Overview of High Temperature and Thermo-Mechanical Fatigue (TMF) Overview of High Temperature and Thermo-Mechanical Fatigue (TMF)

University of Illinois at Urbana-Champaign
Overview
Overview of
of High
High Temperature
Temperature
and
and Thermo-mechanical
Thermo-mechanical
Fatigue
Fatigue (TMF)
(TMF)
Huseyin Sehitoglu
Mechanical and Industrial Engineering,
University of Illinois, Urbana, Il. 61801
Tel : 217 333 4112 Fax: 217 244 6534
e-mail: huseyin@uiuc.edu
Department of Mechanical and Industrial Engineering

Huseyin Sehitoglu 1
Page 1
Talk
Talk Outline
Outline
• Examples of High Temperature Problems
• Basic Terminology at High Temperatures
• Introduction to Constraint : Plasticity and ratchetting,
Out of Phase and In phase TMF
• Experimental Techniques at High Temperatures
• Fatigue Lives of Selected Materials under IF and TMF
• Mechanics- Stress-strain Models
• Life Models-Fatigue-Oxidation and Fatigue-Creep
Modeling
• Future Directions

Huseyin Sehitoglu 2
Page 2
Examples
Examples of
of Components
Components
Experiencing
Experiencing High
High
Temperatures
Temperatures
• Railroad Wheels undergoing Friction Braking
• Brake Rotors
• Pistons, Valves and Cylinder Heads of Spark-
ignition and Diesel Engines
• Turbine Blades and Turbine Disks
• Pressure Vessel and Piping

Huseyin Sehitoglu 3
Page 3
Railroad
Railroad Wheels
Wheels under
under Friction
Friction
Braking
Braking
110 min, 162 C °

.... 120 min, 133 C °
200
....
100 min, 200 C °
95 min, 223 C ° 122.5 min, 78 C °
90 min, 249 C ° 125 min, 24 C °
85 min, 279 C °
..
80 min, 314 C °
75 min, 354 C °
70 min, 401 C °
65 min, 462 C ° . 100
.
-3x10 -3 -2x10 -3 -10 -3 10 -3 2x10 -3
Mechanical Strain
-100
Stress (MPa)
-200
60 min, 615 ° C .... .

55 min, 603 C °
.
50 min, 589 ° C
40 min, 552 C ° ..
30 min, 497 C °
45 min, 572 C °
. . ..
35 min, 527 C ° 5 min, 210 C °
10 min, 295 C °
25 min, 459 C °
20 min, 438 C ° 15 min, 362 C ° -300

Huseyin Sehitoglu 4
Page 4
Schematic of a Railroad Wheel,

Strain-Temperature-Stress Changes on the B1 location
under brake shoe heating (laboratory simulation based
on strain temperature measurements on wheels)
400
Temperature
Stress (MPa), Temperature (°C)
200
-200 Laboratory Simulation of Stress

at B1 Location in Railroad Wheel
Stress
-400
0 100 200 300 400 500 600
Time (minutes)

Huseyin Sehitoglu 5
Page 5
Brake Rotor Cracking

200
cold
cycle 1
cycle 20
cycle 36
100
stress (MPa)
Cast Iron
-100 OP TMF
Minimum Temperature = 150 °C
Maximum Temperature = 500 °C
Cycle Time = 4 mintues
∆εm = 0.6%
Nf = 37 cycles
-200
hot
-0.3 -0.2 -0.1 0.0 0.1 0.2 0.3
mechanical strain (%)

Huseyin Sehitoglu 6
Page 6
Design-Manufacturing-Life
Design-Manufacturing-Life Prediction
Prediction
Methodology
Methodology for
for Cylinder
Cylinder Heads
Heads and
and Blocks
Blocks

Huseyin Sehitoglu 7
Page 7
Percentage of Vehicles with Aluminum

Engine Blocks and Heads(*)
1994 2000 2005
Heads
Passenger cars 78% 85% 95%
Light trucks 20% 40% 60%
Blocks
Passenger cars 13% 30% 50%
Light trucks 5% 10% 20%
(*) Delphi VIII Study,

1996 Department of Mechanical and Industrial Engineering
Huseyin Sehitoglu 8
Page 8
Cylinder Heads (FEM and Fatigue Life Contours)
Spark Plug
Inlet Valve
Exhaust Valve
Huseyin Sehitoglu 9
Page 9
Turbine Blades
TF

Huseyin Sehitoglu 10
Page 10
Turbine
TurbineBlades(
Blades(Thermo-mechanical
Thermo-mechanicalfatigue
fatiguefailure)
failure)

Page 11
Turbine Blades (strain-

temperature variation)

Page 12
Basic Terminology at High

Temperatures
• What is a high temperature problem?
Deformation under Constant or Variable
Stress at homologous temperatures above
0.35 ( T/T m >0.35 where Tmis melting
temperature).
• Stress Relaxation: Decrease in Stress at
Constant Strain
• Creep: Increase in Strain at Constant Stress

Page 13
Isothermal vs. Thermo-mechanical fatigue
High temperature
fatigue testing or modeling
Isothermal fatigue Non-isothermal fatigue
HCF TF
∆εin ≈ 0 internal stresses
LCF TMF
∆εin > 0 external stresses
Page 14
Disk Specimen under TF loading

(Simovich)

Page 15
Limitations
Limitations in
in our
our
Understanding
Understanding ofof High
High
Temperature
Temperature Material
Material Behavior
Behavior
•Experiments on TMF are missing

(difficult, expensive).
•Microstructural damage mechanisms are
not well understood.
•Stress-strain (constitutive) models have
not been established
•Proposed failure models have severe
drawbacks.
Page 16
Experimental
Experimental Techniques
Techniques at
at
High
High Temperatures
Temperatures
Test Frame
LOAD CELL
High RF
Temperature
Extensometer Induction
Coil Induction
Heater
ACTUATOR
C/L THERMOCOUPLE
C/L
Strain, load,position control
GPIB
Temperature
Controller
Control
Tower
LABWIEV
MACINTOSH IICi
Loading History
Page 17
Total
Total Constraint
Constraint
T E σο
ε
Stress
net = 0 C
Mechanical Strain
T
To
− σο
t D B A
α (T-To)

Page 18
Total
Total Constraint
Constraint
(ctd.)
(ctd.)
The compatibility equation

εnet = εth + εmech = α (T-T o ) + εmech
When the net strain is zero and all of the thermal strain is converted to
mechanical strain. Then,
εmech = - α (T-T o )

Page 19
Two-Bar
Two-Bar Model(ctd.)
Model(ctd.)
∆T
A 1, l 1
A ,l
2 2
P
Page 20
Simple
Simple Relations
Relations
• Equilibrium : A1 σ1 + A2 σ 2 = P
• Compatability : l1 ε 1 = l2 ε 2
• Strain :
ε1 = ε1 e + ε 1 in + ε 1 th
ε2 = ε2 e
ε 1 th = α ( T- T0 )
ε 1 in = inelastic (plastic) strain
ε1 e = elastic strain

Page 21
The
The Concepts
Concepts of
of Total,
Total, Partial,
Partial,
Over and Notch Constraint
Over and Notch Constraint
σ
∆T - 1
E A .l
A1 , l
1
A ,l ε1 = 2 , C = 2 1
2 2
C A1 .l2
C→∞ ; Total Constraint
C→ finite ; Partial Constraint
P

Page 22
The
The Stress-strain
Stress-strain Response
Response under
under
Total and Partial Constraint
Total and Partial Constraint

Page 23
The
The Stress-strain
Stress-strain Response
Response under
under
Total and Partial Constraint (ctd.)
Total and Partial Constraint (ctd.)

Page 24
Stress-strain
Stress-strain Behavior
Behavior under
under
Out-of-Phase
Out-of-Phase versus
versus In-Phase
In-Phase
Stress
T
Stress
min
Tmax
Mechanical Strain Mechanical Strain
T max
Tmin
Out-of-Phase TMF Response In-Phase TMF Response

Page 25
Some
Some Definitions
Definitions
min σmax
T
Stress
Inelastic St rain range:
∆σ σB σC
∆εin ≅ ∆εm - +
EB EC
Mechanical Strain
Tmax B
A
σmin
∆ε
m

Page 26
Comparison of TMF IP and TMF OP Tests on

1010 Steel (Jaske’s Data)

Page 27
TMF experiments of Coffin

Page 28
Thermal Block Histories on

Steels under Total Constraint

Page 29
Classification
Classification of
of IF
IF and
and TMF
TMF Studies
Studies
• Metallurgical Studies :
(a) Damage Mechanisms (Crack nucleation from slip bands,
precipitates, porosities, surface and internal oxidation, grain
boundary cavitation)
(b) Alloy Development
• Mechanistic Studies :
(a) Constitutive Modeling ( phenomenological:non-unified
and unified models for stress-strain prediction)
(b) Life Prediction Modeling (Crack nucleation (stress,
strain, time), Crack Growth (Mean stress, crack length)

Page 30
Classification
Classification of
of IF
IF and
and TMF
TMF Studies
Studies
(ctd.)
(ctd.)
• Engineering Application :
(a) Material Selection
(b) Early Design
(c) Residual Life Assesment

Page 31
Constitutive
Constitutive Modeling-
Modeling-
Experimentally
Experimentally Determined Flow
Determined Flow Rule
Rule
15
10
Al319- Solutionized Small SDAS
10
10
Plasticity
n2=7.96
5
ε /A
10
in
0
10
Power Law Creep
n1 =3.12
-5
10
2 3 4 5 6 7 2 3 4 5 6 7 2 3 4 5 6 7
0.01 0.1 1 10
σ/ Κο
Page 32
TMF OP 100-300°C 1.0%

200
100°C
100
Stress (MPa)
200°C
0
-100
300°C
STRESS1-2fea Stress1-2
STRESS300fea Stress300
-200
-3
-6x10 -4 -2 0 2 4 6
Strain
Page 33
Hysteresis loops for the tests

performed at 5x10-3 s-1
240 o
20 C
o
180 130 C
o
250 C
120
o
300 C
Stress (MPa)
60
-60
-120
-180 experimental
TNET
-240
-3
-6x10 -4 -3 -2 -1 0 1 2 3 4 5 6
Strain
Page 34
Drag stress recovery

Hyteresis loops at 20°C for the material pre-exposed at 300°C
300
0h
200
1h
10 h
100 100 h
Stress (MPa)
-100
-200
-300
-0.6 -0.4 -0.2 0.0 0.2 0.4 0.6
Strain
Department of (%)
Mechanical and Industrial Engineering
Page 35
Coarsening
Coarsening of
of the
the Precipitates
Precipitates

Page 36
TMF
TMF OP
OP Stress-Strain
Stress-Strain Prediction
Prediction
300
-5 -1
TMF OP ∆T=100-300°C, ∆ε=0.6%, 5x10 s
Al 319-T7B Small SDAS
200
Cycle 1
Stress (MPa)
100 Cycle 350
-100
Experiment
Simulation
-200
-0.4 -0.2 0.0 0.2 0.4
Mechanical strain, (%)
Page 37
Mechanistic Studies
Constitutive Modeling:
Requirements for a good model:

• Incorporate strain rate, temperature and mean
stress effect on stress-strain response
• Incorporate temperature-strain induced
changes on material’s stress-strain response

Page 38
Mechanistic Studies
Constitutive Modeling:
• Non-unified Plasticity (stress-strain) Models:
Plastic strains (time-independent) and creep
strains are added.
• Unified Creep-Plasticity Models: Plastic strain
and creep srain is combined as inelastic
strain.

Page 39
Life
Life Prediction
Prediction Modeling
Modeling
Requirements for a good model:

• Incorporate stress,strain, thermal expansion,
mean stress, stress state effect on life
• Predict the effect of temperature, strain rate,
metallurgical changes on life.

Page 40
Coffin’s
Coffin’s Approach
Approach

Page 41
Coffin’s
Coffin’sApproach
Approach(Frequency
(Frequency
Modified Life)
Modified Life)

Page 42
Coffin’s
Coffin’s Approach
Approach
Advantages:
Advantages:
(1)
(1)Simple
Simpleto
touse;
use;accounts
accountsfor
forfrequency
frequencyeffects
effects
Disadvantages;
Disadvantages;
(1)
(1)Not
Notsensitive
sensitiveto
tolocation
locationof
ofhold
holdtime
timewithin
withinthe
the
cycle (tension or compression).
cycle (tension or compression).
(2)
(2)Does
Doesnot
notaccount
accountfor
forcreep
creepdamage
damageeffects
effects
(3)
(3)TMF
TMFlife
lifeprediction
predictionnot
notexplicitly
explicitlyhandled.
handled.
(4)
(4)No
Nostress-strain
stress-strainmodel
model
Page 43
Strain Range Partitioning Method(SRP)
∆εcp
∆εpp
∆εpc
∆εcp
∆ε pc
∆εcc

Page 44
SRP Data on Two Class of Steels

(Manson et al.)

Page 45
SRP
SRP Approach
Approach
Advantages:
Advantages:
(1)
(1)Accounts
Accountsfor
forlocation
locationof
ofhold
holdtime
timewithin
withinaacycle
cycle
Disadvantages;
Disadvantages;
(1)
(1)Life
Lifecurves
curvesare
areoften
oftentoo
tooclose,
close,expensive
expensiveto
togenerate
generate
all these curves
all these curves
(2)
(2)Does
Doesnot
notaccount
accountfor
foroxidation/environment
oxidation/environmenteffects
effects
(3)
(3)TMF
TMFLife
Lifeprediction
predictionnot
notexplicitly
explicitlyhandled.
handled.

Page 46
Development
Development of
of aa Mechanism
Mechanism Based
Based
Failure
Failure Model
Model (Sehitoglu
(Sehitoglu et
et al.)
al.)
• Damage per cycle is sum of the dominant

mechanisms Dfat, Dox , Dcreep.
• The terms in the damage equations should be
physically based, specifically, they should be
linked to specific experiments, stress-strain
behavior and microstructural observations.

Page 47
Fatigue
Fatigue -- Oxidation
Oxidation Models
Models
(ctd.)
(ctd.)
• Neu, Sehitoglu, Boismier, Kadioglu, 1987-
2
-1 ox β +1
1 = hcr δo β 2 ∆εmech
ox ox '
Nf BΦ Kpeff ε
(1-a /β)
This equation accounts for the strain range at the

oxide tip hence the oxide-metal properties the shape
of the oxide are included.
ox
Φ Kpeff depends on the temperature strain history
and the temperature- time variation in the cycle.

Page 48
Combined
Combined Damage
Damage Model
Model
Predictions
Predictions
-1
10
WAP319-T7B Small SDAS
All Fatigue Results
300?C Dox=0
Mechanical Strain Range
-2
10
300?C Dox
-3
10 RT 40Hz
250?C 0.5Hz
-5 -1
250?C 5 x10 s
-5 -1
300?C 5 x10 s
TMF OP 100-300?C
TMF IP 100-300?C
-4
10
1 2 3 4 5 6 7 8
10 10 10 10 10 10 10 10
Department ofNf
Mechanical and Industrial Engineering
Page 49
Combined
Combined Damage
Damage Model
Model
Predictions
Predictions (1070
(1070 Steel)
Steel)

Page 50
Combined
Combined Damage
Damage Model
Model
Predictions
Predictions (1070
(1070 Steel)
Steel)

Page 51
Combined
Combined Damage
Damage Model
Model
Advantages:
Advantages:
(1)
(1)Accounts
Accountsfor
forTMF
TMFloading.
loading.
(2)
(2)Damage
Damagedue
dueto
tooxidation
oxidationand
andcreep
creepare
areincluded.
included.
Disadvantages:
Disadvantages:
(1)
(1)Requires
Requiressome
sometime
timeto
tounderstand
understandhow
howititall
allworks.
works.

Page 52
Fatigue Damage Equation

• Modified Strain-Life Relation
−1
∆ε mech
2−b
= C a0 2 b (2N f ) b + ε f (2N f )
' fat ' fat c
2
a0 - initial pore size
C' – fatigue strength coefficient

– fatigue strength exponent
b
ε'f – fatigue ductility coefficient
c – fatigue ductility exponent

Page 53
Creep Damage Equation

mc
tc
 σH  n+1  ∆H 
D = C c (mc − 1)a0 c
cr m −1
∫0  σ H 

σ exp −
RT  dt
Cc ,m c - empirical constants
∆H - activation energy
R - universal gas constant
σH - hydrostatic stress
- effective stress
σ
a0 - initial pore size

Page 54
TMF IP versus TMF OP Comparison- Al 319

5
WAP EAP Prediction
4
TMF-IP
a0 = 70 µm TMF-OP
3
2
300 µm
0.01
9
8
7
2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9
1 2 3 4
10 10 10 10
f N
Page 55
Initial Voids and after TMF IP

Page 56
Future
Future Directions
Directions
• A simple model is developed to predict life

for a given mechanical strain range, maximum
temperature, and material.
• Given a strain and temperature field in a component,

the model can predict the most critical location where
crack nucleation will occur.

Page 57
Future
Future Directions
Directions (ctd.)
(ctd.)
• Given an elastic strain, temperature history
from FEM, the model is able to predict the
stresses and plastic strains assuming the
mechanical strain is equal to the elastic strain
from FEM. This is known as the ‘ strain
invariance method’.
• To predict component behavior the model

accounts for the initial defect size.

Page 58

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University of Illinois at Urbana-Champaign

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

110 min, 162 C °

65 min, 462 C ° . 100

60 min, 615 ° C .... .

Department of Mechanical and Industrial Engineering

Schematic of a Railroad Wheel,

-200 Laboratory Simulation of Stress

Department of Mechanical and Industrial Engineering

Brake Rotor Cracking

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Percentage of Vehicles with Aluminum

(*) Delphi VIII Study,

Cylinder Heads (FEM and Fatigue Life Contours)

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Turbine Blades (strain-

Department of Mechanical and Industrial Engineering

Basic Terminology at High

Department of Mechanical and Industrial Engineering

Isothermal vs. Thermo-mechanical fatigue

Isothermal fatigue Non-isothermal fatigue

Disk Specimen under TF loading

Department of Mechanical and Industrial Engineering

•Experiments on TMF are missing

Department of Mechanical and Industrial Engineering

The compatibility equation

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Mechanical Strain Mechanical Strain

Out-of-Phase TMF Response In-Phase TMF Response

Inelastic St rain range:

Department of Mechanical and Industrial Engineering

Comparison of TMF IP and TMF OP Tests on

Department of Mechanical and Industrial Engineering

TMF experiments of Coffin

Department of Mechanical and Industrial Engineering

Thermal Block Histories on

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Al319- Solutionized Small SDAS

TMF OP 100-300°C 1.0%

Hysteresis loops for the tests

Drag stress recovery

Department of Mechanical and Industrial Engineering

100 Cycle 350

Requirements for a good model:

Department of Mechanical and Industrial Engineering

Department of Mechanical and Industrial Engineering

Requirements for a good model:

Department of Mechanical and Industrial Engineering