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Numerical Simulation Methods for Analyzing Fatigue and Fracture Behavior in Metallic Materials

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

Deadline for manuscript submissions: 20 July 2024 | Viewed by 6342

Special Issue Editors

Prof. Dr. Ulrich Prahl

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Guest Editor
Institute of Metal Forming, Technische Universität Bergakademie Freiberg, Bernhard-von-Cotta-Straße 4, 09599 Freiberg, Germany
Interests: ICME—numerical material and process modeling for metallic materials; production processes (forming and heat treatment) for modern steels; development of alloy concepts and process technologies for the nanostructuring of structures as well as for the adjustment of metastable micro-structural phases; combination of experimental laboratory techniques with numerical simulation to model, evaluate and optimize industrial forming and heat treatment processes; forming technology
Special Issues, Collections and Topics in MDPI journals
Dr. Sergey Guk

E-Mail Website
Guest Editor
Institut für Metallformung, TU Bergakademie Freiberg, 09599 Freiberg, Germany
Interests: thermomechanical processes; metallic materials; materials processing; mechanical behavior; microstructure; crystallography; mechanical testing; mechanical properties
Special Issues, Collections and Topics in MDPI journals
Dr. Faisal Qayyum

E-Mail Website
Guest Editor
Institut für Metallformung, Technische Universität Bergakademie Freiberg, 09599 Freiberg, Germany
Interests: multi-physics modeling; fatigue and fracture; crack propagation; crystal plasticity; metal matrix composite; material characterization; finite element analysis
Special Issues, Collections and Topics in MDPI journals
Dr. Hassan Elahi

E-Mail Website1 Website2
Guest Editor
1. Department of Mechanical and Aerospace Engineering, Sapienza University of Rome, 00185 Rome, Italy
2. Department of Mechatronics Engineering, College of Electrical and Mechanical Engineering, NUST, Islamabad, Pakistan
Interests: energy harvesting; piezoelectric materials; MEMS; NEMS; IoT; smart structures; fatigue
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

An understanding of failure phenomena allows scientists to improve mechanical properties using new manufacturing technologies or invent new materials that meet the desired requirements. One of the broadest classes of structural materials are the metallic materials. These materials are of great interest to science, especially because of their applications, and they permanently expand the spectrum of scientific research into the processes of fatigue failure mechanisms. With the recent improvement of immense computing power, research has been increasing on the use of different numerical modeling and data-driven machine-learning-based methods to analyze fatigue and fracture behavior at all length scales. This is an important research trend. In this regard, research is carried out at various levels of general and micro/nanoscales. The selection of tools based on artificial intelligence is also a real challenge.

The goal of this Special Issue is to publish and highlight the most recent research on this topic in order to advance our understanding of the mechanical and fatigue-life behavior of single- and multiphase metallic materials. Accepted research will focus on new advanced methods or techniques to test, analyze, and monitor the behavior of a material or component during fatigue or fracture mechanics loads. Research based on different numerical models and data-driven approaches for predicting the fatigue life of metallic materials at all scales will be highly prioritized.

Prof. Dr. Ulrich Prahl
Dr. Sergey Guk
Dr. Faisal Qayyum
Dr. Hassan Elahi
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metallic metals
  • fatigue
  • crack propagation
  • microstructural attributes
  • numerical simulations
  • data-driven material modeling
  • artificial neural networks
  • life-cycle predictions

Published Papers (4 papers)

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Research

21 pages, 69865 KiB  
Article
Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy
by Aziz Ul Hassan Mohsan, Mina Zhang, Dafeng Wang, Yishen Wang, Jiahao Zhang, Yanyuan Zhou, Yifei Li and Su Zhao
Materials 2024, 17(5), 969; https://doi.org/10.3390/ma17050969 - 20 Feb 2024
Viewed by 628
Abstract
The design of the resonant ultrasonic vibration-assisted laser cladding (R-UVALC) setup involved employing finite element analysis (FEA) to simulate the ultrasonic transducer, horn, and workpiece in a resonance state. The impact of R-UVALC on AlCrFeMnNi high-entropy alloys was assessed using various ultrasonic vibration [...] Read more.
The design of the resonant ultrasonic vibration-assisted laser cladding (R-UVALC) setup involved employing finite element analysis (FEA) to simulate the ultrasonic transducer, horn, and workpiece in a resonance state. The impact of R-UVALC on AlCrFeMnNi high-entropy alloys was assessed using various ultrasonic vibration amplitudes of 0, 5, 10, and 15 µm, with a constant frequency of 20 kHz. Ultrasonic vibrations reduced pores and cracks and increased the clad breadth, melt pool wetting angle, and laser-clad layer consistency. The columnar elongated grains in proximity to the substrate surface underwent a size reduction and transformed into grains with a more equiaxed shape with the utilization of ultrasonic vibrations at an amplitude of 5 µm. Laser cladding performed without ultrasonic vibrations yields two phases: face-centered cubic (FCC) and body-centered cubic (BCC). However, when the coating is exposed to ultrasonic vibrations with an amplitude of 5 µm, it forms a solitary body-centered cubic (BCC) phase. The microhardness tripled compared to the substrate, and the most significant microhardness value was achieved at 5 µm of ultrasonic vibration. The friction coefficient was assessed at an ambient temperature, revealing that an ultrasonic amplitude yields the lowest friction coefficient, demonstrating the excellent wear resistance properties of the coating. The analysis of the 3D surface profile of the wear indicates that the use of ultrasonic aid with a 5 µm amplitude leads to reduced depth of scars, and the primary wear mechanism observed is abrasive and oxidative wear with fewer grooves and debris. In addition, XPS analysis revealed the presence of metal components in an oxidized condition, suggesting that the wear process is oxidative in nature. Integrating the R-UVALC setup into a resonance state can significantly enhance the efficiency of the laser cladding process in the laser cladding field. Full article
(This article belongs to the Special Issue Numerical Simulation Methods for Analyzing Fatigue and Fracture Behavior in Metallic Materials)
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15 pages, 11416 KiB  
Article
A Micromechanical Analysis to the Viscoplastic Behavior of Sintered Silver Joints under Shear Loading
by Kun Ma, Xun Liu, Yameng Sun, Yifan Song, Zheng Feng, Yang Zhou and Sheng Liu
Materials 2023, 16(12), 4472; https://doi.org/10.3390/ma16124472 - 19 Jun 2023
Viewed by 1381
Abstract
Ag paste has been recognized as a promising substitute for Sn/Pb solder in SiC or GaN power electronic devices, owing to its ability to withstand high temperatures and facilitate low-temperature packing. The reliability of these high-power circuits is greatly influenced by the mechanical [...] Read more.
Ag paste has been recognized as a promising substitute for Sn/Pb solder in SiC or GaN power electronic devices, owing to its ability to withstand high temperatures and facilitate low-temperature packing. The reliability of these high-power circuits is greatly influenced by the mechanical properties of sintered Ag paste. However, there exist substantial voids inside the sintered silver layer after sintering, and the conventional macroscopic constitutive models have certain limitation to describe the shear stress–strain relationship of sintered silver materials. To analyze the void evolution and microstructure of sintered silver, Ag composite pastes composed of micron flake silver and nano-silver particles were prepared. The mechanical behaviors were studied at different temperatures (0–125 °C) and strain rates (1 × 10−4–1 × 10−2) for Ag composite pastes. The crystal plastic finite element method (CPFEM) was developed to describe the microstructure evolution and shear behaviors of sintered silver at varied strain rates and ambient temperatures. The model parameters were obtained by fitting experimental shear test data to a representative volume element (RVE) model built on representative volume elements, also known as Voronoi tessellations. The numerical predictions were compared with the experimental data, which showed that the introduced crystal plasticity constitutive model can describe the shear constitutive behavior of a sintered silver specimen with reasonable accuracy. Full article
(This article belongs to the Special Issue Numerical Simulation Methods for Analyzing Fatigue and Fracture Behavior in Metallic Materials)
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19 pages, 8584 KiB  
Article
Molecular Dynamics Study on Crack Propagation in Al Containing Mg–Si Clusters Formed during Natural Aging
by Sangjun Lee, Heon Kang and Donghyun Bae
Materials 2023, 16(2), 883; https://doi.org/10.3390/ma16020883 - 16 Jan 2023
Cited by 2 | Viewed by 1583
Abstract
The crack propagation behavior of Al containing Mg–Si clusters is investigated using molecular dynamics (MD) simulations to demonstrate the relationship between the natural aging time in Al–Si–Mg alloys and ductility. Experimental results show that the elongation at failure decreases with natural aging. There [...] Read more.
The crack propagation behavior of Al containing Mg–Si clusters is investigated using molecular dynamics (MD) simulations to demonstrate the relationship between the natural aging time in Al–Si–Mg alloys and ductility. Experimental results show that the elongation at failure decreases with natural aging. There are few studies on the relationship between natural aging and ductility because of the difficult observation of Mg–Si clusters. To solve the difficulty, cracked Al containing Mg–Si clusters of varying sizes are assumed for the MD simulations. A larger Mg–Si cluster in Al results in earlier crack opening and dislocation emission. Moreover, as the Mg–Si cluster size increases, the stress near the crack tip becomes more concentrated. This causes rapid crack propagation, a similar effect to that of crack tip sharpening. As a result of long-term natural aging, the cracks expand rapidly. The influence of geometry is also investigated. Crack lengthening and thickness reduction negatively impact the fracture toughness, with the former having a larger impact than the latter. Although there are several discrepancies in the practical deformation conditions, the simulation results can help to more thoroughly understand natural aging in Al–Si–Mg alloys. Full article
(This article belongs to the Special Issue Numerical Simulation Methods for Analyzing Fatigue and Fracture Behavior in Metallic Materials)
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20 pages, 4146 KiB  
Article
The Effect of the Energy Release Rate on the Local Damage Evolution in TRIP Steel Composite Reinforced with Zirconia Particles
by Shao-Chen Tseng, Chen-Chun Chiu, Faisal Qayyum, Sergey Guk, Ching-Kong Chao and Ulrich Prahl
Materials 2023, 16(1), 134; https://doi.org/10.3390/ma16010134 - 23 Dec 2022
Cited by 2 | Viewed by 1740
Abstract
In this study, the effect of the energy release rate on the transformation-induced plasticity (TRIP) steel composite reinforced with 5 vol% ceramic particles is determined using the crystal plasticity simulation of the coupled brittle-ductile damage model and validated by experimental results. A miniature [...] Read more.
In this study, the effect of the energy release rate on the transformation-induced plasticity (TRIP) steel composite reinforced with 5 vol% ceramic particles is determined using the crystal plasticity simulation of the coupled brittle-ductile damage model and validated by experimental results. A miniature dog bone tensile sample is subjected to an interrupted in situ quasi-static tensile test up to a true strain of 20.3%. Using the commercial digital image correlation program VEDDAC and the image processing method in MATLAB, the test data are utilized to monitor the progress of local microstrain and damage. The impact of the energy release rate of ceramic particles is investigated by simulation using a coupled crystal plasticity-dislocation density model with ductile–brittle criteria for the corresponding phases. It can be shown that the local deformations predicted by the numerical simulation and the experimental data are qualitatively comparable. The damage pixel of the experiment, smaller Ecr (1.0 × 108), and larger Ecr (1.2 × 108) cases of energy release rates are 4.9%, 4.3%, and 5.1%, respectively. Furthermore, on a global strain of 20.3%, the relative error between simulation and experimental validation of smaller Ecr (1.0 × 108) and larger Ecr (1.2 × 108) cases is 12.2% and 4%, respectively. Full article
(This article belongs to the Special Issue Numerical Simulation Methods for Analyzing Fatigue and Fracture Behavior in Metallic Materials)
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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Fatigue life prediction of GH4202 alloy under random vibration loading by combining the stress-life model and the strain-life model
Authors: YiChen HAN (1); Ce XIAO* (1); ZHi ZHAI (1); XUEGANG HUANG (2); GUANGXI LI(1,2)
Affiliation: 1.School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China 2. Xi’an Aerospace Propulsion Institute, Xi’an 710100, China)
Abstract: In order to assess the random vibration fatigue life of GH4202 alloy, vibration fatigue tests of plate samples of different loading levels were carried out, and based on the principle of damage accumulation, the life assessment of GH4202 alloy was carried out in the frequency domain with the stress-life model and the strain-life model, respectively. Based on the experimental and simulation results, a new method of random vibration fatigue life assessment of metallic alloys is proposed by combining the stress-life model and the strain-life model.

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