left) : a quest sends a undulation into a test material. There are two indications, one from the initial pulse of the probe, and therefore the second thanks to the rear wall echo.

As shown in below figure (right) : A defect creates a 3rd indication and simultaneously reduces the amplitude of the rear wall indication. The depth of the defect is decided by the ratio D/Ep

 

Fig 3.Ultrasonic Testing

 

Advantages of Ultrasonic Testing

  • High penetrating power, which allows the detection of flaws deep in the part.
  • High sensitivity, permitting the detection of extremely small flaws.
  • In many cases only one surface needs to be accessible.
  • Greater accuracy than other nondestructive methods in determining the depth of internal flaws and the thickness of parts with parallel surfaces.
  • Some capability of estimating the size, orientation, shape and nature of defects.
  • Some capability of estimating the structure of alloys of components with different acoustic properties
  • Non hazardous to operations or to nearby personnel and has no effect on equipment and materials in the vicinity.
  • Capable of portable or highly automated operation.
  • Results are immediate. Hence on the spot decisions can be made.

Disadvantages of Ultrasonic Testing

  • Manual operation requires careful attention by experienced technicians. These signals must be distinguished by a talented technician, possibly requiring follow up with other nondestructive testing methods.
  • Extensive technical knowledge is required for the event of inspection procedures.
  • Parts those are rough, irregular in shape, very small or thin, or not homogeneous are difficult to examine.
  • Surface must be prepared by cleaning and removing loose scale, paint, etc., although paint that’s properly bonded to a surface needn’t be removed.
  • Couplants are needed to produce effective transfer of ultrasonic wave energy between transducers and parts being inspected unless a non-contact technique is employed.
  • In these cases anti-freeze liquids with inhibitors are often used.

(Source:InstTools)

 

3.4 MAGNETIC PARTICLE INSPECTION

 

Magnetic particle inspection could be a non-destructive inspection method that has detection of linear flaws located at or near the surface of ferromagnetic materials. It is seen as primary surface examination method.

The area is magnetised with the yoke magnet. Within the event of a surface or slightly sub surface defect being present, the lines of attractive force will deform round the defect.

The ink is applied and also the iron powder particles will bridge the gap caused by the defect and provides a visual indication against the white contrast background.

Magnetic Particle Inspection (MPI) provides excellent defect resolution and is employed extensively on:

                                                    

     Fig4.Magnetic particle test

 

Locating fatigue cracks in items subject to cyclical stress.

ADVANTAGES OF MAGNETIC PARTICLE INSPECTION

  • both surface and near sub-surface defects
  • portable and low cost
  • Immediate results can be obtained by rapid inspection
  • on the specimen surface, Indications are visible to the inspector directly
  • detect defects that are smeared over
  • inspect parts with irregular shapes (external splines, crankshafts, connecting rods, etc.)

DISADVANTAGES OF MAGNETIC PARTICLE INSPECTION

  • ferromagnetic is must (e.g. steel, cast iron)
  • Before inspection, paint should be removed.
  • post demagnetization and cleaning of oil is must
  • it is important to take alignment between magnetic flux and defect.

 

4. UNDERTAKING EXPERIMENTS

 

Now for obtaining the required results, the experiments need to be done on the machine. The sample work piece and machine is checked and prepared for the tests. The experimental procedures for all the test were given below:-

 

4.1 EXPERIMENTAL PROCEDURE OF FATIGUE TESTING

 

The arrangement of analyses was performed on various examples of 2011-T3 and 6082-T6 aluminum combinations having tremendous application in as aviation and auxiliary material. The weariness testing was performed by utilizing servo-water powered Zwick Roell 25kN, where every material was tried for around 4-5 arrangements of an examination. This Hydraulic testing machine has qualities that it can give different stacking conditions according to prerequisites Its water-driven force back go about as the machine bed and along these lines limit the impression. This hardware is ordinarily considered as perfect for research center testing of materials.

The stacking condition for example either longitudinal or transverse can impact the incline of the S-n bend. Test planning is likewise basic for the exhaustion testing of the materials and in our investigation, we kept the ASTM Standard to set up an example. The standard component of the example according to ASTM was 7,5 mm while the example was minor cleaned before exhaustion testing so to stay away from the nearness of stress risers and anomalies on the outside of the example. The example was set in the machine and afterward, stress differed with time and it is approximated with time by utilizing the sinusoidal stacking cycle.

The given pressure and loading conditions are referenced in Table 3. For both the aluminium alloys (2011 and 6082) were gone through a few tests according to given estimations of stress and loading variety, which appeared in Table 3.

 

Aluminium Alloy 2011-T3

Aluminium Alloy 6082-T6

Load (kN)

Stress (Mpa)

Load (kN)

Stress (Mpa)

6.1

487

4.2

337

5.8

462

4.0

320

5.5

438

3.8

303

5.2

414

3.6

286

4.9

390

3.4

270

4.6

365

3.2

253

4.3

340

3.0

236

4.0

316

2.8

219

3.7

292

2.5

202

3.4

268

2.3

185

3.1

244

2.1

168

Area=12.57 mm2  R=-1 f=10Hz (Tentative)

 

These heaps and stress esteem for every material was chosen by profound writing study and afterward improved by remembering the normal continuance cutoff of the materials. After the fruition of the test, the number of cycles was extricated through the machine programming to where materials flop under exhaustion stacking. After this information was plotted as the S-N bend. The S is utilized for pressure, named as ostensible pressure and it tends to be determined by utilizing the underneath equation and through cautious writing study.

 

4.2 NDT TEST BY ULTRASONIC TESTING (Pulse-Echo)

 

To research the harm in the metallic segment, a typically beat reverberation strategy for the ultrasonic technique is utilized. A transducer has piezoelectric materials that convert electrical vitality into sound vitality (mechanical vitality ) and the other way around. Fig.5 shows gear for the ultrasound testing utilized in this examination.

 

Fig5.Experimental Ultrasonic Testing of Aluminium Alloys

Above all else, ultrasonic waves are presented in the gentle steel material as appeared in Fig 2. By utilizing the gear’s transducer. The sound waves move in the straight line with steady speed uncles the distinguish a few deformities or imperfections inside the material. At the point when they experience some imperfection surface, their motivation impression of the sound waves. The following are the parameters that are upgraded before ultrasonic testing of the gentle steel example.

 

4.3 NDT TEST BY MAGNETIC PARTICLE INSPECTION

 

Materials used for magnetic particle inspection was mild steel, the same as in the case of the ultrasonic testing experiment. There are some solid steps in magnetic particle testing that should be followed in a proper way to gain perfect results. The first step is the precleaning of the sample specimen. The surface is cleaned and then dried so to have an unimpeded path for the migration of weak and strength leakage of magnetic flux. It is a very important step because if any sort of contamination or oil is present in the surface, it not only hinders dye particles to get attracted toward the leakage but also causes a bad casual indication of the defect.

In the second step, the magnetic field is introduced on the surface of the specimen. Although there are different reported ways to introduce magnetic field on the material but for our experiment, we used a coil of wire as shown in the Fig.6

 

Fig6. Magnetic field introduction to specimen

In this step, the specimen is placed inside the coil and then electric flow through the coil of wire and through the central conductor which is present near the specimen. In this way, steel is magnetized for the next step to perform. One thing to note here is the direction of magnetization is also an important parameter to consider. The best approach is to magnetize the specimen in both the direction as it best direct of defect is established when the line of magnetization force is parallel to it. So, defects can be present in any point or direction so two-way magnetization was done in the direction of a right angle to each other.

The third step is the application of the magnetic media. In literature, there are two ways of using magnetic media either in dry or wet form. In our experiment, we used wet magnetic media by using the solution of small iron particles as shown in Fig 7. The solution is smoothly spread on the surface of the magnetized specimen.

 

Fig 7. Magnetic Field is applied on the sample

 

The final step is the inter-operation of the indications after application of magnetic media. Examiner must easily distinguish between the relevant and irrelevant indications. In our observation, we observe some the service induced defects near the surface which may be part of the specimen during the manufacturing of the raw material into the billets of the mild steel.

Finally, the specimen was demagnetized by sliding on the surface of the de-magnetizer as shown in the Fig.8. If this step is not followed NDT testing service component, it may interfere in the service manufacturing and operation of the component.

 

Fig 8. Sample Demagnetization

 

5. RESULTS AND ANALYSIS

 

5.1 FATIGUE TESTS RESULTS

 

The above tested data were shown below in the table 4 and 5 for the aluminium alloys.The numerical information got because of weakness testing on both viable Aluminum Alloys.This information was then plotted on source programming to get the necessary S-N bend of the 2011 and 6082 Al compounds.

Load (kN)

Stress (MPa)

Test 1

Test 2

Test 3

Test 4

5.2

414

544

602

1997

332

4.9

390

1133

1759

1387

973

4.6

365

3434

2729

2703

2389

4.3

340

5493

17910

8020

4820

4.0

316

9724

15771

8401

8861

3.7

292

23271

13437

41696

13185

3.4

268

37182

26781

30014

26703

3.1

244

51282

24836

51221

44450

Table 4 : Number of cycles recorded for the Aluminium Alloy 2011-T3 Samples Tested

 

Load (kN)

Stress (MPa)

Test 1 (cycles)

Test 2 (cycles)

Test 3 (cycles)

Test 4 (cycles)

Test 5 (cycles)

Test 6 (cycles)

3.6

286

14391

14211

16369

11412

15829

3544

3.4

270

8916

31614

34976

46742

27316

5979

3.2

253

44857

40274

55628

58774

29922

21071

3.0

236

98719

48519

86715

112550

103636

72010

2.8

219

42664

118317

105751

208875

190134

73894

2.5

202

76813

130999

294881

113683

176302

89534

2.3

185

643641

1000000

153235

1000000

1000000

1000000

2.1

168

1000000

1000000

1000000

1000000

1000000

1000000

Table 5 : Number of cycles recorded for the Aluminium Alloy 6082-T6 Samples Tested

 

5.2 S-N CURVE PLOTTING

 

Based upon the above results the S-N curve have been plotted. For the aluminium alloy 2011-T3, the 4 test results have been noted.The S-N curve for that is given in the below figures.In the X-axis, the no. Of cycles were plotted while in y-axis, the Stress in MPa is placed.

 

Fig.9 S-N curve for test 1 2011-T3

 

Fig10 S-N curve for test 2 2011-T3

 

 

Fig.11 S-N curve for test 3 2011-T3

 

 

Fig.12 S-N curve for test 4 2011-T3

 

For the aluminium alloy 6082-T6, the test results have been noted.The S-N curve for that is given in the below figure.

 

Fig.13 S-N curve for 6082-T6

 

5.3 FRACTOGRAPY ASPECTS

 

There are several types of fractures; brittle-, ductile-and fatigue-fracture being the main categories. One of the best methods of studying a fracture is, as earlier mentioned, with the use of SEM [Hjelen, J. and Sinte]. By studying the fracture surface, it is possible to determine what type of fracture has occurred. In this section,the three fracture types mentioned will be presented, with focus on fatigue fracture.

 Ductile fracture :A ductile material usually exhibits ductile fractures under normal circumstances. This type of fracture occurs when a material in tension reaches an instability point,where the strain hardening of the material cannot keep up with the loss of cross-sectional area. This is when the infamous “necking” occurs.A ductile fracture is shown in Figure 14. Ductile fractures are commonly observed in three stages [Anderson, T.L.]

  1. Formation of a free surface at an inclusion or second-phase particle by either interface de-cohesion or particle cracking.
  2. Growth of the void around the particle, by means for plastic strain and hydrostatic stress.

Fig14: Ductile fracture surface of aluminium.

 

Taken from [Hjelen, J. and Sintef].

Brittle fracture: A brittle fracture is a rapid fracture. This type of fracture either grows along side the grain boundaries, or along crystal planes. They are named inter-crystalline and trans-crystalline fracture, respectively. The mechanism for trans-crystalline brittle fracture is called “cleavage” [Anderson, T.L.].Such a fracture is shown in Figure 15.

 

Fig 15: A brittle inter-crystalline cleavage fracture.

 

Taken from [Hjelen, J. and Sintef]

Fatigue fracture: This section will deal with high-cycle fatigue fracture, as it is the relevant fatigue-type for this study. Fatigue is failure due to cyclic stress, as earlier mentioned.Fatigue fracture separates itself from the other fracture types, as it does not need to surpass the yield strength of the material. Tiny cracks and surface defects are frequent initiation points,because they yield greater local stresses.Other favourable orientated slip planes are also good initiation points. Every crack does not necessarily develop into a critical crack [18].A fatigue crack usually develops in three stages [Hjelen, J. and Sintef]:

  1. Crack initiation and growth along slip-planes, often in a 45°angle to the applied tension direction.As the crack grows along certain crystal-planes, it can be confused with a cleavage fracture.
  2. The crack changes its growth direction,from going along certain crystal-planes, to perpendicular to the tension direction.
  3. Cross-section area has been greatly reduced,and the material can no longer withstand the tension. A transition over to either a ductile, brittle or combination fracture will then occur.This canal so be called overload fracture.Studying the fracture on a macroscopic level, it is possible to see these stages with the naked eye. They are then called“beach marks”. It is also possible to figure out the fracture initiation point with the naked eye [Hjelen, J. and Sintef]. However, this is not always possible. Therefore, SEM is used.On a microscopic level, it is possible to see “striations”. These are results of either one or possible several load cycles [Hjelen, J. and Sintef]. It is possible for fatigue to occur without striations [Campbell, F.C]. In Figure 17, striations in an aluminium alloy can be seen. The length in between each striation tends to increase with crack length. By tracing them back to their origin,it is possible to discover the location of the crack initiation point. If the cyclic-frequency and length between striations is known, crack growth can be calculated.

Fig16: Striations inaluminium (from a helicopter rotor).

Source: [Campbell, F.C]

 

5.4 ULTRASONIC TEST RESULTS

 

The results are generated for the sample material Mild steel.

Material: Mild Steel

Depth of the material: 50.71mm

Gate Start: 3.00mm

Gate Width: 47.00mm

Gain: 6.8dBA

The measure of reflected vitality gives a thought regarding the size of deformity or intermittence while travel time gives the thought regarding separation secured by the sound waves or how far is the imperfection from the outside of the material. Tables 6 outlines the discoveries gathered post ultrasonic testing of the mellow steel example through various arrangements of the examination.

Defect

Actual depth(mm)

Measured depth(mm)

1

45.78

45.76

2

40.84

40.92

3

30.86

30.86

4

25.78

25.87

5

10.65

10.80

 

Table 6. Depth findings of ultrasonic testing of mild steel

 

Fig 17. Phaser XS shows phased array imaging of the defected sample

 

6. CONCLUSION AND SUMMARY

 

In this, results of all the given assignments are communicated in a nitty-gritty way. All the outcomes are well as per the information announced in the writing. In the main portion of the report, weariness testing process is examined on two Aluminum compounds and the S-N chart is plotted from information gathered through many weakness tests. It has been seen that there do exist a few abnormalities in the information, which might be a direct result of human mistake or machine blunder. While intruding on information, they are maintained a strategic distance from to give an accurate image of the circumstance. S-N chart of both the combinations shows that 6082-T6 have continuance limits at the high number of cycles when contrasted with the 2011-T3 amalgam. The second area of the report covers the itemized conversation over NDT strategies as through which architects can get an admonition before any disappointment of the material. Albeit both Ultrasonic and Magnetic testing are entirely compact and simple to use there are favorable circumstances and impediments to both the methods also. Legitimate visual interference is significant in these methods to maintain a strategic distance from any off-base outcomes. In closing words, we can say that this report tended to practically all the inquiries featured in the task with certain special cases as human or machine mistakes.

 

7. REFERENCES

 

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