04 Fakultät Energie-, Verfahrens- und Biotechnik
Permanent URI for this collectionhttps://elib.uni-stuttgart.de/handle/11682/5
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Item Open Access Assessing fatigue life cycles of material X10CrMoVNb9-1 through a combination of experimental and finite element analysis(2023) Rahim, Mohammad Ridzwan Bin Abd; Schmauder, Siegfried; Manurung, Yupiter H. P.; Binkele, Peter; Dusza, Ján; Csanádi, Tamás; Ahmad, Meor Iqram Meor; Mat, Muhd Faiz; Dogahe, Kiarash JamaliThis paper uses a two-scale material modeling approach to investigate fatigue crack initiation and propagation of the material X10CrMoVNb9-1 (P91) under cyclic loading at room temperature. The Voronoi tessellation method was implemented to generate an artificial microstructure model at the microstructure level, and then, the finite element (FE) method was applied to identify different stress distributions. The stress distributions for multiple artificial microstructures was analyzed by using the physically based Tanaka-Mura model to estimate the number of cycles for crack initiation. Considering the prediction of macro-scale and long-term crack formation, the Paris law was utilized in this research. Experimental work on fatigue life with this material was performed, and good agreement was found with the results obtained in FE modeling. The number of cycles for fatigue crack propagation attains up to a maximum of 40% of the final fatigue lifetime with a typical value of 15% in many cases. This physically based two-scale technique significantly advances fatigue research, particularly in power plants, and paves the way for rapid and low-cost virtual material analysis and fatigue resistance analysis in the context of environmental fatigue applications.Item Open Access Feasibility study on additive manufacturing of ferritic steels to meet mechanical properties of safety relevant forged parts(2022) Mally, Linda; Werz, Martin; Weihe, StefanAdditive manufacturing processes such as selective laser melting are rapidly gaining a foothold in safety-relevant areas of application such as powerplants or nuclear facilities. Special requirements apply to these applications. A certain material behavior must be guaranteed and the material must be approved for these applications. One of the biggest challenges here is the transfer of these already approved materials from conventional manufacturing processes to additive manufacturing. Ferritic steels that have been processed conventionally by forging, welding, casting, and bending are widely used in safety-relevant applications such as reactor pressure vessels, steam generators, valves, and piping. However, the use of ferritic steels for AM has been relatively little explored. In search of new materials for the SLM process, it is assumed that materials with good weldability are also additively processible. Therefore, the processability with SLM, the process behavior, and the achievable material properties of the weldable ferritic material 22NiMoCr3-7, which is currently used in nuclear facilities, are investigated. The material properties achieved in the SLM are compared with the conventionally forged material as it is used in state-of-the-art pressure water reactors. This study shows that the ferritic-bainitic steel 22NiMoCr3-7 is suitable for processing with SLM. Suitable process parameters were found with which density values > 99% were achieved. For the comparison of the two materials in this study, the microstructure, hardness values, and tensile strength were compared. By means of a specially adapted heat treatment method, the material properties of the printed material could be approximated to those of the original block material. In particular, the cooling medium/cooling method was adapted and the cooling rate reduced. The targeted ferritic-bainitic microstructure was achieved by this heat treatment. The main difference found between the two materials relates to the grain sizes present. For the forged material, the grain size distribution varies between very fine and slightly coarse grains. The grain size distribution in the printed material is more uniform and the grains are smaller overall. In general, it was difficult and only minimal possible to induce grain growth. As a result, the hardness values of the printed material are also slightly higher. The tensile strength could be approximated to that of the reference material up to 60 MPa. The approximation of the mechanical-technological properties is therefore deemed to be adequate.Item Open Access Increasing low-temperature toughness of 09Mn2Si steel through lamellar structuring by helical rolling(2021) Panin, Sergey; Vlasov, Ilya; Moiseenko, Dmitry; Maksimov, Pavel; Maruschak, Pavlo; Yakovlev, Alexander; Gomorova, Julia; Mishin, Ivan; Schmauder, SiegfriedThe aim of the paper was to investigate the helical rolling parameters (a number of passes) for the microstructural modification and the low-temperature impact toughness improvement of the 09Mn2Si High Strength Low-Alloyed (HSLA) steel. In order to achieve this purpose, work spent to crack initiation and propagation was analyzed and compared with patterns of fracture surfaces. The microstructure and impact toughness values were presented in the temperature range from +20 to -70°C. Also, the fracture mechanisms in individual regions on the fracture surfaces were discussed. In addition, a methodology for computer simulation of the process was developed and implemented within the framework of the excitable cellular automata method and its integration with the kinetic theory of fracture. Finally, a theoretical analysis of the effect of grain shapes and orientations on the strain response patterns of a certain meso-volume simulating the material after the helical rolling was carried out.Item Open Access Simulation of the fatigue crack initiation in SAE 52100 martensitic hardened bearing steel during rolling contact(2022) Dogahe, Kiarash Jamali; Guski, Vinzenz; Mlikota, Marijo; Schmauder, Siegfried; Holweger, Walter; Spille, Joshua; Mayer, Joachim; Schwedt, Alexander; Görlach, Bernd; Wranik, JürgenAn investigation on the White Etching Crack (WEC) phenomenon as a severe damage mode in bearing applications led to the observation that in a latent pre-damage state period, visible alterations appear on the surface of the raceway. A detailed inspection of the microstructure underneath the alterations reveals the existence of plenty of nano-sized pores in a depth range of 80 µm to 200 µm. The depth of the maximum Hertzian stress is calculated to be at 127 µm subsurface. The present study investigates the effect of these nanopores on the fatigue crack initiation in SAE 52100 martensitic hardened bearing steel. In this sense, two micro-models by means of the Finite Element Method (FEM) are developed for both a sample with and a sample without pores. The number of cycles required for the crack initiation for both samples is calculated, using the physical-based Tanaka-Mura model. It is shown that pores reduce the number of cycles in bearing application to come to an earlier transition from microstructural short cracks (MSC) to long crack (LC) propagation significantly.Item Open Access Deformation behavior investigation of auxetic structure made of poly(butylene adipate-co-terephthalate) biopolymers using finite element method(2023) Schneider, Yanling; Guski, Vinzenz; Schmauder, Siegfried; Kadkhodapour, Javad; Hufert, Jonas; Grebhardt, Axel; Bonten, ChristianAuxetic structures made of biodegradable polymers are favorable for industrial and daily life applications. In this work, poly(butylene adipate-co-terephthalate) (PBAT) is chosen for the study of the deformation behavior of an inverse-honeycomb auxetic structure manufactured using the fused filament fabrication. The study focus is on auxetic behavior. One characteristic of polymer deformation prediction using finite element (FE) simulation is that no sounded FE model exists, due to the significantly different behavior of polymers under loading. The deformation behavior prediction of auxetic structures made of polymers poses more challenges, due to the coupled influences of material and topology on the overall behavior. Our work presents a general process to simulate auxetic structural deformation behavior for various polymers, such as PBAT, PLA (polylactic acid), and their blends. The current report emphasizes the first one. Limited by the state of the art, there is no unified regulation for calculating the Poisson’s ratio n for auxetic structures. Here, three calculation ways of n are presented based on measured data, one of which is found to be suitable to present the auxetic structural behavior. Still, the influence of the auxetic structural topology on the calculated Poisson’s ratio value is also discussed, and a suggestion is presented. The numerically predicted force-displacement curve, Poisson’s ratio evolution, and the deformed auxetic structural status match the testing results very well. Furthermore, FE simulation results can easily illustrate the stress distribution both statistically and local-topology particularized, which is very helpful in analyzing in-depth the auxetic behavior.Item Open Access Experimental investigations of micro-meso damage evolution for a Co/WC-type tool material with application of digital image correlation and machine learning(2021) Schneider, Yanling; Zielke, Reiner; Xu, Chensheng; Tayyab, Muhammad; Weber, Ulrich; Schmauder, Siegfried; Tillmann, WolfgangCommercial Co/WC/diamond composites are hard metals and very useful as a kind of tool material, for which both ductile and quasi-brittle behaviors are possible. This work experimentally investigates their damage evolution dependence on microstructural features. The current study investigates a different type of Co/WC-type tool material which contains 90 vol.% Co instead of the usual <50 vol.%. The studied composites showed quasi-brittle behavior. An in-house-designed testing machine realizes the in-situ micro-computed tomography (µCT) under loading. This advanced equipment can record local damage in 3D during the loading. The digital image correlation technique delivers local displacement/strain maps in 2D and 3D based on tomographic images. As shown by nanoindentation tests, matrix regions near diamond particles do not possess higher hardness values than other regions. Since local positions with high stress are often coincident with those with high strain, diamonds, which aim to achieve composites with high hardnesses, contribute to the strength less than the WC phase. Samples that illustrated quasi-brittle behavior possess about 100-130 MPa higher tensile strengths than those with ductile behavior. Voids and their connections (forming mini/small cracks) dominant the detected damages, which means void initiation, growth, and coalescence should be the damage mechanisms. The void appears in the form of debonding. Still, it is uncovered that debonding between Co-diamonds plays a major role in provoking fatal fractures for composites with quasi-brittle behavior. An optimized microstructure should avoid diamond clusters and their local volume concentrations. To improve the time efficiency and the object-identification accuracy in µCT image segmentation, machine learning (ML), U-Net in the convolutional neural network (deep learning), is applied. This method takes only about 40 min. to segment more than 700 images, i.e., a great improvement of the time efficiency compared to the manual work and the accuracy maintained. The results mentioned above demonstrate knowledge about the strengthening and damage mechanisms for Co/WC/diamond composites with >50 vol.% Co. The material properties for such tool materials (>50 vol.% Co) is rarely published until now. Efforts made in the ML part contribute to the realization of autonomous processing procedures in big-data-driven science applied in materials science.Item Open Access Validierung der 3D-Prozesskarte und Entwicklung von Prozessstrategien für das äquiaxiale Kornwachstum im Laserstrahlschweißen von Aluminium(2021) Nasr, YassinUm das äquiaxial dendritische Kornwachstum abhängig von den Prozessparametern im Laserstrahlschweißprozess von Aluminiumlegierungen einstellen zu können wurde die 3D-Prozesskarte entwickelt. Diese gibt eine erforderliche tiefenspezifische Laserleistung, welche für das äquiaxiale Kornwachstum absorbiert werden muss, für eine beliebige Aluminiumlegierung in Abhängigkeit der Schweißgeschwindigkeit an. In vorangegangenen Experimenten wurde der prozessseitige Einfluss auf die Kornstruktur für die Legierung EN AW-6016 untersucht und validiert. Um den werkstoffseitigen Einfluss auf die Kornstruktur zu validieren, wurden im Rahmen dieser Arbeit Laserstrahlschweißungen mit fünf verschiedenen Legierungen durchgeführt. Dabei wurden die Prozessparameter Fokusdurchmesser, Laserleistung, Schweißgeschwindigkeit und Blechstärke variiert. Die Kornstruktur der Schweißnähte wurde anschließend mithilfe metallografischer Schliffe untersucht.Item Open Access Numerische Simulationen von bioinspirierten und natürlichen Materialien(2021) Schäfer, Immanuel; Schmauder, Siegfried (Prof. Dr. rer. nat. Dr. h. c.)Die Arbeit befasst sich mit Finite-Elemente-Simulationen und Modellierungen von natürlichen und bioinspirierten Materialien. Die bioinspirierten Materialien sind künstliche Materialien, die ein oder mehrere Prinzipien der biologischen Vorbilder erfolgreich umgesetzt haben. Die natürlichen Materialien sind biologischen Ursprungs. Zu Beginn benötigt man immer eine funktionelle Analyse des Systems, um dann die notwendigen Reduzierungen für die Modellierungen herstellen zu können. Wenn das Modell steht, werden Eigenschaften wie zum Beispiel die Dämpfung oder der Widerstand gegen eine lineare Krafteinwirkung in Finite-Elemente-Simulationen analysiert. Die daraus gewonnenen Ergebnisse werden zur Beurteilung des Versagenverhaltens (z. B. des natürlichen Materials) oder zur Erklärung der Eigenschaften des bioinspirierten Materials genutzt. Die vorliegende Arbeit ist in die Analyse und die Diskussion der Ergebnisse verschiedener Materialien in neun Veröffentlichungen unterteilt. Zu Beginn werden die Ergebnisse des ersten bionischen Projektes präsentiert sowie die Lichtaufnahme, Lichtleitung- und Lichtverarbeitungsmöglichkeiten einer sukkulenten Art, der Fensterpflanze diskutiert. Die Perlmuttschale einer Schnecke bzw. ihr bioinspiriertes Produkt ist das Thema der anschließend vorgestellten Arbeiten. Daraus hervor ging auch die Veröffentlichung zu Enzymen und deren Bindungsaffinitäten zu Zinkoxid. Die Schale der Pomelo, die die kiloschwere Frucht beim Herunterfallen von den ca. 15 m hohen Bäumen vor Beschädigungen schützt, ist das Vorbild für einen Metallschaum im nächsten Beispiel. Als letztes werden die Vorbilder Kokosnuss und Seeigelstachel präsentiert, die im Rahmen eines Transregios (einem von der Deutschen Forschungsgemeinschaft (DFG) geförderten Sonderforschungsbereich, TRR 141) betrachtet wurden. Für den TRR 141 wurde auch eine Ausstellung im Naturkundemuseum Stuttgart organisiert. Im Kapitel 12 wird eine Präsentationsstation beschrieben, die mit NFC(Near-Field-Communication)-Chips gesteuert werden kann. Die Präsentationsstation wurde im Rahmen dieser Arbeit entwickelt und mit dem Museum zusammen gebaut. Mit ihr werden Filme und Präsentationen zu dem Thema des TRR mit Ausstellungsgegenständen (z. B. eine 3D gedruckte Struktur des Seeigelstachels in Vergrößerung) kombiniert. Auf diese Weise zeigt die vorliegende kumulative Dissertation einen Überblick über die gesamten bionischen Arbeiten, die am Institut für Materialprüfung, Werkstoffkunde und Festigkeitslehre bei Herrn Prof. Dr. rer. nat. Dr. h. c. Siegfried Schmauder mit meiner Beteiligung entstanden sind.Item Open Access Numerical investigations on the damage behaviour of a reconstructed anode for solid oxide fuel cell application(2021) Steier, Katharina; Guski, Vinzenz; Schmauder, SiegfriedThis paper addresses the damage behaviour of a nickel/yttria-stabilised zirconia (Ni-YSZ) anode, in order to understand microstructural degradation processes of Solid Oxide Fuel Cells (SOFCs) during long-term operation. Numerical investigations are carried out to analyse the failure mechanisms in detail. For this purpose, finite element (FE) models are generated from focused ion beam-scanning electron microscopy 3D image data, representing the anode microstructure with varying phase compositions. A brittle model and a ductile material model were assigned to the YSZ phase and the nickel phase, respectively. The porosity is found to affect the strength of the microstructure significantly, leading to low compressive strength results. A high Ni content generally increases the toughness of the overall structure. However, the orientation and the geometry of the nickel phase is essential. When the Ni phase is aligned parallel to the loading direction, a supporting effect on the microstructure is observed, resulting in a significant high toughness. On the contrary, a rapid failure of the sample occurs when the Ni phase is oriented perpendicular to the loading direction. Two main failure mechanisms are identified: (i) cracking at the Ni/YSZ interface and (ii) cracking of struts at the location of the smallest diameter.Item Open Access Numerische Simulation des Materialzustandes einer Epoxidformmasse im Spritzgießprozess(2022) Yan, Shuang; Schmauder, Siegfried (Prof. Dr. rer. nat. Dr. h. c.)Ziel dieser Arbeit ist es, ein vertieftes Verständnis bzw. die quantitative Beschreibung der interagierenden Materialzustandsgrößen, beschrieben durch die Temperaturverteilung und den Vernetzungsgrad einer duroplastischen Formmasse, unter Berücksichtigung der thermochemischen Mechanismen bei der Spritzgießverarbeitung zu ermöglichen. Die Arbeit konzentriert sich einerseits auf die numerische Simulation von Materialzustandsgrößen wie Temperatur und Vernetzungsgrad, andererseits wird die Online-Überwachung des Vernetzungsgrads mittels dielektrischer Analyse und IR-Spektroskopie im Spritzgießprozess untersucht. Die in dieser Arbeit durchgeführten Simulationen und Experimente werden auf einer realen Spritzgießmaschine mit einem Plattenspritzgießwerkzeug für einen duroplastischen Werkstoff durchgeführt. Als Beispielmaterial wird eine Epoxidformmasse, die üblicherweise in der Industrie angewendet wird, ausgewählt und untersucht.