Skip to main content
SpringerLink
Log in

Numerical calculation and experimental research on crack arrest by detour effect and joule heating of high pulsed current in remanufacturing

  • Published:
Chinese Journal of Mechanical Engineering Submit manuscript

Abstract

The remanufacturing blanks with cracks were considered as irreparable. With utilization of detour effect and Joule heating of pulsed current, a technique to arrest the crack in martensitic stainless steel FV520B is developed. According to finite element theory, the finite element(FE) model of the cracked rectangular specimen is established firstly. Then, based on electro-thermo-structure coupled theory, the distributions of current density, temperature field, and stress field are calculated for the instant of energizing. Furthermore, the simulation results are verified by some corresponding experiments performed on high pulsed current discharge device of type HCPD-I. Morphology and microstructure around the crack tip before and after electro pulsing treatment are observed by optical microscope(OM) and scanning electron microscope(SEM), and then the diameters of fusion zone and heat affected zone(HAZ) are measured in order to contrast with numerical calculation results. Element distribution, nano-indentation hardness and residual stress in the vicinity of the crack tip are surveyed by energy dispersive spectrometer(EDS), scanning probe microscopy(SPM) and X-ray stress gauge, respectively. The results show that the obvious partition and refined grain around the crack tip can be observed due to the violent temperature change. The contents of carbon and oxygen in fusion zone and HAZ are higher than those in matrix, and however the hardness around the crack tip decreases. Large residual compressive stress is induced in the vicinity of the crack tip and it has the same order of magnitude for measured results and numerical calculation results that is 100 MPa. The relational curves between discharge energies and diameters of the fusion zone and HAZ are obtained by experiments. The difference of diameter of fusion zone between measured and calculated results is less than 18.3%. Numerical calculation is very useful to define the experimental parameters. An effective method to prevent further extension of the crack is presented and can provide a reference for the compressor rotor blade remanufacturing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. LIU Zhengdao, ZHANG Xiancheng, XUAN Fuzhen, et al. Effect of laser power on the microstructure and mechanical properties of TiN/Ti3Al composite coating on Ti6Al4V[J]. Chinese Journal of Mechanical Engineering, 2013, 26(4): 714–721.

    Article  Google Scholar 

  2. TAN Jun, CHEN Jianmin, LIU Min, et al. Surface engineering towards green manufacturing and remanufacturing[J]. Journal of Mechanical Engineering, 2011, 47(20): 95–103. (in Chinese)

    Article  Google Scholar 

  3. XU Binshi, DONG Shiyun, ZHU Sheng, et al. Prospects and developing of remanufacture forming technology[J]. Journal of Mechanical Engineering, 2012, 48(15): 96–105. (in Chinese)

    Article  Google Scholar 

  4. TU J F, PALEOCRASSAS A G. Fatigue crack fusion in thin-sheet aluminum alloys AA7075-T6 using low-speed fiber laser welding[J]. Journal of Materials Processing Technology, 2011, 211: 95–102. (in Chinese)

    Article  Google Scholar 

  5. SCHNUBEL D, HORSTMANN M, VENTZKE V, et al. Retardation of fatigue crack growth in aircraft aluminium alloys via laser heating-Experimental proof of concept[J]. Materials Science & Engineering A, 2012, 546: 8–14.

    Article  Google Scholar 

  6. SONG P S, SHIEH Y L. Stop drilling procedure for fatigue life improvement[J]. International Journal of Fatigue, 2004, 26: 1333–1339.

    Article  Google Scholar 

  7. ZHAO Yuguang, MA Bingdong, GUO Haicha, et al. Electropulsing strengthened 2GPa boron steel with good ductility[J]. Materials and Design, 2013, 43: 195–199.

    Article  Google Scholar 

  8. YIN Zhenxing, LIANG Dong, CHEN Yue, et al. Effect of electrodes and thermal insulators on grain refinement by electric current pulse[J]. Transactions of Nonferrous Metals Society of China, 2013, 23: 92–97.

    Article  Google Scholar 

  9. LIU Yan, ZHOU Hong, SU Hang, et al. Effect of electrical pulse treatment on the thermal fatigue resistance of bionic compacted graphite cast iron processed in water[J]. Materials and Design, 2012, 39: 344–349.

    Article  Google Scholar 

  10. ZHOU Y Z, GAO J D, GAO M. Crack healing in a steel by using electropulsing technique[J]. Materials Letters, 2004, 58: 1732–1736.

    Article  Google Scholar 

  11. GOLOVIN Y I, FINKEL V M, SLETKOV A. A. Effects of current pulse on crack propagation kinetics in silicon iron[J]. Problemy Prochnosti, 1975 (2): 86–91.

    Google Scholar 

  12. FAN Hualin, CHEN Ping. Crack arrest effect in thin plates[J]. Acta Arm Amentarii, 2005, 26(6): 791–794. (in Chinese)

    Google Scholar 

  13. ZHANG Hongchao, YU jing, HAO Shengzhi, et al. Application of electro-magnetic heat effect on arresting the crack in remanufacturing blank[J]. Journal of Mechanical Engineering, 2013, 49(7): 21–28. (in Chinese)

    Article  Google Scholar 

  14. FU Yuming, TIAN Zhengguo, ZHENG Lijuan. Analysis on the thermal stress field when crack arrest in an axial symmetry metal die using electromagnetic heating[J]. Applied of Mathematics and Mechanics, 2006, 8(3): 53–55.

    MATH  Google Scholar 

  15. ZHENG Lijuan, FU Yuming, TIAN Zhenguo, et al. Analysis on temperature field on a metal component with a circle half-embedding crack at the moment when the current is switched on[J]. Journal of Mechanical Engineering, 2004, 40(11): 90–93. (in Chinese)

    Article  Google Scholar 

  16. FU Yuming, ZHOU Hongmei, WANG Junli, et al. Analysis of crack arrest by electromagnetic heating in metal with oblique-elliptical embedding crack[J]. Key Engineering Materials, Advances in Fracture and Damage Mechanics XI, 2012, 525–526: 404–408.

    Google Scholar 

  17. FU Yuming, CHAI Xuan, ZHENG Lijuan, et al. Pulse discharge strengthening of 16Mn welded joint and mechanical performance[J]. Advanced Materials Research, Advanced Materials Research, 2011, 197–198: 1460–1463.

    Article  Google Scholar 

  18. WANG Ping, BAI Xiangzhong. Phase transformation stress and its influence for arresting crack propagation using electro-heating effect[J]. China Mechanical Engineering, 2011, 22(8): 980–984. (in Chinese)

    Google Scholar 

  19. GAO Diankui, LI Hui, FU Yuming, et al. Acted a pulse current to prevent the thermal fatigue crack subcritical extending[J]. Journal of Mechanical Engineering, 2001, 37(11): 28–31. (in Chinese)

    Article  Google Scholar 

  20. LIU T J C. Thermo-electro-structural coupled analyses of crack arrest by Joule heating[J]. Theoretical and Applied Fracture Mechanics, 2008, 49: 171–184.

    Article  Google Scholar 

  21. LIU T J C. Application of Thermo-Electric Joule Heating for Crack Detection[C]//International Conference on Mechanical and Electronics Engineering, Kyoto, Japan, August 1–3, 2010: 103–107.

  22. LIU T J C. Finite element modeling of melting crack tip under thermo-electric Joule heating[J] Engineering Fracture Mechanics, 2011, 78: 666–684.

    Article  Google Scholar 

  23. CAI G X, YUAN F G. Stresses around the crack tip due to electric current and self-induced magnetic field[J]. Advances in Engineering Software, 1998, 29: 297–306.

    Article  Google Scholar 

  24. CAI G X, YUAN F G. Electric current-induced stresses at the crack tip in conductors[J]. International Journal of Fracture, 1999, 96: 279–301.

    Article  Google Scholar 

  25. CHENG D K. Field and wave electromagnetics[M]. MA: Addison-Wesley, 1983.

    Google Scholar 

  26. INCROPERA F P, DEWITT D P. Fundamentals of heat and mass transfer[M]. 5th edition. New York: John Wiley & Sons, Inc., 2002.

    Google Scholar 

  27. BORESI A P, CHONG K P. Elasticity in engineering mechanics[M]. 2th ed. New York: John Wiley & Sons, Inc., 2000.

    MATH  Google Scholar 

  28. ANSYS 10. 0: online documentation[DB / OL]. Canonsburg, PA: ANSYS Inc, 2005. http://www.ansys.com/Support/Documentation/.

  29. SOSNIN O V, GROMOVA A V, FLVANOV Y, et al. Control of austenite steel fatigue strength[J]. International Journal of Fatigue, 2005, 27: 1186–1191.

    Article  Google Scholar 

  30. QIN Rongshan, SU Shengxia. Thermodynamics of crack healing under electropulsing[J]. Journal of Materials Research, 2002, 17(8): 2048–2052.

    Article  Google Scholar 

  31. MA Bingdong, ZHAO Yuguang, BAI Hui, et al. Gradient distribution of mechanical properties in the high carbon steel induced by the detour effect of the pulse current[J]. Materials and Design, 2013, 49: 168–172.

    Article  Google Scholar 

  32. NISHIMURA Toshihiko. Experimental and numerical evaluation of crack arresting capability due to a dimple[J]. Transactions of the ASME, 2005, 127: 244–250.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Institute of Sustainable Design and Manufacture, Dalian University of Technology, Dalian, 116023, China

    Jing Yu, Hongchao Zhang & Asif Iqbal

  2. School of Materials Science and Engineering, Dalian University of Technology, Dalian, 116023, China

    Dewei Deng

  3. Key Laboratory of Materials Modification by Laser, Ion and Electron Beams of Ministry of Education, Dalian University of Technology, Dalian, 116023, China

    Shengzhi Hao

Authors
  1. Jing Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hongchao Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dewei Deng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shengzhi Hao
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Asif Iqbal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jing Yu.

Additional information

Supported by National Basic Research Program of China(973 Program, Grant No. 2011CB013402)

YU Jing, born in 1984, is currently a PHD candidate at Institute of Sustainable Design and Manufacture, Dalian University of Technology, China. Her research interests include remanufacturing technology, crack arrest technology, etc.

ZHANG Hongchao, born in 1953, is currently a professor and a doctoral supervisor at Dalian University of Technology, China. His main research interests are sustainable design and manufacturing, life cycle assessment, green manufacturing, remanufacturing.

DENG Dewei, born in 1974, is currently an associate professor at Dalian University of Technology, China. He received his PhD degree from Dalian University of Technology, China, in 2003. His main research interests are surface material microscopic structure analysis and test, nuclear pump material research and application, sustainable manufacturing and remanufacturing.

HAO Shegnzhi, born in 1970, is currently an associate professor at Dalian University of Technology, China. He received his PhD degree from Dalian University of Technology, China, in 2000. His main research interest is surface treatment by high current pulsed electron beam.

IQBAL Asif, born in 1975, is currently an associate professor at Dalian University of Technology, China. He received his PhD degree from Nanjing University of Aeronautics and Astronautics, China, in 2006. His main research interests are high-speed milling, intelligent manufacturing, energy modeling of machining processes for sustainability.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yu, J., Zhang, H., Deng, D. et al. Numerical calculation and experimental research on crack arrest by detour effect and joule heating of high pulsed current in remanufacturing. Chin. J. Mech. Eng. 27, 745–753 (2014). https://doi.org/10.3901/CJME.2014.0414.075

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.3901/CJME.2014.0414.075

Keywords

Search

Navigation