Abstract
Based on the heterogeneous material model, an integrated analysis method was introduced to predict the service life of propeller. The morphology and distribution characteristic of non-continuous defects (porosity & inclusion) were calculated and mapped into the finite element model by 3D-mapping algorithm, and the fatigue life was predicted based on the heterogeneous material model. In this paper, the coupling analysis of casting process and fatigue prediction of marine propeller was done. The results show that porosity and mass inclusions in blade roots of propeller form serious heterogeneous characteristics in those parts, which increased the maximum stress of the propeller and decreased its theoretical fatigue life by 1/2, indicating that the effect of non-continuous defects on the service performance of casting is notable and cannot be ignored. Based on the integrated analysis method, the inference of the pouring temperature and gating system on the service life of propeller was studied further. The integrated analysis method brings the influence of the casting defects into structural analysis and fatigue analysis, which can improve the accuracy of the fatigue life prediction significantly.
Similar content being viewed by others
References
L. Rao, L.B. Zhu, and Q.Y. Hu, The Influence of Pore Defects Distribution Characteristic on Casting Service Performance and Fatigue Life, Adv. Mater. Res., 2012, 476, p 2530–2533
B. Skallerud, T. Iveland, and G. Harkegard, Fatigue Life Assessment Of Aluminum Alloys with Casting Defects, Eng. Fract. Mech., 1993, 44, p 857–874
D.A. Gerard and D.A. Koss, Low-Cycle Fatigue Crack Initiation: Modelling the Effect of Porosity, Int. J. Powder Metall., 1990, 26(4), p 337–343. International Journal of Fatigue, 1991
Q.Y. Wang, N. Kawagoishi, and Q. Chen, Fatigue and Fracture Behaviour of Structural Al-Alloys Up to Very Long Life Regimes, Int. J. Fatigue, 2006, 28(11), p 1572–1576
K.M. Sigl, R.A. Hardin, R.I. Stephens et al., Fatigue of 8630 Cast Steel in the Presence of Porosity, Int. J. Cast Met. Res., 2004, 17(3), p 130–146
J. Linder, M. Axelsson et al., The Influence of Porosity on the Fatigue Life for Sand and Permanent Mould Cast Aluminium, Int. J. Fatigue, 2006, 28(12), p 1752–1758
M. Vincent, C. Nadotmartin, and Y. Nadot, Fatigue from Defect Under Multiaxial Loading: Defect Stress Gradient (DSG) Approach Using Ellipsoidal Equivalent Inclusion Method, Int. J. Fatigue, 2014, 59, p 176–187
F. Morel, A. Morel, and Y. Nadot, Comparison Between Defects and Micro-Notches In Multiaxial Fatigue—The Size Effect and the Gradient Effect, Int. J. Fatigue, 2009, 31(2), p 263–275
T. Miyazaki, H. Kang, H. Noguchi et al., Prediction of High-Cycle Fatigue Life Reliability of Aluminum Cast Alloy from Statistical Characteristics of Defects at Meso-Scale, Int. J. Mech. Sci., 2008, 50(2), p 152–162
Zhan, Z., Hu, W., Meng, Q., et al. A Damage Mechanics-Based Fatigue Life Prediction Approach for 30crmnsia Alloy Steel with Impact Defect, in First International Conference on Reliability Systems Engineering (2016)
O.M. Herasymchuk and O.V. Kononuchenko, Model for Fatigue Life Prediction of Titanium Alloys. Part 1. Elaboration of a Model of Fatigue Life Prior to Initiation of Microstructurally Short Crack and a Propagation Model for Physically Short and Long Cracks, Strength Mater., 2013, 45(1), p 44–55
A. Yadollahi, M.J. Mahtabi, A. Khalili et al., Fatigue Life Prediction of Additively Manufactured Material: Effects of Surface Roughness, Defect Size, and Shape, Fatigue Fract. Eng. Mater. Struct., 2018, 41(3), p 1602–1614.
M. Tiryakioğlu, On the Relationship Between Statistical Distributions of Defect Size and Fatigue Life in 7050-T7451 Thick Plate and A356-T6 Castings, Mater. Sci. Eng. A, 2009, 520(1), p 114–120
Q. Jin, M. Li, and Q. Wen, Inner Defect Induced Crack Growth Analysis and Fatigue Life Prediction for Anthropogenic CO2 Pipelines, Progress in Industrial and Civil Engineering, in International Conference on Civil, Architectural and Hydraulic Engineering (ICCAHE), Applied Mechanics and Materials, Vol 204–208, Aug 10–12, 2012, Zhangjiajie, PR China, p 2981–2984
Odegard, J.A., Pedersen, K. Fatigue Properties of an A356 (AlSi7Mg) Aluminium Alloy for Automotive Applications - Fatigue Life Prediction. 1994.
R.A. Hardin and C. Beckermann, Prediction of the Fatigue Life of Cast Steel Containing Shrinkage Porosity, Metall. Mater. Trans. A, 2009, 40(3), p 581
J.Z. Yi, P.D. Lee, T.C. Lindley et al., Statistical modeling of Microstructure and Defect Population Effects on the Fatigue Performance of Cast A356-T6 Automotive Components, Mater. Sci. Eng. A, 2006, 432(1–2), p 59–68
Q.G. Wang, D. Apelian, and D.A. Lados, Fatigue Behavior of A356-T6 Aluminum Cast Alloys. Part I. Effect of Casting Defects, J. Light Met., 2001, 1(1), p 73–84
V. Balasubramanian and B. Guha, Influence of Weld Size on Fatigue Life Prediction for flux Cored Arc Welded Cruciform Joints Containing Lack of Penetration Defects, Sci. Technol. Weld. Joining, 2013, 5(2), p 99–104
S.C. Haldimann-Sturm and A. Nussbaumer, Fatigue Design of Cast Steel Nodes in Tubular Bridge Structures, Int. J. Fatigue, 2008, 30(3), p 528–537
R. Kapoor, V. Sree Hari Rao, R.S. Mishra et al., Probabilistic Fatigue Life Prediction Model for Alloys with Defects: Applied to A206, Acta Materialia, 2011, 59(9), p 3447–3462
J. Chen, B. Diao, J. He et al., Equivalent Surface Defect Model for Fatigue Life Prediction of Steel Reinforcing Bars with Pitting Corrosion, Int. J. Fatigue, 2018, 110, p 153–161
W. Pabst, E. Gregorová, T. Uhlíová et al., Elastic Properties of Porous Alumina, Zirconia and Composite Ceramics, Key Eng. Mater., 2013, 592–593, p 618–621
Y.N. Podrezov, N.I. Lugovoi, A.G. Kostornov et al., Elastic Modulus of Highly Porous Nickel-Based Materials, Powder Metall. Met. Ceram., 1997, 36(3–4), p 203–206
A.R. Boccaccini, G. Ondracek, P. Mazilu et al., On the Effective Young’s Modulus of Elasticity for Porous Materials: Microstructure Modelling and Comparison Between Calculated and Experimental Values, J. Mech. Behav. Mater., 1993, 4(2), p 119–128
T. Sumitomo, C.H. Cáceres, and M. Veidt, The Elastic Modulus of cast Mg–Al–Zn Alloys, J. Light Met., 2002, 2(1), p 49–56
R.W. Rice, Use of Normalized Porosity in Models for the Porosity Dependence of Mechanical Properties, J. Mater. Sci., 2005, 40(4), p 983–989
A.P. Roberts and E.J. Garboczi, Elastic Properties of Model Porous Ceramics, J. Am. Ceram. Soc., 2000, 83(12), p 3041–3048
O.D. Velev and E.W. Kaler, Structured Porous Materials via Colloidal Crystal Templating: from Inorganic Oxides to Metals, Adv. Mater., 2000, 12(7), p 531–534
Z. Yuyuan et al., Optimisation of Compaction and Liquid-State Sintering in Sintering and Dissolution Process for Manufacturing Al Foams, Mater. Sci. Eng. A, 2004, 364, p 117–125
B. Jiang, N.Q. Zhao, C.S. Shi et al., A Novel Method for Making Open Cell Aluminum Foams by Powder Sintering Process, Mater. Lett., 2005, 59, p 3333–3336
J.F. Despois, A. Marmottant, L. Salvo et al., Influence of the Infiltration Pressure on the Structure and Properties of Replicated Aluminium Foams, Mater. Sci. Eng. Struct. Mater. Properties Microstruct. Process, 2007, A462(1–2), p 68–75
Acknowledgments
We are grateful for grants from the National Natural Science Foundation of China (No. 51775167), and the Qing Lan Project of Jiangsu province.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
You, K., Rao, L., Bai, X. et al. An Integrated Analysis Method of Service Life Based on the 3D Heterogeneous Material Model with Casting Defects. J. of Materi Eng and Perform 29, 4641–4651 (2020). https://doi.org/10.1007/s11665-020-04937-0
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-020-04937-0