• Journal of the Korean Society for Aeronautical & Space Sciences
• /
• v.39 no.5
• /
• pp.400-407
• /
• 2011

The stress distribution and stress amplitude of a membrane are major factors to decide the mechanical fatigue life of PEMFC (Polymer Electrolyte Membrane Fuel Cell). In this paper, mechanical stresses under operating hygro-thermal condition of the membrane are numerically modelled. Contact analysis between gas diffusion layer (GDL) and the membrane is performed under various temperature-humidity conditions. The structural model has nonlinear material properties depending on temperature and relative humidity. Several geometric conditions are applied to the model. The numerical analysis results indicate that deformations of the membrane are strongly related with assembly conditions of the fuel cell. The fatigue life is predicted for practical operating condition through experimental data.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.34 no.7
• /
• pp.911-917
• /
• 2010

In this study, we performed structural and fatigue analyses of the engine exhaust manifold that was subjected to thermo-mechanical cyclic loading. The methodologies used in this study are based on an approach in which the techniques for modeling the exhaust system, the temperature-dependent properties of the material, and thermal cyclic loading are taken into consideration and a reliable strategy is adopted for failure prediction. An application example shows that at an elevated temperature, considerable compressive plastic deformation is observed and that at a low temperature, tensile stresses remain in those parts of the test exhaust manifold where failure is observed. In order to predict fatigue life, mechanical damage is determined on the basis of the stress.strain hysteresis loops by using the classical Coffin.Manson equation and by adopting a method in which the dissipated plastic energy is taken into consideration.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.29 no.10 s.241
• /
• pp.1384-1391
• /
• 2005

Damage often occurs on the surface of railway wheels due to wheel-rail contact fatigue. It should be removed before reaching wheel failure, because wheel failure can cause derailment with loss of life and property. The increase or decrease of the contact fatigue lift by the metal removal of the contact surface were investigated by many researchers, but they have not considered initial residual stress and traction force. The railway wheel has the initial residual stress formed during the manufacturing process, and the residual stress is changed by thermal stress induced by braking. The traction force and residual stress are operated on wheels of locomotive and electric motor vehicle. In this study, the effect of metal removal depth on the contact fatigue life for a railway wheel has been evaluated by applying lolling contact fatigue test. The effect of the traction force and metal removal on the contact fatigue life has been estimated by finite element analysis. It has been found that the initial residual stress determines the amount of metal removal depth if the traction coefficient is less than 0.15. If the traction coefficient is greater than 0.2, however, the amount of metal removal depth is independent on the intial residual stress.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.28 no.4
• /
• pp.427-434
• /
• 2004

Ferritic stainless steel is recently used in high temperature structures because of its good properties of thermal fatigue resistance, corrosion resistance, and low price. Tensile and low-cycle fatigue (LCF) tests on 429EM stainless steel used in exhaust manifold were performed at several temperatures from room temperature to 80$0^{\circ}C$. Elastic Modulus, yield strength, and ultimate tensile strength monotonically decreased when temperature increased. Cyclic hardening occurred considerably during the most part of the fatigue life. Dynamic strain aging was observed in 200~50$0^{\circ}C$, which affects the cyclic hardening behavior. Among the fatigue parameters such as plastic strain amplitude, stress amplitude, and plastic strain energy density (PSED), PSED was a proper fatigue parameter since it maintained at a constant value during LCF deformation even though cyclic hardening occurs considerably. A phenomenological life prediction model using PSED was proposed considering the influence of temperature on fatigue life.

• Journal of the Korean Society for Heat Treatment
• /
• v.28 no.2
• /
• pp.68-74
• /
• 2015

The low cycle fatigue (LCF) and creep-fatigue (hold time tension fatigue, HTTF) tests were performed on the modified 25Cr-13Ni cast stainless steel, which was selected as a candidate material for exhaust manifold in automotive engine. The exhaust manifold is subjected to an environment in which heating and cooling cycle occur due to the running pattern of automotive engine. Several types of fatigue behaviour such as thermal fatigue, thermal mechanical fatigue and creep-fatigue are belong to the main failure mechanisms. High temperature tensile test was firstly carried out to compare the sample with the traditional cast steel for the component. The low cycle fatigue and HTTF tests were carried out under the strain controlled condition with the total strain amplitude from ${\pm}0.6%$ to ${\pm}0.7%$ at $800^{\circ}C$. The hysteresis loops of HTTF tests showed significant stress relaxation during tension hold time. With the increase of tension hold time, the fatigue life was remarkably deceased which caused from the formation of intercrystalline crack by the creep failure mechanism.

• Korean Journal of Materials Research
• /
• v.24 no.9
• /
• pp.481-487
• /
• 2014

The effect of alpha phase on the fatigue properties of Fe-29%Ni-17%Co low thermal expansion alloy was investigated. Two kinds of alloys (Base alloy and Alpha alloy) were prepared by controlling the minimal alloy composition. Microstructure observation, tensile, high-cycle fatigue, and low-cycle fatigue results were measured in this study. The Base alloy microstructure showed typical austenite ${\gamma}$ phase. Alpha alloy represented the dispersed phase in the austenite ${\gamma}$ matrix. As a result of tensile testing, Alpha alloy was found to have higher strengths (Y.S. & T.S.) and lower elongation compared to those of the Base alloy. High cycle fatigue results showed that Alpha alloy had a higher fatigue limit (360MPa) than that (330MPa) of the Base alloy. The Alpha alloy exhibited the superior high cycle fatigue property in all of the fatigue stress conditions. SEM fractography results showed that the alpha phase could act to effectively retard both fatigue crack initiation and crack propagation. In the case of low-cycle fatigue, the Base alloy had longer fatigue life in the high plastic strain amplitude region and the Alpha alloy showed better fatigue property only in the low plastic strain amplitude region. The fatigue deformation behavior of the Fe-29%Ni-17%Co alloy was also discussed as related with its microstructure.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.28 no.12
• /
• pp.1856-1863
• /
• 2004

In the last 50 years, lead-contained solder materials have been the most popular interconnect materials used in the electronics industry. Recently, lead-free solders are about to replace lead-contained solders for preventing environmental pollutions. However, the reliability of lead-free solders is not yet satisfactory. Several researchers reported that lead-contained solders have a good fatigue property. The others published that the lead-free solders have a longer thermal fatigue life. In this paper, the reason for the contradictory results published on the estimation of fatigue life of lead-free solder is investigated. In the present study, fatigue behavior of 63Sn37Pb, and two types of lead-free solder joints were compared using pseudo-power cycling testing method, which provides more realistic load cycling than chamber cycling method does. Pseudo-power cycling test was performed in various temperature ranges to evaluating the shear strain effect. A nonlinear finite element model was used to simulate the thermally induced visco-plastic deformation of solder ball joint in BGA packages. It was found that lead-free solder joints have a good fatigue property in the small temperature range condition. That condition induce small strain amplitude. However in the large temperature range condition, lead-contained solder joints have a longer fatigue life.

• Steel and Composite Structures
• /
• v.34 no.1
• /
• pp.35-51
• /
• 2020

Integral abutment bridges (IABs) are those bridges without expansion joints. A single row of steel H-piles (SHPs) is commonly used at the thin and stub abutments of IABs to form a flexible support system at the bridge ends to accommodate thermal-induced displacement of the bridge. Consequently, as the IAB expands and contracts due to temperature variations, the SHPs supporting the abutments are subjected to cyclic lateral (longitudinal) displacements, which may eventually lead to low-cycle fatigue (LCF) failure of the piles. In this paper, the potential of using finite element (FE) modeling techniques to estimate the LCF life of SHPs commonly used in IABs is investigated. For this purpose, first, experimental tests are conducted on several SHP specimens to determine their LCF life under thermal-induced cyclic flexural strains. In the experimental tests, the specimens are subjected to longitudinal displacements (or flexural strain cycles) with various amplitudes in the absence and presence of a typical axial load. Next, nonlinear FE models of the tested SHP specimens are developed using the computer program ANSYS to investigate the possibility of using such numerical models to predict the LCF life of SHPs commonly used in IABs. The comparison of FE analysis results with the experimental test results revealed that the FE analysis results are in close agreement with the experimental test results. Thus, FE modeling techniques similar to that used in this research study may be used to predict the LCF life of SHP commonly used in IABs.

• Journal of the Korean Society for Aeronautical & Space Sciences
• /
• v.35 no.1
• /
• pp.52-57
• /
• 2007

One of the hot issues in composite patching is to reduce the thermal residual stresses between composite patch and aluminum surface which occurs after bonding of composite patch. In this study, the edge crack patching is adopted for different curing cycles. For the analysis, three layer Mindlin plate elements are used, and Paris' law is adopted to predict the fatigue life of composite patch plate. The analysis results show a good agreement with the experimental fatigue life and this technique can be applied for the prediction of fatigue life of aircraft structures.

• KEPCO Journal on Electric Power and Energy
• /
• v.2 no.4
• /
• pp.583-588
• /
• 2016

The high-temperature steam pipes of thermal power plants are subjected to severe conditions such as creep and fatigue due to the power plant frequently being started up and shut down. To prevent critical pipes from serious damage and possible failure, inspection methods such as computational analysis and online piping displacement monitoring have been developed. However, these methods are limited in that they cannot determine the life consumption rate of a critical pipe precisely. Therefore, we set out to develop a life assessment system, based on a three-dimensional piping displacement monitoring system, which is capable of evaluating the life consumption rate of a critical pipe. This system was installed at the "M" thermal power plant in Malaysia, and was shown to operate well in practice. The results of this study are expected to contribute to the increase safety of piping systems by minimizing stress and extending the actual life of critical piping.