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Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Mechanics of Materials".

Deadline for manuscript submissions: closed (20 January 2024) | Viewed by 14341

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Dr. Wei Gao

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School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou 510006, China
Interests: computational mechanics; fracture mechanics; FEM/DEM coupling methods; fluid structure interactions; pedestrian safety and protection
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Dr. Shunhua Chen

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School of Marine Engineering and Technology, Sun Yat-sen University, Zhuhai 519082, China
Interests: computational mechanics; fracture mechanics; fluid structure interactions; renewable energy
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Dr. Peng Xie

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School of Marine Engineering and Technology, Sun Yat-sen University, Zhuhai 519082, China
Interests: fracture mechanics; submarine pipeline; structural safety; corrosion

Dr. Hui Liu

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Guest Editor

Department of Engineering Mechanics, School of Civil Engineering, Wuhan University, Wuhan 430072, China
Interests: computational mechanics; structural and multidisciplinary optimization; multiscale modeling and computation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Fatigue and fracture that are the common failure modes for many materials and composites have attracted widespread concern in various engineering and industrial communities, as such failure modes contribute to structural integrity reduction and affect the usage life. Experimental, theoretical and numerical approaches can be used to predict and investigate the fatigue and fracture characteristics of materials and composites. This Special Issue will address advances in experiment, modeling and theory for material fatigue and fracture. The aim is to collect recent and up-to-date developmental contributions concerning the fatigue and fracture of various materials, such as ceramics, matrix-based composites, rock-like materials, metallic material and glass. Articles and reviews dealing with fatigue and fracture in processing, manufacturing, structural engineering, and engineering and industrial products are also welcome.

Dr. Wei Gao
Dr. Shunhua Chen
Dr. Peng Xie
Dr. Hui Liu
Guest Editors

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Keywords

fatigue
fracture
experiments
theoretical approaches
numerical simulations
composites
ceramics
rock-like materials

Published Papers (10 papers)

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Research

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18 pages, 11400 KiB

Open AccessArticle

Comparative Fatigue Performance of Decarburized Surfaces in Railway Rails

by Apiwat Muttamara, Jinnaphat Sommanat, Chaosuan Kanchanomai and Ekkarut Viyanit

Materials 2024, 17(2), 290; https://doi.org/10.3390/ma17020290 - 06 Jan 2024

Viewed by 612

Abstract

This study explores the comparative fatigue performance of decarburized surfaces in railway components, emphasizing rolling contact fatigue, crack propagation, and acoustic emission. The investigation entails the examination of two grades of railway steels, namely R260 and U71Mn, to analyze crack and surface characteristics subsequent to fatigue testing employing a Twin Roller Machine. The purpose is to discern the impact of decarburization on the fatigue life of these materials. The results reveal distinct patterns in crack propagation and acoustic emission between decarburized and non-decarburized surfaces, providing valuable insights into the fatigue behavior of railway components. This comparative analysis contributes to a nuanced understanding of the material’s response to cyclic loading. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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20 pages, 6418 KiB

Open AccessArticle

Variation of Corrosion Rate, V_corr, during the Carbonation-Induced Corrosion Propagation Period in Reinforced Concrete Elements

by Javier Sánchez Montero, Pascual Saura Gómez, Julio Emilio Torres Martín, Servando Chinchón-Payá and Nuria Rebolledo Ramos

Materials 2024, 17(1), 101; https://doi.org/10.3390/ma17010101 - 24 Dec 2023

Viewed by 758

Abstract

The structural systems of residential buildings in many developed countries have widely utilized reinforced concrete as the most common solution in construction systems since the early 20th century. The durability of reinforced concrete columns and beams is compromised, in most cases, by pathologies caused by the corrosion of their reinforcements. This study analyses the corrosion processes induced by carbonation in 25 buildings with reinforced concrete structures. The models estimate the service life of reinforced concrete elements by differentiating between the initiation period and the propagation period of damage, considering two possible stages: the time of corrosion propagation until the cracking of the concrete cover, and the time of propagation until a loss of section is considered unacceptable for structural safety. However, the mathematical expressions that model the propagation periods consider the same corrosion rate in both cases. This research has found that the average corrosion rate in elements with an unacceptable loss of reinforcement section was in the order of 8 times higher than the corrosion rate in cracked columns and beams without a loss of reinforcement. This opens up a path to improve the definition of the different stages experienced by a reinforced concrete element suffering corrosion of its reinforcements due to carbonation, because once the concrete has cracked, the corrosion rate increases significantly. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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27 pages, 25761 KiB

Open AccessArticle

Impact Fracture Simulation of Laminated Glass Based on Thick Shell Elements and a Cohesive Zone Model

by Wei Xia, Zhen Yue and Mengyan Zang

Materials 2023, 16(21), 6966; https://doi.org/10.3390/ma16216966 - 30 Oct 2023

Cited by 1 | Viewed by 813

Abstract

Laminated glass is extensively used in automotive windshields, making it crucial to have a comprehensive understanding of its fracture mechanism to ensure driver and pedestrian safety in various windshield impact scenarios. Current research on the cohesive zone model of glass impact failure has encountered challenges related to accuracy and computational efficiency. This paper addresses these issues by utilizing the finite element software LS-DYNA, which integrates a cohesive zone model and thick shell (Tshell) elements to simulate and analyze the impact failure process of laminated glass. The combination of Tshell and cohesive elements was validated using a DCB example. Subsequently, the proposed method was applied to simulate the impact damage on an automobile’s front windshield, providing valuable insights from the obtained results. Finally, the influence of curvature, the number of layers, and the thickness ratio of each layer were investigated, leading to some valuable conclusions. Firstly, an increase in the thickness of the upper glass layer correlates with a decrease in the peak acceleration of the dummy-head model due to the ductility of PVB material. Secondly, when a curvature exists, the arched configuration of the windshield promotes higher resistance against impact, consequently leading to increased peak acceleration. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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19 pages, 6480 KiB

Open AccessArticle

Development of Al-Mg₂Si Alloy Hybrid Surface Composites by Friction Stir Processing: Mechanical, Wear, and Microstructure Evaluation

by R. Raja, Ragavanantham Shanmugam, Sabitha Jannet, G. B. Veeresh Kumar, N. Venkateshwaran, K. Naresh and Monsuru Ramoni

Materials 2023, 16(11), 4131; https://doi.org/10.3390/ma16114131 - 01 Jun 2023

Cited by 2 | Viewed by 1162

Abstract

Surface composites are viable choices for various applications in the aerospace and automotive industries. Friction Stir Processing (FSP) is a promising method for fabricating surface composites. Aluminum Hybrid Surface Composites (AHSC) are fabricated using the FSP to strengthen a hybrid mixture prepared with equal parts of Boron carbide (B₄C), Silicon Carbide (SiC), and Calcium Carbonate (CaCO₃) particles. Different hybrid reinforcement weight percentages (reinforcement content of 5% (T1), 10% (T2), and 15% (T3)) were used in fabricating AHSC samples. Furthermore, different mechanical tests were performed on hybrid surface composite samples with different weight percentages of the reinforcements. Dry sliding wear assessments were performed in standard pin-on-disc apparatus as per ASTM G99 guidelines to estimate wear rates. The presence of reinforcement contents and dislocation behavior was investigated using Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) studies. The results indicated that the Ultimate Tensile Strength (UTS) of sample T3 exhibited 62.63% and 15.17% higher than that of samples T1 and T2, respectively, while the Elongation (%) of T3 exhibited 38.46% and 15.38% lower than that of samples T1 and T2, respectively. Moreover, it was found that the hardness of sample T3 increased in the stir zone compared to samples T1 and T2, owing to its higher brittle response. The higher brittle response of sample T3 compared to samples T1 and T2 was confirmed by the higher value of Young’s modulus and the lower value of Elongation (%). Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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14 pages, 7597 KiB

Open AccessArticle

Fatigue Crack Growth Rate Description of RF-Plasma-Sprayed Refractory Metals and Alloys

by Ondrej Kovarik, Jan Cizek and Jakub Klecka

Materials 2023, 16(4), 1713; https://doi.org/10.3390/ma16041713 - 18 Feb 2023

Cited by 1 | Viewed by 1168

Abstract

A fitting method capable of describing the fatigue crack growth rate (FCGR) data in all stages of crack propagation by a simple Forman-style analytical formula was developed. To demonstrate its robustness, this method was used to quantify the fracture behavior of RF-plasma-sprayed W, Mo, W-Mo composite, and four selected Ni-based tungsten heavy alloys (WHA). The fitted FCGR parameters categorized the studied materials into two distinct sets. W, Mo, and W-Mo composite deposits made from inherently brittle refractory metals that contained a range of defects inherent to plasma spray process represented the first class. This class was characterized by low fracture toughness and a relatively wide range of fatigue crack growth thresholds. The second class of materials was represented by WHA. Here, the deposit defects were suppressed by liquid state diffusion that formed a typical WHA structure consisting of a Ni-rich matrix and large spherical W reinforcement particles. The WHA generally showed higher fatigue crack growth thresholds, but differed in fracture toughness values based on the W particle concentrations. The obtained fracture mechanical data represent a reference dataset of plasma-sprayed refractory materials, and their classification into groups clearly demonstrates the capabilities of the developed method to capture a wide range of different types of FCGR behavior. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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18 pages, 4939 KiB

Open AccessArticle

Experimental and RSM-Based Process-Parameters Optimisation for Turning Operation of EN36B Steel

by Ramesh Kumar, Ashwani Kumar, Laxmi Kant, Arbind Prasad, Sandeep Bhoi, Chandan Swaroop Meena, Varun Pratap Singh and Aritra Ghosh

Materials 2023, 16(1), 339; https://doi.org/10.3390/ma16010339 - 29 Dec 2022

Cited by 9 | Viewed by 1392

Abstract

The main objective of this article is to perform the turning operation on an EN36B steel work-billet with a tungsten carbide tool, to study the optimal cutting parameters and carry out an analysis of flank-wear. Experimental and simulation-based research methodology was opted in this study. Experimental results were obtained from the lab setup, and optimisation of parameters was performed using RSM (response surface methodology). Using RSM, cutting-tool flank-wear was optimised, and the cutting parameters which affect the flank wear were determined. In results main effect plot, contour plot, the surface plot for flank-wear and forces (Fx, Fy and Fz) were successfully obtained. It was concluded that tool flank-wear is affected by depth of cut, and that flank-wear generally increases linearly with increasing cutting-speed, depth of cut and feed-rate. To validate the obtained results, predicated and measured values were plotted and were in very close agreement, having an accuracy level of 96.33% to 98.92%. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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15 pages, 1819 KiB

Open AccessArticle

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

by Aki Sorsa, Mika Ruusunen, Suvi Santa-aho and Minnamari Vippola

Materials 2023, 16(1), 159; https://doi.org/10.3390/ma16010159 - 24 Dec 2022

Cited by 2 | Viewed by 1271

Abstract

Barkhausen noise (BN) measurements are commonly used for surface characterisation. However, often there is also a need to verify the sub-surface region because detrimental tensile stresses may be present after different manufacturing steps. Especially in a grinding burn, the surface stress may be compressive, but it changes quickly into tensile stress below the surface. The aim of this study was to find out whether regular surface-sensitive BN measurement is also sensitive to the stresses below the surface caused by grinding burns. More specifically, the aim was to study the relationship between BN features and sub-surface stresses and to identify a model that estimates sub-surface stresses. Real samples were collected from an actual process. The samples were cylindrical samples manufactured from commercial alloyed AISI/SAE L6 steel that was through-hardened prior to grinding. Barkhausen noise measurements were carried out for 42 grinding burn locations followed by X-ray diffraction-based residual stress surface measurements and residual stress depth profiles. Depth information was obtained through step-by-step electrolytic removal of thin layers. The stress profiles were pre-processed through interpolation and averaged stress was calculated as a function of depth below the surface. Correlation analysis was carried out to evaluate the relationships between BN features and stress at different depths and among BN features. The main outcome of the analysis was that BN measurement is dominated by the sub-surface tensile stresses rather than the compressive stress at the surface. It was also noticed that BN features form two groups, corresponding to average Barkhausen activity and magnetising field strength leading to maximum Barkhausen activity. Models for stress at different steps were identified systematically. The performance of the models for sub-surface stresses was reasonable with R² values of around 0.85 and root mean squared error (RMSE) values of around 95 MPa. Based on the results, it is concluded that BN measurement provides information about sub-surface stresses and that stress can be evaluated through straightforward modelling, allowing fast detection of grinding burns. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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13 pages, 2639 KiB

Open AccessArticle

Network Optimization of CNT Yarn Sensor Based on NNIA Algorithm in Damage Monitoring of 3D Braided Composites

by Minrui Jia, Zhenkai Wan, Xiaoyuan Pei, Jianmin Guo, Weichen Bao, Liying Gong, Yan Liu and Jun Zhao

Materials 2022, 15(23), 8534; https://doi.org/10.3390/ma15238534 - 30 Nov 2022

Cited by 2 | Viewed by 942

Abstract

In order to solve the optimization problem of carbon nanotube (CNT) yarn sensor network embedded in three-dimensional (3D) braided composite materials and realize the structural health monitoring of internal damage of aerospace parts, the multi-objective optimization of the number and location of sensors was studied using non-dominated neighborhood immune algorithm (NNIA). Through the research of 3D six-direction braiding process, stress sensitivity of single CNT yarn sensor, and damage location of 3D braided composites, the number, position, and coverage constraint functions based on NNIA algorithm are constructed. In addition, the number and position of three-dimensional braided composite embedded CNT yarn sensors with different sizes are solved. Through the stress experiment and data analysis of damaged parts, it is proved that the optimized configuration result of CNT yarn sensor obtained by NNIA algorithm is suitable for the damage monitoring of 3D braided composites. The damage location error is less than 1 mm. This study lays a foundation for the establishment of damage source localization model of 3D braided composites. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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24 pages, 8000 KiB

Open AccessArticle

Displacement Calculation for Service Loads of Reinforced Concrete Beams and Slabs Using Physically Non-Linear Analysis

by Antonio Renato Bicelli, Pedro Cantor, Rafael Wong and Mario Rui Arruda

Materials 2022, 15(23), 8307; https://doi.org/10.3390/ma15238307 - 23 Nov 2022

Cited by 1 | Viewed by 1512

Abstract

This paper aims to use non-linear physical analysis to calculate the displacement of beams and slabs in a cracked state. This study uses the commercial software SAP2000 to perform a numerical analysis using the finite element formulation, applying the multi-layer method. Initially, a parametric study was carried out to evaluate the vertical displacement for service loads of reinforced concrete beams and slabs using different spans, support conditions and geometry. In order to validate the finite element model, the study compared displacement values for linear analysis using Bares tables. Subsequently, simplified methods of displacement calculation in the long term are applied, using an abacus from Comité Euro-International du Béton (CEB). These values are then compared with the physically non-linear analysis in the long-term cracked state with SAP2000. Two structural codes were used in the numerical and analytical methods, Regulamento de Estruturas de Betão Armado e Pré-Esforçado (REBAP) and Eurocode 2 (EC2), to evaluate their differences in deformation control. Therefore, the main goal is to establish comparisons between the two methods of analysis in order to show that non-linear finite element modelling provides values that are lower than the analytical calculation, thus allowing greater economy in the design of structural reinforced concrete elements. In addition, it can be noted that EC2 has some inconsistencies in the design of simply supported slabs, requiring a greater thickness than a flat square slab and that indirect deformation for REBAP is underestimated for beams and, in some cases, for slabs. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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Review

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47 pages, 9139 KiB

Open AccessReview

A Comprehensive Review of Self-Healing Polymer, Metal, and Ceramic Matrix Composites and Their Modeling Aspects for Aerospace Applications

by Sri Ram Murthy Paladugu, P. S. Rama Sreekanth, Santosh Kumar Sahu, K. Naresh, S. Arun Karthick, N. Venkateshwaran, Monsuru Ramoni, Rhoda Afriyie Mensah, Oisik Das and Ragavanantham Shanmugam

Materials 2022, 15(23), 8521; https://doi.org/10.3390/ma15238521 - 29 Nov 2022

Cited by 15 | Viewed by 3672

Abstract

Composites can be divided into three groups based on their matrix materials, namely polymer, metal and ceramic. Composite materials fail due to micro cracks. Repairing is complex and almost impossible if cracks appear on the surface and interior, which minimizes reliability and material life. In order to save the material from failure and prolong its lifetime without compromising mechanical properties, self-healing is one of the emerging and best techniques. The studies to address the advantages and challenges of self-healing properties of different matrix materials are very limited; however, this review addresses all three different groups of composites. Self-healing composites are fabricated to heal cracks, prevent any obstructed failure, and improve the lifetime of structures. They can self-diagnose their structure after being affected by external forces and repair damages and cracks to a certain degree. This review aims to provide information on the recent developments and prospects of self-healing composites and their applications in various fields such as aerospace, automobiles etc. Fabrication and characterization techniques as well as intrinsic and extrinsic self-healing techniques are discussed based on the latest achievements, including microcapsule embedment, fibers embedment, and vascular networks self-healing. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Advanced Materials and Composites: Experiment, Modeling and Theory)

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