Ref 1

DEVELOPMENT OF A THERMAL FATIGUE
TESTING MACHINE AND INVESTIGATION OF

VARIOUS THERMAL FAILURES IN DIFFERENT
TOOL CONDITIONS.
A PROJECT REPORT
Submitted by
SUBRAMANI R S
Reg No: 1541210016

Under the Guidance of
Mr. P. KARTHIKEYAN, M.E. (Ph.D.,)

(Assistant Professor, Department of Mechanical Engineering)
in partial fulfillment for the award of the degree

of
MASTER OF TECHNOLOGY
in
COMPUTER INTEGRATED MANUFACTURING
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF ENGINEERING & TECHNOLOGY
S.R.M. Nagar, Kattankulathur, Kancheepuram District
MAY, 2014
BONAFIDE CERTIFICATE
Certified that this project report titled “DEVELOPMENT OF A THERMAL
FATIGUE TESTING MACHINE AND INVESTIGATION OF VARIOUS
THERMAL FAILURES IN DIFFERENT TOOL CONDITIONS” is the bonafide
work of Mr.SUBRAMANI R S , Register no. 1541210016 , who carried out the project
work under my supervision. Certified further, that to the best of my knowledge the work
reported herein does not form any other project report or dissertation on the basis of
which a degree or award was conferred on an earlier occasion on this or any other
candidate.
SIGNATURE SIGNATURE
P. KARTHIKEYAN, M.E. (Ph.D.,) Dr.D.KINGSLY JEBA SINGH,
GUIDE DEAN
Assistant Professor (Sr.G) School of Mechanical Engineering
Department of Mechanical Engineering Faculty of engineering and technology
SRM UNIVERSITY SRM UNIVERSITY
Signature of the Internal Examiner Signature of the External Examiner
Date:
ABSTRACT
Thermal fatigue failure occurs in materials that are subjected to
thermal loading continuously for a period of time. Few materials break early
tend to break at their early time, because the life of the material is not
properly tested before production. So fatigue machines were introduced to
find the failure rate of the mould specimen before production.
A thermal fatigue testing machine will be developed for a low cost with the
same accuracy compared with costly machines. The main objective of this
project is to develop a fatigue testing machine at a low cost and test thermal
fatigue failure of a mould specimen in their early stage. The type of results
that could be identified using this project are Crack initiation, Crack
propagation, and Fast fracture. SEM analysis will be done to all the
experiments that were done at various conditions to check for cracks in the
tools steels. SEM analysis will also reveal the condition of the tool when it is
tested at various intervals of fatigue cycle. Hence Tool steel which can stand
high number of fatigue cycles and which has less crack compared to others
tools will be the best tool for doing mould specimen.
iii
ACKNOWLEDGEMENT
I am very grateful to my guide Mr.P.KARTHIKEYAN, M.E., Assistant
Professor, School of Mechanical Engineering, who has guided me with inspiring
dedication, untiring efforts and tremendous enthusiasm in making this interim phase of
the project successful and presentable.
I sincerely acknowledge in all earnestness, the patronage provided by our

Director Dr. C. MUTHAMIZHCHELVAN, Engineering and Technology to Endeavour
this project.
I wish to express my deep sense of gratitude and sincere thanks to our professor
and Head of the Department Dr. KINGSLY JEBA SINGH, for his encouragement,
timely help and advice offered to me.
I thank our Project Co-ordinators Dr.M.GOPAL, Professor and

Dr.T.RAJASEKARAN, Professor School of Mechanical Engineering, for the support
and advice given us through the project reviews.
I extend my gratitude and thanks to all the staff and non-teaching staff of School
of Mechanical Engineering and to my parents and friends, who extended their kind co-
operation by means of valuable suggestions and timely help during the course of this
project work.
iv
TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.

ABSTRACT iii
LIST OF TABLES viii
LIST OF FIGURES ix
1. INTRODUCTION 1
1.1 TYPES OF FATIGUE 3
1.2 FATIGUE FAILURE UPON TIME – 3
VARYING LOADING
1.3 CRACK GROWTH 3
1.4 PREVENTING FATIGUE FAILURE 5
1.5 OBJECTIVE OF THE PROJECT 5
2. LITERATURE SURVEY 6
2.1 THERMAL FATIGUE CRACKING 6
2.2 SIMULATION AND EVALUATION OF 9
THERMAL FATIGUE
3. METHODOLOGY 13
3.1 EXPERIMENTAL METHOD 15
3.1.1 Experiment No.1: Untreated Specimen 15
(H13) Tool Steel
3.1.2 Experiment No. 2: Untreated Specimen 16
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
3.1.5 Experiment No. 5: Heat Treated Specimen 19
(H13) Tool Steel
(H13) Tool Steel
v
3.1.7 Experiment No. 7: Nitrided Specimen 21

(H13) Tool Steel
3.1.8 Experiment No. 8: Nitrided Specimen 22
(H13) Tool Steel
(H13) Tool Steel
3.1.10 Experiment No. 10: Heat Treated 24
Specimen (H13) Tool Steel
3.1.11 Experiment No. 10: Heat Treated 25
Specimen (H13) Tool Steel
3.1.12 Experiment No.12: Nitrided Specimen 26
(H13) Tool Steel
4. RESULTS AND DISCUSSION 27
4.1 MICROSTRUCTURE OF THE SPECIMENS 27
4.1.1 Untreated Specimen (H13) Tool Steel 27
(Base Material)
` 4.1.2 Microstructure of the Untreated Specimen 28
(232 Cycles)
4.1.3 Microstructure of the Untreated Specimen 29
(1150 Cycles)
(2000 Cycles)
(1400 Cycles)
4.1.6 Microstructure of the Treated Specimen 32
(1150 Cycles)
(232 Cycles)
4.1.8 Microstructure of the Nitrided Specimen 34
(1150 Cycles)
vi

(232 Cycles)
(1400 Cycles)
(2000 Cycles)
(2000 Cycles)
(1400 Cycles)
4.2 HARDNESS OF THE SPECIMENS 40
5. CONCLUSION 42
REFERENCES 43
vii
LIST OF TABLES
TABLE NO TITLE PAGE NO
3.1 Experimental Conditions for Untreated 15

(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
3.5 Experimental Conditions for Treated 19
(H13) Tool Steel
(H13) Tool Steel
3.7 Experimental Conditions for Nitrided 21
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
(H13) Tool Steel
4.1 Hardness Values of the Experiment Specimens 40
viii
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1.1 Example of The Thermal Fatigue Failure Material 2

1.2 Thermal Failure of Aluminium Material 2
3.1 Thermal Fatigue Machine (Top View) 14
4.1 Untreated Specimen (H13) Tool Steel 27
4.2 Untreated Specimen (H13) Tool Steel (232 Cycles) 28
4.6 Treated Specimen (H13) Tool Steel (1150 Cycles) 32
4.8 Nitrided Specimen (H13) Tool Steel (1150 Cycles) 34
4.9 Nitrided Specimen (H13) Tool Steel (232 Cycles) 35
4.12 Nitrided Tool Steel (2000 Cycles) 38
4.13 Nitrided Tool Steel (1400 Cycles) 39
ix
CHAPTER 1
INTRODUCTION
A perusal of the broken parts in almost any scrap yard will reveal that the
majority of failures occur at stresses below the yield strength. This is the result of the
phenomenon called fatigue which has been estimated to be responsible for up to 90% of
the in-service part failure which occurs in the industry. Fatigue is the condition where by
the material cracks or fails as result of repeated (cyclic) stresses applied below the
ultimate strength of the material. The type of fatigue of most concern in gasoline, diesel,
gas turbine engines, and moulds for aluminium casting and much industrial application is
thermal fatigue. Thermal fatigue can arise from thermal stresses produced by cyclic
changes in temperature. Example for thermal fatigue failure materials are shown in
Figure 1.1 and Figure 1.2
Fatigue failures generally involve three stages:
1. Crack initiation
2. Crack propagation
3. Fast fracture
Basic fatigue testing involves the preparation of carefully polished test specimens
(surface flaws are stress concentrators) which are cycled to failure at various values of
constant amplitude alternating stress levels .The data are condensed into an alternating
stress(S), versus number of cycles to failure (N), curve which is generally referred to as
material’s S-N curve.The fatigue life (Nf) of a component is defined by the total number
of stress cycles required to cause failure.
Nf=Ni+Np
Where Ni=Crack initiation, Np=Crack growth. A prediction of failure for various stress
levels can be made by studying a material’s S-N curve.
1
Figure 1.1: Example of the Thermal Fatigue Failure Material [14]
Figure 1.2: Thermal Failure of Aluminium Material [14]
2
1.1 TYPES OF FATIGUE
Some common fatigue mechanisms are:
 Time-varying Loading Fatigue

 Thermal Fatigue
 Corrosion Fatigue
 Surface/Contact Fatigue
 Combined Creep and Fatigue
According to ASTM international (originally American Society for Testing and

Materials), fatigue is “the process of progressive localized structural change occurring in
a material subjected to conditions which produce fluctuating stresses and strains at some
point or points and which may complete fracture after a sufficient number of
fluctuations”.
1.2 FATIGUE FAILURE UPON TIME –VARYING LOADING
Time –varying Loading Fatigue can be defined as a process caused by time-

varying loads which never reach a high enough level to cause failure in a single
application, and yet results in progressive localized permanent damages on the material.
The damages, usually cracks, initiate and propagate in regions where the strain is most
severe. When the local damages grow out of control, a sudden fracture/rupture ends the
service life of the structure. Common categories and approaching methods include
High-cycle fatigue associated with low loads and long life (less then 103 cycles) is
commonly analyzed with a “stress life” method (the S-N curve), which predicts the
number of cycles sustained before failure, or with a “total-life” method (endurance limit),
which puts a cap stress that allows the material to have infinite life(less then 106 cycles).
1.3 CRACK GROWTH
The life of a fatigue crack has two parts, initiation and propagation. The most
common reasons for crack growth initiation include:
3
 Notches, corners, or other geometric inconsistencies that act as stress risers. These
features may be inherent in the product design or mistakenly caused during
manufacturing.
 Material impurities, inclusions, or product usage causing material loss due to wear
or corrosion.
 Mechanical or thermal fatigue encountered during the products normal life cycle.
Material fatigue fractures have common phases, such as crack initiation, crack growth
propagation (followed by) and a sudden failure. Once a crack has been initiated (crack
initiation phase), repeated loadings can cause the crack to lengthen or propagate (crack
growth phase). If fatigue loading is continued, crack growth will occur resulting in a final
sudden fracture of the remaining cross section (overload failure).
By analyzing the material fatigue fractures of several iterations of mechanical fatigue

tests, a crack growth curve can be formed to assist with fatigue life predictions. The crack
growth rate (da/dN) is obtained by taking the derivative of the crack length, a, versus
cycles, N. A well planned and executed DTB material test program will be able to take
into account the crack growth curves, obtained from the material fatigue testing, and
establish a fatigue life prediction for the product, as well as possibly provide damage
tolerances for the product.
Damage tolerance is a property of a material or structure relating to its ability to

sustain defects safely until repair can be made or the structure replaced. The material
approach to damage tolerance in material testing is to account on the assumption that
initial flaws exist in any structure or material and such flaws will propagate with usage.
Our material test programs will locate the initial flaws, recommend the proper
modification to correct the flaw, and then test again to prove that the recommendations
worked.
4
1.4 PREVENTING FATIGUE FAILURE
Preventing fatigue failure is the most effective method of improving fatigue

performance in designs. A materials testing program will allow manufacturers to:
 Eliminate or reduce stress risers in the part.

 Improve manufacturing process by helping manufacturer avoid sharp surface tears
resulting from punching, stamping, shearing, or surface finish processes.
 Help prevent the development of surface discontinuities during manufacturing.
 Eliminate or reduce tensile residual stresses caused by manufacturing.
Material fatigue is the progressive damage that occurs when a material or

structure is subjected to cyclic loading. Fatigue failure is when the progressive damage
caused by the cyclic loading leads to failure of the material or structure.
Fatigue failures are a significant problem for the reason that they can occur due to
repeated loads below the static yield strength and can result in an unexpected and
catastrophic failure causing monetary loss and/or even loss of life.
Many engineering designs include materials and structures that contain

discontinuities or stress risers. Most metal fatigue cracks initiate from discontinuities in
highly stressed regions of the structure.
The stress risers may be due the discontinuities in the material, inherent in the
design, improper manufacturing technique or even improper maintenance. Our material
fatigue test program and comprehensive analysis can determine the cause of the fatigue
failure.
1.5 OBJECTIVE OF THE PROJECT
The objective of the project is to find the life of the specimen before life of the
application as due to thermal loading externally, H13 tool steel tends to loss their life.
And to develop a very low cost and handy thermal fatigue testing machine and to find out
the thermal fatigue failure of normal tool steel, heat treated tool steel and nitrided tool
steel under cyclic load conditions. The main aim of this project is to find the problem in
early stages itself without making 60000 components.
5
CHAPTER 2
LITERATURE SURVEY
2.1 THERMAL FATIGUE CRACKING
Klobcar D, et.al. [12] explained the aluminium alloy die casting die failures with
the emphasis on thermal cracks. The aim of that study was to prolog the in-service die
life by cladding with maraging steels, which would be economically beneficial. A vast
analysis of thermal fatigue cracks in aluminium alloy die casting was done. Immersion
test apparatus was developed, which enables simulation of conditions during aluminium
alloy die casting and enables controlled thermal fatigue testing of materials. Special
specimens made of the AISI H13 tool steel were differently heat treated. On the edges of
some specimens, the maraging steel is cladded using gas tungsten arc (GTA) welding.
These samples are tested in as welded and in optimally aged condition. After completion
of a particular number of cycles, the specimen edge surfaces were examined visually. The
specimens were then sectioned and examined with light and scanning electron
microscopy (SEM). The energy-dispersive X-ray spectroscopy (EDS) mapping of areas
around the cracks was done. The number and length of thermal fatigue cracks were
statistically evaluated and a Vickers hardness profiles were measured. The results
confirmed a good thermal fatigue resistance of the properly hardened H13 hot work tool
steel. The surface cracks growth is accelerated by surface oxidation.
Mitja Muhic, et.al. [1] described the Die casting moulds to high cyclic
temperatures, mechanical loads and severe chemical conditions. Thermal and mechanical
loads caused high local stresses and consequently surface cracks. This paper introduced a
new approach to establishing thermal fatigue cracks in die casting moulds by measuring
the resulting defect-fins on aluminium alloy castings in the actual die casting process.
The investigation showed that cracks occurred sooner and were bigger if the mould
material had a lower hardness. The maximum depth of the defect-fin observed on the
casting due to thermal fatigue crack on the mould with the lowest hardness (42 HRc) at
10000 cycles was 0.37 mm, the maximum width of the defect-fin was 0.76 mm and
6
maximum length was 9.6 mm. The observed cracks were bigger closer to the entrance of
melt flow, especially at the places with stress concentrators, due to higher melt
temperature and higher melt flow.
Fuchs K D, et.al. [5] explained to get a better die life in die casting which is
necessary to look at the main reasons for damage. More than 80% of the dies fail by
crack initiation caused by heat checking. To increase the heat checking resistance the tool
steel must possess good high-temperature strength, high-temperature toughness and
thermal conductivity. Thyrotherm 2367, a steel with 3% molybdenum, combines the
good properties of the well-known grades mat.-№. 1.2343 (H11) and 1.2344 (H13) while
offering better high-temperature strength and temperature resistance. It is thus
increasingly replacing these grades in the production of die castings made of light metal.
Another reason for damage of moulds are tension cracks. Causal for these tension cracks
is mainly the constructional design of the tool with corners and sharp edges. If it is not
possible to change the design it is helpful for the die life to use a tool steel with high
toughness. The new developed steel Thyrotherm E 38 K has the highest toughness
potential compared to the other hot-work tool steels. This advantage has a particularly
positive effect in the production of large dies. Due to the combination of high tensile
strength and toughness the maraging hot-work tool steel Thyrotherm 2799 has the best
potential for getting the highest life time of all.
Klobcar.D, et.al. [4] states that the study to find the thermal fatigue resistance of
different hot-work tool steels; AISI H11 and H13, special tool steel and 18% Ni maraging
steel. The maraging steel is surface cladded by GTA welding to study the thermal fatigue
resistance of surface layer. An influence of mechanical and microstructural properties on
thermal fatigue resistance is evaluated. An innovative apparatus for thermal fatigue
testing is developed to study the thermal fatigue resistance. The test specimens are
subjected to cyclic heating in bath of molten Aluminum Alloy 226 and cooling in bath of
water-based lubricant. They are continuously internally cooled with cold water. The
specimens are periodically analyzed after completion of particular number of cycles. The
microstructure, hardness profile and the surface cracks developed are analyzed.
Temperature transients at different locations of test specimen are measured and used in
computation of transient stresses performed by finite elements. The specimens of special
7
geometry are developed using finite element modeling to improve testing efficiency. An
optimal set of thermal fatigue testing parameters are developed to establish efficient
testing. The influence of thermal loading on tempering of hot work tool steel and on
aging of maraging steel claddings during testing is determined. The results showed
significant differences in thermal fatigue resistance of tested materials and their heat
treatments. The best thermal fatigue resistance achieved special tool steel due to its high
thermal stability. The resistance of AISI H11 tool steel is slightly superior to that of
maraging steel weld.
Kulkarni K, et.al. [3] analysed the thermal cracking is the primary mode of
failure of large steel dies in aluminum die casting of automotive engine blocks or
transmission housing. This cracking is due to the large thermal shock experienced by the
die steel when it is quenched by cold water after a die casting cycle. The propagation of
cracks depends on the severity of the thermal fatigue cycle (peak and range), that is
caused by die surface being in contact alternatively with the liquid melt at 700°C and
cold water at room temperature. Previous work at The Ohio State University has shown
that single layer hard PVD and CVD coatings do not protect the die steel surface from
cracking. On the other hand, they may enhance cracking. This paper presents an
interesting multi-layer duplex coating approach with a nitriding H-13 steel substrate and a
multi-layer, hard outer film applied by LAFAD technique that prevents reaction with the
liquid melt, and alters the thermal fatigue behavior. Results of thermal cycling tests
indicate that the multi-layer duplex coating system helps reduce the density of the
thermal cracks.
Mirko Sokovic, et.al. [2] explained a comparative tool life test of protected tools
was made in aluminium die-casting of driving wheels for automobiles with two types of
cores in one casting plate. One set of cores was improved with plasma nitriding process,
while another one was improved with duplex treatment (plasma nitriding + PVD CrN
coating). After 2700 and 4150 shots, surfaces on both types of tools were analysed using
optical and scanning electron microscopes to identify damages of tool working surfaces.
The performance tests, made under real manufacturing conditions, showed that wear of
duplex treated tool is smaller compare to only plasma nitrided tool.
8
Muhic M ,et.al. [1] explained the Die casting moulds to high cyclic temperatures,
mechanical loads and severe chemical conditions. Thermal and mechanical loads caused
high local stresses and consequently surface cracks. This paper introduces a new
approach to establishing thermal fatigue cracks in die casting moulds by measuring the
resulting defect-fins on aluminium alloy castings in the actual die casting process. The
investigation showed that cracks occurred sooner and were bigger if the mould material
had a lower hardness. The maximum depth of the defect-fin observed on the casting due
to thermal fatigue crack on the mould with the lowest hardness (42 HRc) at 10000 cycles
was 0.37 mm, the maximum width of the defect-fin was 0.76 mm and maximum length
was 9.6 mm. The observed cracks were bigger closer to the entrance of melt flow,
especially at the places with stress concentrators, due to higher melt temperature and
higher melt flow.
2.2 SIMULATION AND EVALUATION OF THERMAL FATIGUE

CRACKING
Anders Persson, et.al. [13] states that the Die casting is a very cost efficient
method to manufacture near net-shaped and complex cast products. One limitation for
further cost reduction is fatigue cracking of the tool due to thermal cycling, which is
observed as a crack network on the tool surface. Hot work tool steels are commonly used
as die material. In this study, an experimental test machine for simulation of thermal
fatigue is described. The test is based on cyclic induction heating and internal cooling of
hollow cylindrical test rods. The surface strain is continuously recorded during the
thermal cycling through a non-contact laser speckle technique. The applicability of the
test is demonstrated on two hot work tool steel grades, hardened and tempered to
different conditions, and heat cycled between Tmin 170oand Tmax 600–850 oC. It is
shown that the test method can simulate surface cracking of tools exposed to thermal
fatigue. The surface strain recordings proved to give sufficient information to
successfully deduce the strains and stresses behind the mechanism of thermal fatigue
surface cracking, without knowledge of the temperature distribution below the surface. It
was also found that low-cycle fatigue occurs for the tests with Tmax 600 and 700 oC,
although the estimated tensile stress after cooling does not exceed the initial yield
strength of the steel. Most probably, the reason is the gradual softening of the tool steels
9
during the thermal cycling. Additionally, the presence of stress concentrators play a
critical role during these conditions.
Kosec B, et.al. [6] explained the cracks in the surface of a fixed die half resulting
in imprints on AlSi9Cu3 alloy castings were analysed. The cracks were revealed and
identified by the use of penetrants. some of them were clearly seen by the use of a
magnifying glass or even by the naked eye .non destructive metallographic examination
by SEM of polymeric replicas was applied.
Franc Kosel, et.al. [7] described the defects produced in aluminium alloy die
casting dies during die operation. The most frequent defect is thermal fatigue cracking.
Hardness and toughness is measured on specimens cut from different parts of used die
casting die. The results show a significant difference in material microstructure and
hardness between the surface and the core. The intense martensite tempering is observed
on the die surface, while the core material microstructure remains unchanged. A
considerable hardness drop is measured on the material surface and no change is
observed in the depth of six millimetres from surface.
Rodriguez M P, et.al. [8] states that the large difference in thermal expansion
between dissimilar materials present in any electronic package is the source of a major
problem to be solved in order to achieve improved reliability .In this papper, simplified
thermal and mechanical finite element models are presented for the analysis of thermal
stress derived problems . the problems investigated here include ,thermal stress in
adhesive back bonds in surface mounted structures and effects of thermal fatigue in soft
solder interfaces in conventional power modulus such as insulated gate bipolar
transistors modulus. Full multi dimensional mechanical and thermal analysis is made by
using the commercial engineering computer packages ANSYS .Validation of the
thermal simulation is achieved by comparison between simulation and experimental
test results ,whereas a simple analytical model based upon the lap joint theory is used to
verify the structural simulation.
Srivastava A, et.al. [9] explained the thermal fatigue cracking is a major mode of
failure of hot working tool steel dies in die-casting and forging applications. This results in
huge loss owing to high cost of dies, downtime and die repair and replacement. The
10
cracking initiates due to the large thermal shock experienced by the die surface when it is
rapidly heated to 700 ◦C and then quenched to 150 ◦C by the lubricant spray. This
thermal fatigue loading propagates the crack until gross failure occurs or die becomes
unusable. Most of the previous efforts have been focused on the improvement of die
steels and heat treatment techniques for high fracture toughness. This paper investigates
the cracking mechanism using laboratory experiments. The thermal fatigue loading is
applied by dipping the test coupons in molten liquid aluminum bath and quenching in
water at room temperature. The dip times in aluminum and water are changed to
represent different conditions. Commercial FEM software is used to simulate the test
conditions and to analyze the temperature and stress profile. The general thermal fatigue
equations are modified to model the cracking in die-casting and predict the number of
cycles and regions more susceptible to such cracking. It also presents a methodology to
use a computer model to predict failure in actual dies and to make design changes like
placement of cooling lines, thermal cycles, etc. to minimize cracking and increase die
life.
shadan Tabibian, et.al. [10] described a thermo mechanical fatigue criterion in

order to predict the failure of the cylinder heads issued with the lost foam casting process.
The microstructure of the materials (A356-A319) is affected by the lost foam casting
process which can directly affect the mechanical properties, the damage mechanisms and
the fatigue failure of the materials. The major problem in defining a predictive fatigue
criterion in this case is the fact that it should be on one side applicable for the structure
which is submitted to complex multi axial thermo mechanical loadings and on the other
side should take into account the micro structural effects of casting process.
Fajdiga G, et.al. [11] explained a computational model for contact fatigue

damage analysis of gear teeth flanks is presented in this paper. The model considers the
conditions required for the surface fatigue crack initiation and then allows for proper
simulation of the fatigue crack propagation that leads to the appearance of small pits on
the contact surface. The fatigue process leading to pitting is divided into crack initiation
and a crack propagation period. The model for prediction of identification of critical
material areas and the number of loading cycles, required for the initial fatigue crack to
appear, is based on Coffin–Manson relations between deformations and loading cycles,
11
and comprises characteristic material fatigue parameters. The computational approach is
based on continuum mechanics, where a homogenous and elastic material model is
assumed and results of cyclic loading conditions are obtained using the finite element
method analysis. The short crack theory together with the finite element method is then
used for simulation of the fatigue crack growth. The virtual crack extension (VCE)
method, implemented in the finite element method, is used for simulating the fatigue
crack growth from the initial crack up to the formation of the surface pit. The relationship
between the stress intensity factor K and crack length a, which is needed for
determination of the required number of loading cycles Np for a crack propagation from
the initial to the critical length.
12
CHAPTER 3
METHODOLOGY
The basic steps involved in this work are
1. A number of fatigue procedure have been developed to satisfy specific objective:

 Life distribution at a constant stress level
 Strength distribution at a constant life
 Design data at a minimum cost and time etc..
We have conducted the Thermal Fatigue Test at constant stress level which means
that the maximum and minimum stresses were constant for each cycle of test.
2. In one container molten aluminium was kept 670oC and in another container
water was kept at ambient temperature.
3. The molten aluminium temperature was maintained by heating it with a burner.
4. Twelve specimens from Tool steel bar of size 12mm x 60mm long wire made.
5. To increase the hardness of the metals out of the four specimens were heat treated
and four specimens were nitrided and four were kept without any treatment. we
wanted to make a study whether the increase in hardness of the metals has got
any effect on its fatigue life or not.
6. Heat treatment process followed on the metals step wise slow heating to
austenizing temperature (1050oC): room temp >200>400>600>850>1050oC.:Hold
at 1050oC for half an hour (called soaking).Remove from furnace air cool to 50-
60oC.As soon as the temperature reaches 50-60oC place in furnace already
steadied at required tempering temperature of 525-550oC .Hold for two hours.
Remove from furnace air cool to room temperature.
7. The specimen was hung on the arm of the Thermal fatigue testing machine
developed and with the help of the oscillating wiper mechanism the specimen
was first dipped in molten aluminium and kept for 20 seconds and then kept in air
for 10 seconds and finally it was dipped in water for 20 seconds. After taking out
13
from water it was again kept in air for 10 seconds. This complete one cycle
operation.
8. The number of cycles the specimen was subjected to measured by the counter.
The basic setup for the project experimentation has been shown in the
Figure 3.1.the primary work is to achieve reciprocating motion from rotation of
motor, which is monitored and controlled by specific circuit.
Figure 3.1: Thermal Fatigue Machine (TOP VIEW)
The circuit controls the arm to pause for desired time (in sec) at three
locations. The feedback is taken through three proximity sensor at three fixed
locations and speed of motor is controlled through regulator power supply
module.
14
3.1 EXPERIMENTAL METHOD
3.1.1 Experiment No.1: Untreated Specimen (H13) Tool Steel
Table 3.1: Experimental Conditions for Untreated (H13) Tool Steel
Specimen material H13
Specimen Treatment Untreated
Specimen Coating -
Specimen size Φ: 8 mm L: 80mm
Nature of fatigue test Immersed in aluminium
Temperature of hot chamber -
Temperature of aluminium 670 OC
Total cycle time 20 S
Time in air 6 S
Time in hot chamber -
Time immersed in aluminium 10 S
Number of cycles 232
The specimen was hung on the arm of the Thermal fatigue testing machine
developed and with the help of the oscillating wiper mechanism the specimen was first
dipped in molten aluminium and kept for 10 seconds and then kept in air for 6 seconds.
After taking out from air it was complete one cycle operation. This process is repeated till
232 cycles. The experiment conditions are shown in Table 3.1.
15
Specimen Coating -
Temperature of hot chamber -
Time in air 6 S
1150 cycles. The experiment conditions are shown in Table 3.2.
16
Specimen Coating -
Nature of fatigue test Hot chamber
Temperature of hot chamber 350 OC
Temperature of aluminium -
Time in air 14 S
Time in hot chamber 10 S
Time immersed in aluminium -
dipped in hot chamber and kept for 10 seconds and then kept in air for 14 seconds. After
taking out from air it was complete one cycle operation. This process is repeated till 2000
cycles The experiment conditions are shown in Table 3.3.
17
3.1.4 Experiment No. 4: Untreated Specimen (H13) Tool Steel
Specimen Coating Dilute coated
Time in air 14 S
cycles. The experiment conditions are shown in Table 3.4.
18
3.1.5 Experiment No. 5: Heat Treated Specimen (H13) Tool Steel
Table 3.5: Experimental Conditions for Treated (H13) Tool Steel
Specimen Treatment Treated
Specimen Coating -
-
Temperature of hot chamber
Time in air 25 S
1150 cycles. The experiment conditions are shown in Table 3.5
19
3.1.6 Experiment No.6: Heat Treated Specimen (H13) Tool Steel
Specimen Coating -
-
Time in air 9 S
20
3.1.7 Experiment No.7: Nitrided Specimen (H13) Tool Steel
Table 3.7: Experimental Conditions for Nitrided (H13) Tool Steel
Specimen Treatment Nitrided
Specimen Coating -
-
Time in air 9 S
21
3.1.8 Experiment No. 8: Nitrided Specimen (H13) Tool Steel
Specimen Coating -
-
Time in air 9 S
22
3.1.9 Experiment No.9: Heat Treated Specimen (H13) Tool Steel
Time in air 9 S
cycles The experiment conditions are shown in Table 3.9
23
3.1.10 Experiment No. 10: Heat Treated Specimen (H13) Tool Steel
Specimen Coating -
Time in air 9 S
24
Specimen Coating -
Time in air 9 S
25
Time in air 9 S
26
CHAPTER 4
RESULTS AND DISCUSSION
4.1 MICROSTRUCTURE OF THE SPECIMENS
Experiments were conducted for different conditions i.e. four specimens were
heat treated and four specimens were nitrided and four specimens without any treatment..
The experiments microstructures are shown below.
4.1.1 Untreated Specimen (H13) Tool Steel(Base Material)
Figure 4.1 : Untreated Specimen (H13) Tool Steel
(Base Material)
Figure 4.1 shows the microstructure of base material H13 tool steel .the base
material shows there is no crack on it .for this material fatigue testing is conducted up to
2000 cycles.that is different conditions and different cycles.
27
4.1.2 Microstructure of the Untreated Specimen (232 Cycles)
Figure 4.2: Untreated Specimen (H13) Tool Steel (232 Cycles)
Aluminum is placed inside the Crucible and heated at 670° C using the LPG gas
stove and the temperature can be seen by using pyrometer. Two position sensors are used
for controlling the movement of tool. The first position in chamber, with aluminum for 10
seconds and outside the chamber, in air for 6 seconds. This process is repeated till 232
cycles. An analogue counter is used to count the number of cycles made. The aluminum
placed inside the crucible should be heated continuously. Figure 4.2 shows the
microstructure of the above condition, the circle spotted shows the crack on the
specimen.
28
Figure 4.3: Untreated Specimen (H13) Tool Steel (1150 Cycles)
microstructure of the above condition, the circle spotted shows the crack on the
specimen.
29
Figure 4.4: Untreated Specimen (H13) Tool Steel Hot
Chamber (2000 cycles)
Crucible is heated to a temperature of 275o C to 285OC using the LPG gas stove
and the temperature is measured using pyrometer. Reading is measured at two positions
and these two positions are controlled by using sensors, the first position is, the tool gets
dipped into the crucible and remains there for 10sec then in air for 14sec outside the
chamber. This process is repeated till it finishes 2000 cycles. Analogue counter is used to
count the number of cycles made. Figure 4.4 shows the microstructure of the above
condition, there is no crack on the specimen.
30
4.1.5 Microstructure of The Untreated Specimen (1400 Cycles)
Figure 4.5: Untreated Specimen (H13) Tool Steel Hot
Chamber (1400 Cycles)
Crucible is heated to a temperature of 275o C to 285OC using the LPG gas

stove and the temperature is measured using pyrometer. Reading is measured at
two positions and these two positions are controlled by using sensors, the first
position is, the tool gets dipped into the crucible and remains there for 10sec then
in air for 14sec outside the chamber. This process is repeated till it finishes 1400
cycles. Analogue counter is used to count the number of cycles made. . Figure 4.5
shows the microstructure of the above condition, the circle spotted shows the
crack on the specimen
31
4.1.6 Microstructure of The Treated Specimen (1150 Cycles)
Figure 4.6: Treated Specimen (H13) Tool Steel (1150 Cycles)
microstructure of the above condition, there is no crack on the specimen.
32
4.1.7 Microstructure of the Treated Specimen (232 Cycles)
33
4.1.8 Microstructure of the Nitrided Specimen (1150 Cycles)
Figure 4.8: Nitrided Tool Steel (1150 Cycles)
34
Aluminum is placed inside the Crucible and heated at 670 ° C using the
LPG gas stove and the temperature can be seen by using pyrometer. Two position
sensors are used for controlling the movement of tool. The first position in
chamber, with aluminum for 3 seconds and outside the chamber, in air for 9
seconds. This process is repeated till 232 cycles. An analogue counter is used to
count the number of cycles made. The aluminum placed inside the crucible should
be heated continuously. Figure 4.9 shows the microstructure of the above
condition, there is no crack on the specimen
35

position is, the tool gets dipped into the crucible and remains there for 3 sec then
in air for 9 sec outside the chamber. This process is repeated till it finishes 1400
cycles. Analogue counter is used to count the number of cycles made. Figure 4.9
shows the microstructure of the above condition, there is no crack on the
specimen
36

position is, the tool gets dipped into the crucible and remains there for 3 sec then
in air for 9 sec outside the chamber. This process is repeated till it finishes 2000
cycles. Analogue counter is used to count the number of cycles made. Figure 4.11
shows the microstructure of the above condition, there is no crack on the
specimen
37
dipped into the crucible and remains there for 3 sec then in air for 9 sec outside the
condition, the circle spotted shows the crack on the specimen.
38
dipped into the crucible and remains there for 3 sec then in air for 9 sec outside the
condition, there is no crack on the specimen
39
4.2 HARDNESS OF THE SPECIMENS
The hardness of the specimens was measured using Rockwell Hardness Tester.
The hardness values are shown in Table 4.1. The hardness of specimen before fatigue
test is less than the hardness of specimen after fatigue test in all the cases of untreated,
nitrided and heat treated tools. As the hardness after testing is less than before testing, the
specimen tools will be considered as more for suitable for machining operations and it
will also give increased tool life.
Table 4.1: Hardness Values of the Experiment Specimens
Hardness of Hardness of
Experiment
Description specimen before specimen after
number
fatigue test (HRC) fatigue test (HRC)
Untreated specimen
1 38 36
(H13) tool steel
Untreated specimen
2 (H13) tool steel 38 36
(232 cycles)
Untreated specimen
(1150 cycles)
Untreated specimen
(2000 cycles)
Untreated specimen
(H13) tool steel
5 38 30
(1400 cycles)
Hardening tool
6 48 47
steel (1150 cycles)
Hardening tool
7 48 46
steel (232 cycles)
40
Nitrided tool steel
8 54 30
(232 cycles)
Nitrided tool steel
9 54 32
(1150 cycles)
Hardening tool
10 48 46
steel (1400 cycles)
Hardening tool
11 48 46
steel (2000 cycles)
Nitrided tool steel
12 54 48
(2000 cycles)
Nitrided tool steel
13 54 39
(1400 cycles)
41
CHAPTER 5
CONCLUSION
A thermal fatigue testing machine was developed at a low cost. The main
objective of this project is to develop that machine and test thermal fatigue failure of a
mould specimen in their early stage. The Thermal fatigue machine was developed by
using a viper motor to oscillate at three different points, with the help of proximity
switches. The Fatigue machines cycles were calculated using a counter which counts
after every rotation of the motor. H13 tool steel has been used in three different
conditions to find the fatigue. As purchased, heat treated and nitrided are the three
conditions of H13 tool steel.
From the microstructures that were taken during some hundred cycles shows that
H13 tool steel at purchased condition has crack too early in the fatigue cycle. Heat treated
H13 tool steel doesn’t have any crack even till 2000 cycles, and nitrided tools seems to
get crack formation at 750 to1000 cycles. Hence it was studied that H13 tool steel, heat
treated is best, compared to the other two tool conditions. So a H13 tool steel which is
heat treated can be used for doing casting for at least 2000 cycles without the mould
getting any crack on it.
42
REFERENCES
[1] Muhic M., Kosel Franc., Puksic Andrej., and Klobcar Damjan.,“A New
Approach to Monitoring Thermal Fatigue Cracks in Die Casting Moulds,”
International Journal of Material Research.,102(1),pp. 69-75, 2011.
[2] Sokovic M., Panjan Peter., and ekada Miha C., “Improvement of Tool Life of
Die-Casting Tools With Duplex Treatment,” International Journal of
Microstructure and Material Properties.,231,pp.231-240,2006.
[3] Kulkarni K., Srivastava A., Shivpuri R., Bhattacharya R., Dixit S., and Bhat D.,
“Thermal Cracking Behavior of Multi-Layer LAFAD Coatings on Nitrided Die
Steels in Liquid Aluminum Processing,”Surface and Coating Technology.,149(2-
3),pp.171–178,2002.
[4] Klobcar D., Tusek Janez., and Taljat Bostjan., “Thermal Fatigue of Materials for
Die-Casting Tooling,” Material Science and Engineering.,472(1-2),pp.198–207,
2008.
[5] Fuchs KD., “Hot-Work Tool Steels With Improved Properties for Die Casting
Applications,”Proc.6thInternational Tooling Conference.,pp.17-26,2010.
[6] Kosec B., Kosec L., and Kopac J., “Analysis of Casting Die Failures,”
Engineering Failure Analysis.,8(4),pp.355-359, 2001.
[7] Muhic Mitja., Tusek Janez., Kosel Franc., Klobcar Damjan., and Pleterski Matej.,
“Analysis of Die Casting Tool Material,”Journal of Mechanical
Engineering.,56,pp.351-356, 2010.
[8] Rodriguez M.P., “Finite Element of Thermal Fatigue in Multilayer Structures
Thermal and Mechanical Approach,” Microelectronics Reliability.,41(4),pp.517-
523,2001.
[9] Srivastava A., Joshi V.,and Shivpuri R., “Computer Modeling and Prediction of
Thermal Fatigue Cracking in Die-Casting Tooling,”International Journal of
Science and Technology of Friction, Lubrication and Wear.,256(1-2),pp.1-
220,2004.
[10] Shadan., Eric charkaluk B., Andrei c., Constantinescu alexis oudin C.,and Fabien
A., “Thermo Mechanical Fatigue Criterion in Order to Predict the Failure of The
Cylinder Heads,”Procedia Engineering.,2(1),pp.1145-1154,2010.
[11] Fajdiga G., and Sraml M.,“Fatigue Crack Initiation and Propagation Under
Cyclic Contact Loading,”Engineering Fracture Mechanics.,76(9),pp.1320-
1335,2000.
[12] Klobcar D., Kosec L., Kosec B.,and Tusek J., “A Thermo Fatigue Cracking of
Die Casting Dies,” Engineering Failure Analysis.,20,pp. 43–53,2012.
43
[13] Anders Persson A, Sture Hogmark B,and Jens Bergstroma, “Simulation and
Evaluation of Thermal Fatigue Cracking of Hot Work Tool Steels,” International
Journal of Fatigue.,26,pp. 1095–1107 ,2004.
[14] http://en.wikipedia.org/wiki/Fatigue_(material).
[15] http://www.ndted.org/EducationResources/
44

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DEVELOPMENT OF A THERMAL FATIGUE

TESTING MACHINE AND INVESTIGATION OF

Reg No: 1541210016

Mr. P. KARTHIKEYAN, M.E. (Ph.D.,)

in partial fulfillment for the award of the degree

FACULTY OF ENGINEERING & TECHNOLOGY

S.R.M. Nagar, Kattankulathur, Kancheepuram District

Certified that this project report titled “DEVELOPMENT OF A THERMAL

FATIGUE TESTING MACHINE AND INVESTIGATION OF VARIOUS

THERMAL FAILURES IN DIFFERENT TOOL CONDITIONS” is the bonafide

P. KARTHIKEYAN, M.E. (Ph.D.,) Dr.D.KINGSLY JEBA SINGH,

Assistant Professor (Sr.G) School of Mechanical Engineering

Department of Mechanical Engineering Faculty of engineering and technology

SRM UNIVERSITY SRM UNIVERSITY

Signature of the Internal Examiner Signature of the External Examiner

Thermal fatigue failure occurs in materials that are subjected to

properly tested before production. So fatigue machines were introduced to

find the failure rate of the mould specimen before production.

tools will be the best tool for doing mould specimen.

I sincerely acknowledge in all earnestness, the patronage provided by our

I thank our Project Co-ordinators Dr.M.GOPAL, Professor and

CHAPTER NO. TITLE PAGE NO.

3.1.7 Experiment No. 7: Nitrided Specimen 21

4.1.9 Microstructure of the Nitrided Specimen 35

4.2 HARDNESS OF THE SPECIMENS 40

3.1 Experimental Conditions for Untreated 15

1.1 Example of The Thermal Fatigue Failure Material 2

Fatigue failures generally involve three stages:

Figure 1.2: Thermal Failure of Aluminium Material [14]

Some common fatigue mechanisms are:

 Time-varying Loading Fatigue

According to ASTM international (originally American Society for Testing and

1.2 FATIGUE FAILURE UPON TIME –VARYING LOADING

Time –varying Loading Fatigue can be defined as a process caused by time-

1.3 CRACK GROWTH

By analyzing the material fatigue fractures of several iterations of mechanical fatigue

Damage tolerance is a property of a material or structure relating to its ability to

Preventing fatigue failure is the most effective method of improving fatigue

 Eliminate or reduce stress risers in the part.

Material fatigue is the progressive damage that occurs when a material or

Many engineering designs include materials and structures that contain

1.5 OBJECTIVE OF THE PROJECT

2.1 THERMAL FATIGUE CRACKING

2.2 SIMULATION AND EVALUATION OF THERMAL FATIGUE

shadan Tabibian, et.al. [10] described a thermo mechanical fatigue criterion in

Fajdiga G, et.al. [11] explained a computational model for contact fatigue

The basic steps involved in this work are

1. A number of fatigue procedure have been developed to satisfy specific objective:

Figure 3.1: Thermal Fatigue Machine (TOP VIEW)

3.1.1 Experiment No.1: Untreated Specimen (H13) Tool Steel

Table 3.1: Experimental Conditions for Untreated (H13) Tool Steel

Specimen material H13

Specimen Treatment Untreated

Specimen size Φ: 8 mm L: 80mm

Nature of fatigue test Immersed in aluminium

Temperature of hot chamber -

Temperature of aluminium 670 OC

Total cycle time 20 S

Time in hot chamber -

Time immersed in aluminium 10 S

Number of cycles 232

Table 3.2: Experimental Conditions for Untreated (H13) Tool Steel

Specimen material H13