Integration of Finite Element Analysis and Laboratory Analysis on 3D Models for Methodology Calibration.

To better address mechanical behavior, it is necessary to make use of modern tools through which it is possible to run predictions, simulate scenarios, and optimize decisions. sources integration. This will increase the capability of detecting material modifications that forerun damage and/or to forecast the stage in the future when very likely fatigue is initiating and propagating cracks. Early warning outcomes obtained by the synergetic implementation of NDE-based protocols for studying mechanical and fatigue and fracture behavior will enhance the preparedness toward economically sustainable future damage control scenarios. Specifically, these early warning outcomes will be developed in the form of retopologized models to be used coupled with FEA. This paper presents the first stage of calibration and the combination of a system of different sensors (photogrammetry, laser scanning and strain gages) for the creation of volumetric models suitable for the prediction of failure of FEA software. The test objects were two components of car suspension to which strain gauges were attached to measure its deformation under cyclic loading. The calibration of the methodology was carried out using models obtained from photogrammetry and experimental strain gauge measurements.

Fatigue and Fracture Behavior of Composite Materials.

Presently, composites are one of the top-of-the-range materials used in different industrial sectors and represent the best alternative to metal alloys in those applications where higher mechanical properties and lower weights are required [...].

Estimation of the Dissipative Heat Sources Related to the Total Energy Input of a CFRP Composite by Using the Second Amplitude Harmonic of the Thermal Signal.

Theories for predicting the fatigue behaviour of composite laminates often make strong assumptions on the damage mechanisms that strongly depend on the designed laminate lay-up. In this regard, several physical and empirical models were proposed in the literature that generally require experimental validations. The experimental techniques, such as thermography, also provide useful tools for monitoring the behaviour of the specific material so, that they can be used to support the study of the damage mechanisms of materials. In this research, the second amplitude harmonic of the thermal signal has been investigated and used to assess the relationship with the total energy input in order to estimate the fatigue strength of the material. A thermal index was assessed by monitoring the constant amplitude tests (S/N curve) that were performed on a quasi-isotropic carbon fibre reinforced polymer (CFRP) laminate obtained by the automated fibre placement process. The obtained results demonstrated the capability of the second amplitude harmonic of the thermal signal to describe and monitor the fatigue damage.

Correlation between Thermal Behaviour of AA5754-H111 during Fatigue Loading and Fatigue Strength at Fixed Number of Cycles.

The characterization of the fatigue behaviour of aluminium alloys is still capturing the attention of researchers. As it is well known in literature, for certain alloys, in a specific range of cycles number, the S-N curves do not present any asymptote. So that, problems result in the assessment of the fatigue life. In these conditions, the concept of the fatigue limit has to be replaced by the fatigue strength at a fixed number of loading cycles. Temperature acquisitions during fatigue tests allow for a specific analysis that can support the researchers in understanding the complex processes that are involved in fatigue and their influence on fatigue life, even for aluminium alloys. In fact, the analysis of the surface temperature signal that was detected during a self-heating test provides a curve that is characterized by a distinct slope-change point at a specific stress value. Even though researchers have been investigating fatigue life characterisation and temperature variations for more than a decade, it is not clear what this point represents in terms of fatigue strength. The aim of the present paper is to find out a possible correlation between the thermal behaviour of AA5754-H111 undergoing self-heating testing procedure and fatigue strength at a specific loading cycles.

Optimization and Characterization of the Friction Stir Welded Sheets of AA 5754-H111: Monitoring of the Quality of Joints with Thermographic Techniques.

Friction Stir Welding (FSW) is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In particular, the thermal behavior of the material during the process has been investigated and two thermal indexes, the maximum temperature and the heating rate of the material, correlated to the frictional power input, were investigated for different process parameters (the travel and rotation tool speeds) configurations. Moreover, other techniques (micrographs, macrographs and destructive tensile tests) were carried out for supporting in a quantitative way the analysis of the quality of welded joints. The potential of thermographic technique has been demonstrated both for monitoring the FSW process and for predicting the quality of joints in terms of tensile strength.