Sharif Digital Repository

Aluminum alloy (A356.0) is used in the production of cylinder head. Automobile engines are often subjected to thermo-mechanical loadings. In order to investigate the material performance, it is crucial to obtain fatigue properties of the material under thermo-mechanical and isothermal fatigue tests. The specimen is subjected to tensile and compressive stresses in a constant temperature. But in thermo-mechanical tests, the temperature and the strain vary in a specific span (between maximum and minimum values). By using the strain- stress hysteresis loop (obtained by fatigue tests), we can determine fatigue properties. Then, these properties are used in the simulation. In this thesis,... 

Most engineering components must be manufactured so they are safe to use and are ‘‘fit for purpose’’. However despite all the efforts, cracking of the engineering components is inevitable. Residual stresses play an important role in either increasing or decreasing the possibility of failure. For instance, enhancement in apparent toughness following pre-loading arises principally because of the creation of local crack tip compressive residual stresses. Introducing compressive residual stresses can also slow the fatigue crack growth. Yet, the dilemma is choosing an efficient method growth to introduce such stresses for retardation of fatigue crack growth. There are many methods available in... 

Offshore structures are valuable structures used in the offshore petroleum and gas fields for the purpose of hydrocarbon production operation. These structures are influenced by wave loads. Sea waves are inherently alternative and for this reason fatigue failure is considered as one of the most important modes of failure in these structures. Joints in these structures are made by tubes and they are called tubular joints. The joining process in manufacturing of these joints is welding. Welding process induces residual stresses, mostly tensional, in the substructure of materials. This tensional residual stress has a destructive effect on fatigue life of the joint and increases probability of... 

Residual stresses are one of the influencing factors on fatigue life. These stresses may cause cracking and failure of the element even in the absence of any applied stress or any external load. For this reason they are very important, and their measurement is crucial. The methods for measuring the residual stress in spite of their name often measure the strain and by analyzing the measured strain, determine the residue stress of the element. The important problem about residual stresses is that their values in the element often remain unknown and usually no simple and non destructive method for measuring is available. Usually finite element analyzing is used for modeling the production... 

Shot peening is a cold-working process commonly used in industry to improve the fatigue performance, stress corrosion resistance and surface nano-crystallization of metallic parts. This process extends fatigue life via two mechanisms: Preventing the crack growth due to compressive residual stresses and, preventing the crack initiation because of increased material hardness. These mechanisms are the results of the bombardment of the component's surface with small spherical particles. In this research, an analytical model is developed for estimating the residual stress distribution induced by shot peening process. The modifications of the developed analytical model are related to... 

According to the widespread application of shape memory alloys, their study in the presence of cracks has received lots of attention in the last two decades. The phase transformation ahead of the crack tip may change the stress field and the fracture behavior, especially at the nanoscale. Thus, modeling this phenomenon helps to recognize the affecting factors on crack propagation and prediction of material behavior when cracks exist. In the first step of this thesis, a phase field approach for crack propagation was presented, first by considering fracture as phase transformation and then as bond breaking. According to the scaling-up strategy, the developed theory is applicable from the... 

Residual stresses are stress fields that exist in the absence of any external loads. All mechanical processes can cause deformation that may lead to residual stresses. It is well established that virtually no material, no component and no structure of technical importance exists free of residual stresses. However, in practice, the knowledge of the true distribution of exiting residual stress is rare. The residual stress fields are very challenging to evaluate, independent of the measurement techniques. The important aspect about the residual stress determination is that often true distribution is unknown in the engineering specimen. A simple and non-destructive method to measure residual... 

Accurate description of kinematics of continuum mechanics is essential in simulation of large deformation problems in solid mechanics. From the numerical viewpoint, two main approaches have been used for such description; the Lagrangian approach and the Eulerian approach. However, each of these approaches suffer from shortcomings which hinders their application in large deformation problems. A more general approach called the Arbitrary Lagrangian-Eulerian method (ALE) provides an opportunity to exploit the advantages of both Lagrangian and Eulerian approach, while avoiding their shortcoming. In an ALE analysis, the FE mesh is neither attached to the material nor fixed in space, necessarily.... 

Application of light metals such as Magnesium alloys due to proper mechanical behavior is increasing in industries such as automotive, electronics and so on. In this project, ingot of Mg-9Li-1Zn alloy with 10 mm thickness were produced by casting, then hot rolled at 300oC to reach 2mm thickness. Annealing at 350oC for 3 hours resulted homogenous properties in the final sheet.Study of monotonic and cyclic behavior of Mg-Li alloy by experiments and FE simulation was the goal of this project. Experimental monotonic and cyclic test were carried out in order to obtain the hysteresis loops and cyclic stress-strain curve. The Chaboche constant were extracted from the experimental test and used to... 

Laser cladding is a processing technique of layer-by-layer material deposition which is widely used to repair important components. However, tensile residual stresses generated in this process may result in detrimental effects such as crack, undesirable deformation and reduced fatigue life. A thermo-mechanical finite element model is developed to accurately predict residual stresses of the multiple beads laser cladding process with incorporating the cyclic plasticity into the analysis by utilizing the nonlinear kinematic hardening behavior. FE results are presented for Inconel 718, a material for which the laser cladding process is widely used. The FE results are compared with those of... 

Recent research studies on ductile fracture of metals have shown that the ductile fracture initiation is significantly affected by the stress state. In this study, the effects of the stress invariants as well as the effect of the reverse loading on ductile fracture are considered. To estimate the reduction of load carrying capacity and ductile fracture initiation, a scalar damage expression is proposed. This scalar damage is a function of the accumulated plastic strain, the first stress invariant and the Lode angle. To incorporate the effect of the reverse loading, the accumulated plastic strain is divided into the tension and compression components and each component has a different weight... 

Welded joints are the most used joints in industrial applications. Fatigue analysis of welded joints is of great importance. Residual stresses produced during welding process play an important role in fatigue failure of welded joints. Residual stresses’ effect on fatigue life of the structures is similar to mean stresses and can be accounted for like mean stress effect. However residual stresses are not constant and do change in service. In this thesis, welding process has been modeled using FE software ABAQUS in order to predict residual stress distribution due to welding. The predictions show good agreement with measurements especially for longitudinal residual stresses. Then cyclic load... 

Components in cryogenic milieu with relative motion, like seals and pumps cannot be lubricated by using oils or other lubricants. Therefore materials wear in cryogenic condition is a great concern. To earn valid data about the wear properties of common and super useful material in cryogenic tribosystems, reconstruction wear test apparatus at cryogenic temperature is needed. Investigations on metal-metal couple show that austenitic stainless steels have favorable and auspicious sliding properties at cryogenic temperature. This persuades us to survey the wear parameter of these prolific materials like austenitic stainless steels specifically. This research provides the wear parameters of... 

Thermal barrier coating (TBC) systems have been widely used in gas turbines and diesel engines. Their advantages include reducing the fuel consumption, improving the performance and increasing the fatigue lifetime at high temperatures. In the present thesis, the fatigue behavior of an aluminum alloy (the A356.0 alloy), with and without a typical TBC system is studied. The application of this research can be introduced as coating the cylinder head in diesel engines. Initially, coating process parameters (including the feed rate and the nozzle distance) of the plasma spraying, with the objective of bending strength are optimized. The optimum value of the TBC thickness is obtained based on... 

Magnesium alloys have been used in the production of light weight components in automobile industries (for example: the ladder frame and the valve cover) due to a good combination of low density (1740 kg/m3), the tensile strength (160-365 MPa) and the elastic modulus (45 GPa). For the design and the optimization of these components under various loadings and different conditions, it is necessary to determine fatigue properties of the material by using thermo-mechanical and low cycle fatigue tests at different temperatures. In thermo-mechanical fatigue tests, the temperature varies in a specific range with the mechanical strain. The goal of this research is to investigate low cycle fatigue... 

Wear is the most important cause of surface damage occurs by direct contact of surfaces. Increasing the quality and strength of surface against different kinds of destructive phenomena is significant in manufacturing of mechanical parts. Surface nanocrystallisation can improve the surface protection against wear and can be done by lazer beam and shot peening. In this investigation by sever shot peening process the surface of A356 Aluminium alloy transforms to nanocrystal structure. The dry sliding wear and friction behaviors of A356 Aluminum were evaluated using a pin-on-disk apparatus at ambient conditions. The stationary diameter of 5mm stainless steel pin produced a wear track (scar) on... 

The most failures caused by wear, fatigue and corrosion are very sensitive to surface of material. Since the most failures starts or occurs at the surface of material, so control and improvement of the surface properties can have a significant effect on increasing the service life and improve the overall behavior of the material. Reforming of the structure and grain size is one of the methods to improve elastic properties, hardness, softness, toughness, etc. Also the macroscopic residual stresses in fracture toughness test specimens, can have tremendous effect on fracture toughness measurements. Many methods are used to modify the surface structure and to create a compressive residual stress... 

In this study a layer with compressive residual stress was created by severe shot peening and hence surface grains was changed to nanostructure. Fatigue life will be increased as a result of compressive residual stress. Surface roughness increase, is one of the disadvantages of severe shot-peening process. Re-shot-peening with the smaller shots and lower intensity is proposed for reducing surface roughness. Numerical simulation as a powerful method, used to investigate the effects of shot-peening parameters on the residual stress distribution, surface roughness and grain size. Obtained results indicate that more energy in process can improve residual stress distribution and grain size unlike...