Abstract
Aluminum alloys are widely used as materials for machine components because they have excellent specific strengths. The strength reliability of components made of aluminum alloys is often evaluated by conducting finite element analysis (FEA). In particular, in order to evaluate the reliability of the components subjected to cyclic loading at high temperatures, the FEA should be conducted as an elastic–plastic–creep analysis, and the fatigue strength of the components should be estimated based on the analysis results. However, in order to conduct an elastic-plastic-creep FEA, the material constants used for the analysis must be estimated by conducting not only tensile tests but also long-time creep tests under at least three stress levels at several temperatures. This will become an obstacle to completing the design and development of the machine components in a short period. Therefore, the present paper proposes a method by which one can efficiently estimate the material constants for elastic–plastic–creep FEA by effectively using stored test data without conducting creep tests. The validity of the estimation method is discussed by conducting simulations of cyclic compression-tension loadings showing strain rate and temperature effects using an elastic-plastic-creep constitutive model with the estimated constants.
Similar content being viewed by others
Data Availability
Derived data supporting the findings of the present study are available from the corresponding author upon request.
References
Azadi, M., Shirazabad, M.M.: Heat treatment effect on thermo-mechanical fatigue and low cycle fatigue. Mater. Des. 45, 279–285 (2013). https://doi.org/10.1016/j.matdes.2012.08.066
Azadi, M., Farrahi, G.H., Winter, G., Huter, P., Eichlseder, W.: Damage prediction for un-coated and coated aluminum alloys under thermal and mechanical fatigue loadings based on a modified plastic strain energy approach. Mater. Des. 66, 587–595 (2015). https://doi.org/10.1016/j.matdes.2014.04.022
Azeez, A., Eriksson, R., Leidermark, D., Calmunger, M.: Low cycle fatigue life modelling using finite element strain range partitioning for a steam turbine rotor steel. Theor. Appl. Fract. Mech. 107, 102510 (2020). https://doi.org/10.1016/j.tafmec.2020.102510
Brusa, E., Ossola, E., Bonavolontà, R., Mazzetto, A.: LCF/TMF model based approach for the prediction of fatigue life of components in lightweight automotive engines. Int. J. Automot. Technol. 21(2), 297–308 (2020). https://doi.org/10.1007/s12239-020-0028-5
Farrahi, G.H., Azadi, M., Winter, G., Eichlseder, W.: A new energy-based isothermal and thermo-mechanical fatigue lifetime prediction model for aluminium–silicon–magnesium alloy. Fatigue Fract. Eng. Mater. Struct. 36, 1323–1335 (2013). https://doi.org/10.1111/ffe.12078
Fischer, C., Schweizer, C.: Experimental investigation of the damage characteristics of two cast aluminium alloys: part II – LCF/HCF and TMF/HCF loading with special focus on the short crack growth behavior. Int. J. Fatigue 152, 106387 (2021). https://doi.org/10.1016/j.ijfatigue.2021.106387
Fukuchi, K., Ohguchi, K., Sasaki, K., Tsubota, Y., Mita, T., Nagai, W., Ohsato, K., Shinya, N.: Evaluation of high-temperature fatigue life of aluminium alloys using plastic-creep separation method. Trans. JSME 87(895), 20-00378 (2021). https://doi.org/10.1299/transjsme.20-00378. (In Japanese)
Ge, B., Liu, X., He, G., Le, P., Wen, Z., Wang, Q.: Quantitative relationship between microstructure characteristics and fatigue parameters of A319 casting alloy. Fatigue Fract. Eng. Mater. Struct. 43, 605–616 (2020). https://doi.org/10.1111/ffe.13170
Han, S.W., Katsumata, K., Kumai, S., Sato, A.: Effects of solidification structure and aging condition on cyclic stress–strain response in Al–7% Si–0.4% Mg cast alloys. Mater. Sci. Eng. A 337, 170–178 (2002). https://doi.org/10.1016/S0921-5093(02)00004-7
Jeong, C.Y.: Effect of alloying elements on high temperature mechanical properties for piston alloy. Mater. Trans. 53(1), 234–239 (2012). https://doi.org/10.2320/matertrans.M2011259
Kang, H.T., Lee, Y-L., Chen, J., Wu, X.: Fatigue life prediction of Al319-T7 subjected to thermomechanical loading conditions. Proc. Eng. 213, 730–742 (2018). https://doi.org/10.1016/j.proeng.2018.02.069
Kobayashi, M., Mukai, M., Takahashi, H., Ohno, N., Kawakami, T., Ishikawa, T.: Implicit integration and consistent tangent modulus of a time-dependent non-unified constitutive model. Int. J. Numer. Methods Eng. 58, 1523–1543 (2003). https://doi.org/10.1002/nme.825
Minichmayr, R., Riedler, M., Winter, G., Leitner, H., Eichlseder, W.: Thermo-mechanical fatigue life assessment of aluminium components using the damage rate model of Sehitoglu. Int. J. Fatigue 30, 298–304 (2008). https://doi.org/10.1016/j.ijfatigue.2007.01.054
Nakai, T., Motegi, J., Nakamura, T., Asada, Y.: Effect of air environment on creep–fatigue interaction of 316 FR Stainless Steel. JSME Int. J. Ser. A 41(1), 149–155 (1998). https://doi.org/10.1299/jsmea.41.149
Neu, R.W., Sehitoglu, H.: Thermomechanical fatigue, oxidation and creep: part I. Damage mechanisms. Metall. Mater. Trans. A 20, 1755–1767 (1989). https://doi.org/10.1007/BF02663207
Neu, R.W., Sehitoglu, H.: Thermomechanical fatigue, oxidation and creep: part II. Life prediction. Metall. Mater. Trans. A 20, 1769–1783 (1989b). https://doi.org/10.1007/BF02663208
Ohguchi, K.: Development of solver system for FEM analysis of solder joints. J. Jpn. Weld. Soc. 79(3), 215–219 (2010). https://doi.org/10.2207/jjws.79.215. (In Japanese)
Ohguchi, K., Sasaki, K.: Elastic-plastic-creep simulation of Pb/Sn solder alloys by separation of plastic and creep. JSME Int. J. Ser. A 46(4), 559–566 (2003). https://doi.org/10.1299/jsmea.46.559
Ohguchi, K., Sasaki, K.: Constitutive modeling for SAC lead-free solder based on cyclic loading tests using stepped ramp waves. Proc. Eng. 10, 1139–1144 (2011). https://doi.org/10.1016/j.proeng.2011.04.189
Ohguchi, K., Sasaki, K.: Viscoplastic constitutive model to divide inelastic strain into time-independent and time-dependent strains. In: Advanced Structured Materials, Advanced Materials Modelling for Structure, vol. 19, pp. 285–296 (2013). https://doi.org/10.1007/978-3-642-35167-9_26
Ohguchi, K., Sasaki, K., Ishibashi, M., Hoshino, T.: Plasticity-creep separation method for viscoplastic deformation of lead-free solders. JSME Int. J. Ser. A 47(3), 371–379 (2004). https://doi.org/10.1299/jsmea.47.371
Ohguchi, K., Sasaki, K., Ishibashi, M.: A quantitative evaluation of time-independent and time-dependent deformations of lead-free and lead-containing solder alloys. J. Electron. Mater. 35(1), 132–139 (2006). https://doi.org/10.1007/s11664-006-0195-9
Ohguchi, K., Sasaki, K., Yuze, Y., Fukuchi, K.: Fatigue life estimation of SAC solder based on inelastic strain analysis using stepped ramp wave loading. J. Mech. Eng. 6(5), 19–00137 (2019). https://doi.org/10.1299/mej.19-00137
Sehitoglu, H., Qing, X., Smith, T., Maier, H.J., Allison, J.A.: Stress-strain response of a cast 319-T6 aluminum under thermomechanical loading. Metall. Mater. Trans. A 31, 139–151 (2000). https://doi.org/10.1007/s11661-000-0060-z
Takahashi, T., Sasaki, K.: Low cycle thermal fatigue of aluminum alloy cylinder head in consideration of changing metrology microstructure. Proc. Eng. 2, 767–776 (2010). https://doi.org/10.1016/j.proeng.2010.03.083
Toda, H., Katano, J., Kobayashi, T., Akahori, T., Niinomi, M.: Assessment of thermo-mechanical fatigue behaviors of cast Al-Si alloys. Mater. Trans. 46(1), 111–117 (2005). https://doi.org/10.2320/matertrans.46.111
Tokimasa, K.: Creep-fatigue properties of Sn–37Pb solder material evaluated by room temperature testing under various strain waveform. JSME Int. J. Ser. A 47(3), 380–388 (2004). https://doi.org/10.1299/jsmea.47.380
Wang, M., Pang, J.C., Liu, H.Q., Li, S.X., Zhang, M.X., Zhang, Z.F.: Effect of constraint factor on the thermo-mechanical fatigue behavior of an Al–Si eutectic alloy. Mater. Sci. Eng., A 783, 139279 (2020). https://doi.org/10.1016/j.msea.2020.139279
Yamamoto, T., Itoh, T., Sakane, M., Tsukada, Y.: Creep-fatigue life of Sn–8Zn–3Bi solder under multiaxial loading. Int. J. Fatigue 43, 235–241 (2012). https://doi.org/10.1016/j.ijfatigue.2012.04.007
Funding
The authors did not receive support from any organization for the submitted work.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Competing Interests
The authors declare that they have no conflict of interest.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Ohguchi, Ki., Sasaki, K., Fukuchi, K. et al. A material constants estimation method for efficient elastic–plastic–creep simulation of aluminum alloys by effective utilization of stored test data. Mech Time-Depend Mater 28, 1–17 (2024). https://doi.org/10.1007/s11043-022-09575-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11043-022-09575-8