Search

In-situ manufacturing of thermoplastic composites using the automated fiber placement (AFP) process consists of heating, consolidation and solidification steps. During the heating step using hot gas torch (HGT) as a moving heat source, the incoming tape and the substrate are heated up to a temperature above the melting point of the thermoplastic matrix. The convective heat transfer occurs between the hot gas flow and the composites in which the convective heat transfer coefficient h plays an important role in the heat transfer mechanism which in turn significantly affects temperature distribution along the length, width and through the thickness of the deposited layers. Temperature is the most important process parameter in AFP in-situ consolidation that affects bonding quality, crystallization and consolidation. Although it is well known the convective heat transfer coefficient h is not constant and has a distribution, most studies have assumed a constant value for h for heat transfer analysis which leads to discrepancy between numerical and experimental results. In this study a new function is proposed to approximate the distribution of the convective heat transfer coefficient h in the vicinity of the nip point. Using the proposed convective heat transfer coefficient distribution, a three-dimensional finite element transient heat transfer analysis is performed to predict temperature distribution in the composite parts. An optimization loop is employed to find the free parameters of the distribution function so that the predicted temperature match experimental data. It is shown that, unlike other studies assuming constant h value, not only maximum temperature can be well predicted, but also predicted heating and cooling curves agree well with experimental results. The cooling rate is of significant importance in crystallization behavior and residual stress calculation.

Fatigue evaluation based on the effective notch stress approach requires stress concentration factors for idealized notch geometries. In this paper, stress concentration factors are calculated numerically for different idealizations of the weld geometry. The joints covered here are one-sided Y-butt joints and two-sided DY-butt joints, each with partial and full penetration. The variable parameters of the finite element models are the weld flank angle, the notch radius, the sheet thickness, the ratio of weld seam width to sheet thickness, and the ratio of height of non-fused root face to sheet thickness. Existing estimation formulae for stress concentration factors will be compared with new methods for stress concentration factor estimation: (a) polynomial regression using mixed terms and (b) artificial neural networks. These two methods show similar or superior quality compared with the existing estimations which is expressed through lower estimation errors with respect to the numerically calculated stress concentration factors. The database for the regression analysis using methods (a) and (b) consists of a total of 11,871 design alternatives obtained by finite element analysis. In addition to the improved quality of prognosis, the range of allowable geometrical parameters is significantly increased compared with the existing formulae. The methods (a) and (b) provide a possibility to a fast estimation of stress concentration factors of sufficient quality for a large range of geometrical weld seam parameters. The presented formulae could also be part of a programmed solution.

Stress concentration factors (SCF) related to specific geometries, loadings and stress quantities can be calculated efficiently using approximate equations. Those relations are typically based on metamodeling via the results of linear elastic analyses. Existing equations for the, technically speaking, very important circular shafts with shoulder fillets or U-shaped notches under bending, torsion or tension/compression can be appropriated, for example, from the DIN 743-2 : 2012-12. Using these relations requires compliance with underlying constraints and assumptions. For example, equations from that code do not provide SCFs larger than 6 and refer only to the maximum principle stress. Furthermore, DIN 743-2 : 2012-12 does not provide SCFs for combined loading, i. e. simultaneous bending, torsion and tensile/compressive loading. This paper presents new and improved equations based on sampling computational finite element simulations and subsequent regression analyses. Multiple improvements could be achieved: The six equations for circular shafts with shoulder fillets or U-shaped grooves derived from DIN 743-2 : 2012-12 were simplified down to two equations. Despite this simplification, the new equations have been generalized for combined loading and include SCFs larger than 6 as well. Choosing between various equations for each type of loading is no longer necessary. Only one equation for each of the two basic geometries is needed. Moreover, two further equations which refer to von Mises equivalent stress have been added. Although the new equations are easier to handle and allow for an estimation of stress concentration factors larger than 6, the accuracy of the new equations is higher than the accuracy of DIN 743-2 : 2012–12 when compared to SCFs derived from finite element simulation as reference values.

Commonly, to evaluate the influence of the local weld geometry in fatigue test, small-scale specimens are used, assuming those represent a longer weld adequately. In this study, a comparison between short specimens and a long weld is performed. A method is developed for the statistical evaluation of weld toe radii and angles, stress concentration factors and weld quality classes. The results show a strong sampling rate dependence and lower ISO 5817:2014 weld quality results for higher sampling rates. Comparable results between short specimens and a long weld can be achieved using modal values of the parameters assuming a lognormal distribution.

The main aim of the project was to evaluate the influence of combined effects of fatigue loading and exposure to cyclic corrosion testing on the corrosion and the fatigue resistances of coated thin sheet steel joined by spot welding. Seven types of steel including cold rolled mild steels, high-strength steels, and press-hardened steels (PHS) were selected and provided by steel suppliers for fatigue strength evaluation of resistance spot welding (RSW) assemblies. Panels were joined using conventional resistance spot welding in both lap-shear and T-peel designs. Joined samples were painted by e-coating following the industrial process. Metallographic characterization of the steels revealed that microstructures and metallic coating composition and thickness were as expected. Cross-section of spot welds showed good quality and typical evolutions of hardness. Tensile tests performed on reference samples (non-exposed to corrosion) showed tensile which were obviously configuration and material dependent. For each configuration, three replicates were tested and did not show significant scatter. The results were and will be used to evaluate the influence of corrosion on tensile strength of the joined samples. Fatigue tests were performed “in air”, meaning without corrosion exposition, leading to typical SN-lines. The results will be used to evaluate the influence of corrosion on the fatigue resistance of the joined samples.

The main aim of the project was to evaluate the influence of combined effects of fatigue loading and exposure to cyclic corrosion testing on the corrosion and the fatigue resistances of coated thin ...

The aim of this study is to evaluate fatigue performance of joined assemblies (spot weld and/or adhesive bonding) in corrosive environment. Various assemblies have been tested in alternated and simultaneous fatigue-corrosion modes. Adhesive joints are strongly affected by simultaneous fatigue-corrosion with a large drop of the fatigue life compared to results in air. By alternating fatigue and corrosion, the reduction of fatigue life is important. For spot welding, fatigue life is decreased at higher load amplitudes and increased at lower amplitudes. These results are strongly linked to the opening of the gap near the spot weld at high load amplitudes. At low amplitudes, corrosion might limit the local stress at the notch root of the weld.

As elastic–plastic fatigue analyses are still time consuming the simplified elastic–plastic analysis (e.g. ASME Section III, NB 3228.5, the French RCC-M code, paragraphs B 3234.3, B 3234.5 and B3234.6 and the German KTA rule 3201.2, paragraph 7.8.4) is often applied. Besides linearly elastic analyses and factorial plasticity correction (Ke factors) direct methods are an option. In fact, calculation effort and accuracy of results are growing in the following graded scheme: a) linearly elastic analysis along with Ke correction, b) direct methods for the determination of stabilized elastic–plastic strain ranges and c) incremental elastic–plastic methods for the determination of stabilized elastic–plastic strain ranges. The paper concentrates on option b) by substantiating the practical applicability of the simplified theory of plastic zones STPZ (based on Zarka's method) and – for comparison – the established Twice-Yield method. The Twice-Yield method is explicitly addressed in ASME Code, Section VIII, Div. 2. Application relevant aspects are particularly addressed. Furthermore, the applicability of the STPZ for arbitrary load time histories in connection with an appropriate cycle counting method is discussed. Note, that the STPZ is applicable both for the determination of (fatigue relevant) elastic–plastic strain ranges and (ratcheting relevant) locally accumulated strains. This paper concentrates on the performance of the method in terms of the determination of elastic–plastic strain ranges and fatigue usage factors. The additional performance in terms of locally accumulated strains and ratcheting will be discussed in a future publication.