Experimental dataset from a round robin test of contact parameters and hysteresis loops for nonlinear dynamic analysis.

This data article describes the extensive experimental dataset of friction hysteresis measured during the round robin test of the original research article [1]. The round robin test was performed on the two different fretting rigs of Imperial College London and Politecnico di Torino, and consisted of recording comparable friction hysteresis loops on specimen pairs manufactured from the same batch of raw stainless steel. The reciprocating motion of the specimens was performed at room temperature under a wide range of test conditions, including different normal loads, displacement amplitudes, nominal areas of contact and excitation frequencies of 100 Hz and 175 Hz. Friction forces and tangential relative displacements for each specimen pair were recorded and stored as hysteresis raw data. Each hysteresis loop was post-processed to extract friction coefficient, tangential contact stiffness and energy dissipated, whose evolution with wear was thus obtained and stored as well. MATLABⓇ scripts for post-processing and plotting data are included too. The dataset can be used by researchers as a benchmark to validate theoretical models or numerical simulations of friction hysteresis models and wear mechanisms, and also to study the physics of friction hysteresis and its contact parameters. This friction data can also be used as input in models for nonlinear dynamics applications as well as to provide information on the contact measurement uncertainty under fretting motion. Other applications include using this data as a training set for machine learning applications or data-driven models, as well as supporting grant applications.

Linear Elastic Fracture Mechanics Assessment of a Gas Turbine Vane.

This work assesses the crack propagation at the most critical point of a second stage of a gas turbine blade by means of linear elastic fracture mechanics (LEFM). The most critical zone where the crack may nucleate, due to a combination of thermo-mechanical loads, is detected with an uncracked finite element (FE) model pre-analysis. Then the sub-modelling technique is used to obtain more precise results in terms of stresses within the area of interest. Simulations of the state of stress at the crack apex are performed through an FE model, using the Fracture Tool within ANSYS Workbench, and the stress intensity factors (SIFs) are determined accordingly. The Fracture Tool was previously verified on a simple model, and the results were compared with its analytical solution. Finally, the evaluation of the crack growth due to fatigue stress, creep, and oxidation is performed through in-house software called Propagangui. The crack behavior is estimated along with the component life. Results show an unexpected decrease in KI with increasing crack length and slowing of the crack growth rate with crack propagation. A detailed analysis of this behavior emphasizes that the redistribution of the stresses at the crack apex means that unstable propagation is not expected.

Tribological Characterization of Electrical Discharge Machined Surfaces for AISI 304L.

Surface treatments are normally carried out after machining. Surface treatment is a costly and time-consuming process. Hence, it makes sense to reduce the requirement of surface treatment as much as possible. Electrical Discharge Machining (EDM) is a frequently used machining process. EDM produces a recast layer on the surface of machined components. The tribological performance of this recast layer is not very well understood. The properties of the recast layer formed as a result of EDM depend upon the discharge current, electrodes and dielectrics. This work aims to study the effects of each on the tribological performance - in terms of the wear depth, friction coefficient, friction force and contact surface temperature of recast layers. Subsequent improvement in the quality of surfaces will significantly reduce the cost and time required to treat surfaces after machining. Hence, various combinations of discharge current, dielectrics and electrodes have been used to characterize and deduce their effects. The tribo-tests are performed in the boundary lubrication regime under pin-on-disc configuration to analyze sliding friction, contact surface temperature and the wear of the recast layers formed on AISI 304L. The surface morphology of the test pins has been performed by Scanning Electron Microscopy (SEM) before and after the tests. The results show that indeed it is possible to control the tribological performance of the recast layers by varying EDM parameters. This approach promises to be a useful methodology to improve the tribological performance of the layers formed after EDM and reduce the time and costs required for surface treatments post machining.

Influence of Low-pH Beverages on the Two-Body Wear of CAD/CAM Monolithic Materials.

The aim of this in vitro study is to evaluate the effect of different acidic media on volumetric wear and surface roughness of CAD/CAM monolithic materials. Forty-eight rectangular specimens were prepared using different CAD/CAM monolithic materials: nanohybrid composite (Grandio Blocks, Voco), resin-based composite (Cerasmart, GC), lithium disilicate (E-Max, Ivoclar), and high-translucency zirconia (Katana STML, Kuraray Noritake). After storage in distilled water at 37 °C for two days, the specimens were tested using a chewing machine with a stainless-steel ball as an antagonist (49N loads, 250,000 cycles). Testing was performed using distilled water, Coca-Cola, and Red Bull as abrasive media. Wear and surface roughness analyses of the CAD/CAM materials were performed using a 3D profilometer and analyzed with two-way analysis of variance and post hoc pairwise comparison procedures. Worn surfaces were examined using scanning electron microscopy. Resin-based materials suffered higher volumetric wear than ceramics (p = 0.00001). Water induced significantly less volumetric wear than the other tested solutions (p = 0.0014), independent of the material tested. High-translucency zirconia showed less surface roughness than all the other materials tested. The selection of monolithic CAD/CAM materials to restore worn dentition due to erosive processes could impact restorative therapy stability over time. Resin-based materials seem to be more influenced by the acidic environment when subjected to a two-body wear test.

Fretting Fatigue Analysis of Additively Manufactured Blade Root Made of Intermetallic Ti-48Al-2Cr-2Nb Alloy at High Temperature.

Slots in the disk of aircraft turbines restrain the centrifugal load of blades. Contact surfaces between the blade root and the disk slot undergo high contact pressure and relative displacement that is the typical condition in which fretting occurs. The load level ranges from zero to the maximum during take-off. This cycle is repeated for each mission. In this paper, a fretting fatigue analysis of additively manufactured blades is presented. Blades are made of an intermetallic alloy γTiAl. Fretting fatigue experiments were performed at a frequency of 0.5 Hz and at a temperature of 640 °C to match the operating condition of real blades. The minimum load was fixed at 0.5 KN and three maximum loads were applied, namely 16, 18 and 20 kN. Both an analytical and a two-dimensional finite element model were used to evaluate the state of stress at the contact interfaces. The results of the analytical model showed good agreement with the numerical model. Experiments showed that cracks nucleate where the analytical model predicts the maximum contact pressure and the numerical model predicts the maximum equivalent stress. A parametric analysis performed with the analytical model indicates that there exists an optimum geometry to minimize the contact pressure. Tests showed that the component life changed dramatically with the maximum load variation. Optical topography and scanning electron microscopy (SEM) analysis reveals information about the damage mechanism.