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Description
Aluminum alloys and their composites are attractive materials for applications requiring high strength-to-weight ratios and reasonable cost. Many of these applications, such as those in the aerospace industry, undergo fatigue loading. An understanding of the microstructural damage that occurs in these materials is critical in assessing their fatigue resistance. Two

Aluminum alloys and their composites are attractive materials for applications requiring high strength-to-weight ratios and reasonable cost. Many of these applications, such as those in the aerospace industry, undergo fatigue loading. An understanding of the microstructural damage that occurs in these materials is critical in assessing their fatigue resistance. Two distinct experimental studies were performed to further the understanding of fatigue damage mechanisms in aluminum alloys and their composites, specifically fracture and plasticity. Fatigue resistance of metal matrix composites (MMCs) depends on many aspects of composite microstructure. Fatigue crack growth behavior is particularly dependent on the reinforcement characteristics and matrix microstructure. The goal of this work was to obtain a fundamental understanding of fatigue crack growth behavior in SiC particle-reinforced 2080 Al alloy composites. In situ X-ray synchrotron tomography was performed on two samples at low (R=0.1) and at high (R=0.6) R-ratios. The resulting reconstructed images were used to obtain three-dimensional (3D) rendering of the particles and fatigue crack. Behaviors of the particles and crack, as well as their interaction, were analyzed and quantified. Four-dimensional (4D) visual representations were constructed to aid in the overall understanding of damage evolution. During fatigue crack growth in ductile materials, a plastic zone is created in the region surrounding the crack tip. Knowledge of the plastic zone is important for the understanding of fatigue crack formation as well as subsequent growth behavior. The goal of this work was to quantify the 3D size and shape of the plastic zone in 7075 Al alloys. X-ray synchrotron tomography and Laue microdiffraction were used to non-destructively characterize the volume surrounding a fatigue crack tip. The precise 3D crack profile was segmented from the reconstructed tomography data. Depth-resolved Laue patterns were obtained using differential-aperture X-ray structural microscopy (DAXM), from which peak-broadening characteristics were quantified. Plasticity, as determined by the broadening of diffracted peaks, was mapped in 3D. Two-dimensional (2D) maps of plasticity were directly compared to the corresponding tomography slices. A 3D representation of the plastic zone surrounding the fatigue crack was generated by superimposing the mapped plasticity on the 3D crack profile.
ContributorsHruby, Peter (Author) / Chawla, Nikhilesh (Thesis advisor) / Solanki, Kiran (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2014
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Description
Interstitial impurity atoms can significantly alter the chemical and physical properties of the host material. Oxygen impurity in HCP titanium is known to have a considerable strengthening effect mainly through interactions with dislocations. To better understand such an effect, first the role of oxygen on various slip planes in titanium

Interstitial impurity atoms can significantly alter the chemical and physical properties of the host material. Oxygen impurity in HCP titanium is known to have a considerable strengthening effect mainly through interactions with dislocations. To better understand such an effect, first the role of oxygen on various slip planes in titanium is examined using generalized stacking fault energies (GSFE) computed by the first principles calculations. It is shown that oxygen can significantly increase the energy barrier to dislocation motion on most of the studied slip planes. Then the Peierls-Nabbaro model is utilized in conjunction with the GSFE to estimate the Peierls stress ratios for different slip systems. Using such information along with a set of tension and compression experiments, the parameters of a continuum scale crystal plasticity model, namely CRSS values, are calibrated. Effect of oxygen content on the macroscopic stress-strain response is further investigated through experiments on oxygen-boosted samples at room temperature. It is demonstrated that the crystal plasticity model can very well capture the effect of oxygen content on the global response of the samples. It is also revealed that oxygen promotes the slip activity on the pyramidal planes.

The effect of oxygen impurity on titanium is further investigated under high cycle fatigue loading. For that purpose, a two-step hierarchical crystal plasticity for fatigue predictions is presented. Fatigue indicator parameter is used as the main driving force in an energy-based crack nucleation model. To calculate the FIPs, high-resolution full-field crystal plasticity simulations are carried out using a spectral solver. A nucleation model is proposed and calibrated by the fatigue experimental data for notched titanium samples with different oxygen contents and under two load ratios. Overall, it is shown that the presented approach is capable of predicting the high cycle fatigue nucleation time. Moreover, qualitative predictions of microstructurally small crack growth rates are provided. The multi-scale methodology presented here can be extended to other material systems to facilitate a better understanding of the fundamental deformation mechanisms, and to effectively implement such knowledge in mesoscale-macroscale investigations.
ContributorsGholami Bazehhour, Benyamin (Author) / Solanki, Kiran N (Thesis advisor) / Liu, Yongming (Committee member) / Oswald, Jay J (Committee member) / Rajagopalan, Jagannathan (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Fatigue is a degradation process of materials that would lead to failure when materials are subjected to cyclic loadings. During past centuries, various of approaches have been proposed and utilized to help researchers understand the underlying theories of fatigue behavior of materials, as well as design engineering structures so that

Fatigue is a degradation process of materials that would lead to failure when materials are subjected to cyclic loadings. During past centuries, various of approaches have been proposed and utilized to help researchers understand the underlying theories of fatigue behavior of materials, as well as design engineering structures so that catastrophic disasters that arise from fatigue failure could be avoided. The stress-life approach is the most classical way that academia applies to analyze fatigue data, which correlates the fatigue lifetime with stress amplitudes during cyclic loadings. Fracture mechanics approach is another well-established way, by which people regard the cyclic stress intensity factor as the driving force during fatigue crack nucleation and propagation, and numerous models (such as the well-known Paris’ law) are developed by researchers.

The significant drawback of currently widely-used fatigue analysis approaches, nevertheless, is that they are all cycle-based, limiting researchers from digging into sub-cycle regime and acquiring real-time fatigue behavior data. The missing of such data further impedes academia from validating hypotheses that are related to real-time observations of fatigue crack nucleation and growth, thus the existence of various phenomena, such as crack closure, remains controversial.

In this thesis, both classical stress-life approach and fracture-mechanics-based approach are utilized to study the fatigue behavior of alloys. Distinctive material characterization instruments are harnessed to help collect and interpret key data during fatigue crack growth. Specifically, an investigation on the sub-cycle fatigue crack growth behavior is enabled by in-situ SEM mechanical testing, and a non-uniform growth mechanism within one loading cycle is confirmed by direct observation as well as image interpretation. Predictions based on proposed experimental procedure and observations show good match with cycle-based data from references, which indicates the credibility of proposed methodology and model, as well as their capability of being applied to a wide range of materials.
ContributorsLiu, Siying (Author) / Liu, Yongming (Thesis advisor) / Jiao, Yang (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Widespread knowledge of fracture mechanics is mostly based on previous models that generalize crack growth in materials over several loading cycles. The objective of this project is to characterize crack growth that occurs in titanium alloys, specifically Grade 5 Ti-6Al-4V, at the sub-cycle scale, or within a single loading cycle.

Widespread knowledge of fracture mechanics is mostly based on previous models that generalize crack growth in materials over several loading cycles. The objective of this project is to characterize crack growth that occurs in titanium alloys, specifically Grade 5 Ti-6Al-4V, at the sub-cycle scale, or within a single loading cycle. Using scanning electron microscopy (SEM), imaging analysis is performed to observe crack behavior at ten loading steps throughout the loading and unloading paths. Analysis involves measuring the incremental crack growth and crack tip opening displacement (CTOD) of specimens at loading ratios of 0.1, 0.3, and 0.5. This report defines the relationship between crack growth and the stress intensity factor, K, of the specimens, as well as the relationship between the R-ratio and stress opening level. The crack closure phenomena and effect of microcracks are discussed as they influence the crack growth behavior. This method has previously been used to characterize crack growth in Al 7075-T6. The results for Ti-6Al-4V are compared to these previous findings in order to strengthen conclusions about crack growth behavior.
ContributorsNazareno, Alyssa Noelle (Author) / Liu, Yongming (Thesis director) / Jiao, Yang (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
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Description
In-situ fatigue damage diagnosis and prognosis is a challenging problem for both metallic and composite materials and structures. There are various uncertainties arising from material properties, component geometries, measurement noise, feature extraction techniques, and modeling errors. It is essential to manage and incorporate these uncertainties in order to achieve accurate

In-situ fatigue damage diagnosis and prognosis is a challenging problem for both metallic and composite materials and structures. There are various uncertainties arising from material properties, component geometries, measurement noise, feature extraction techniques, and modeling errors. It is essential to manage and incorporate these uncertainties in order to achieve accurate damage detection and remaining useful life (RUL) prediction.

The aim of this study is to develop an integrated fatigue damage diagnosis and prognosis framework for both metallic and composite materials. First, Lamb waves are used as the in-situ damage detection technique to interrogate the damaged structures. Both experimental and numerical analysis for the Lamb wave propagation within aluminum are conducted. The RUL of lap joints under variable and constant fatigue loading is predicted using the Bayesian updating by incorporating damage detection information and various sources of uncertainties. Following this, the effect of matrix cracking and delamination in composite laminates on the Lamb wave propagation is investigated and a generalized probabilistic delamination size and location detection framework using Bayesian imaging method (BIM) is proposed and validated using the composite fatigue testing data. The RUL of the open-hole specimen is predicted using the overall stiffness degradation under fatigue loading. Next, the adjoint method-based damage detection framework is proposed considering the physics of heat conduction or elastic wave propagation. Different from the classical wave propagation-based method, the received signal under pristine condition is not necessary for estimating the damage information. This method can be successfully used for arbitrary damage location and shape profiling for any materials with higher accuracy and resolution. Finally, some conclusions and future work are generated based on the current investigation.
ContributorsPeng, Tishun (Author) / Liu, Yongming (Thesis advisor) / Chattopadhyay, Aditi (Committee member) / Mignolet, Marc (Committee member) / Papandreou-Suppappola, Antonia (Committee member) / Tang, Pingbo (Committee member) / Arizona State University (Publisher)
Created2016
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Description
All structures suffer wear and tear because of impact, excessive load, fatigue, corrosion, etc. in addition to inherent defects during their manufacturing processes and their exposure to various environmental effects. These structural degradations are often imperceptible, but they can severely affect the structural performance of a component, thereby severely decreasing

All structures suffer wear and tear because of impact, excessive load, fatigue, corrosion, etc. in addition to inherent defects during their manufacturing processes and their exposure to various environmental effects. These structural degradations are often imperceptible, but they can severely affect the structural performance of a component, thereby severely decreasing its service life. Although previous studies of Structural Health Monitoring (SHM) have revealed extensive prior knowledge on the parts of SHM processes, such as the operational evaluation, data processing, and feature extraction, few studies have been conducted from a systematical perspective, the statistical model development.

The first part of this dissertation, the characteristics of inverse scattering problems, such as ill-posedness and nonlinearity, reviews ultrasonic guided wave-based structural health monitoring problems. The distinctive features and the selection of the domain analysis are investigated by analytically searching the conditions of the uniqueness solutions for ill-posedness and are validated experimentally.

Based on the distinctive features, a novel wave packet tracing (WPT) method for damage localization and size quantification is presented. This method involves creating time-space representations of the guided Lamb waves (GLWs), collected at a series of locations, with a spatially dense distribution along paths at pre-selected angles with respect to the direction, normal to the direction of wave propagation. The fringe patterns due to wave dispersion, which depends on the phase velocity, are selected as the primary features that carry information, regarding the wave propagation and scattering.

The following part of this dissertation presents a novel damage-localization framework, using a fully automated process. In order to construct the statistical model for autonomous damage localization deep-learning techniques, such as restricted Boltzmann machine and deep belief network, are trained and utilized to interpret nonlinear far-field wave patterns.

Next, a novel bridge scour estimation approach that comprises advantages of both empirical and data-driven models is developed. Two field datasets from the literature are used, and a Support Vector Machine (SVM), a machine-learning algorithm, is used to fuse the field data samples and classify the data with physical phenomena. The Fast Non-dominated Sorting Genetic Algorithm (NSGA-II) is evaluated on the model performance objective functions to search for Pareto optimal fronts.
ContributorsKim, Inho (Author) / Chattopadhyay, Aditi (Thesis advisor) / Jiang, Hanqing (Committee member) / Liu, Yongming (Committee member) / Mignolet, Marc (Committee member) / Rajadas, John (Committee member) / Arizona State University (Publisher)
Created2016
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Description
There is a concerted effort in developing robust systems health monitoring/management (SHM) technology as a means to reduce the life cycle costs, improve availability, extend life and minimize downtime of various platforms including aerospace and civil infrastructure. The implementation of a robust SHM system requires a collaborative effort in a

There is a concerted effort in developing robust systems health monitoring/management (SHM) technology as a means to reduce the life cycle costs, improve availability, extend life and minimize downtime of various platforms including aerospace and civil infrastructure. The implementation of a robust SHM system requires a collaborative effort in a variety of areas such as sensor development, damage detection and localization, physics based models, and prognosis models for residual useful life (RUL) estimation. Damage localization and prediction is further complicated by geometric, material, loading, and environmental variabilities. Therefore, it is essential to develop robust SHM methodologies by taking into account such uncertainties. In this research, damage localization and RUL estimation of two different physical systems are addressed: (i) fatigue crack propagation in metallic materials under complex multiaxial loading and (ii) temporal scour prediction near bridge piers. With little modifications, the methodologies developed can be applied to other systems.

Current practice in fatigue life prediction is based on either physics based modeling or data-driven methods, and is limited to predicting RUL for simple geometries under uniaxial loading conditions. In this research, crack initiation and propagation behavior under uniaxial and complex biaxial fatigue loading is addressed. The crack propagation behavior is studied by performing extensive material characterization and fatigue testing under in-plane biaxial loading, both in-phase and out-of-phase, with different biaxiality ratios. A hybrid prognosis model, which combines machine learning with physics based modeling, is developed to account for the uncertainties in crack propagation and fatigue life prediction due to variabilities in material microstructural characteristics, crack localization information and environmental changes. The methodology iteratively combines localization information with hybrid prognosis models using sequential Bayesian techniques. The results show significant improvements in the localization and prediction accuracy under varying temperature.

For civil infrastructure, especially bridges, pier scour is a major failure mechanism. Currently available techniques are developed from a design perspective and provide highly conservative scour estimates. In this research, a fully probabilistic scour prediction methodology is developed using machine learning to accurately predict scour in real-time under varying flow conditions.
ContributorsNeerukatti, Rajesh Kumar (Author) / Chattopadhyay, Aditi (Thesis advisor) / Jiang, Hanqing (Committee member) / Liu, Yongming (Committee member) / Rajadas, John (Committee member) / Yekani Fard, Masoud (Committee member) / Arizona State University (Publisher)
Created2016
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Description
The Very High Temperature Reactor (VHTR) is one of six conceptual designs proposed for Generation IV nuclear reactors. Alloy 617, a solid solution strengthened Ni-base superalloy, is currently the primary candidate material for the tubing of the Intermediate Heat Exchanger (IHX) in the VHTR design. Steady-state operation of the nuclear

The Very High Temperature Reactor (VHTR) is one of six conceptual designs proposed for Generation IV nuclear reactors. Alloy 617, a solid solution strengthened Ni-base superalloy, is currently the primary candidate material for the tubing of the Intermediate Heat Exchanger (IHX) in the VHTR design. Steady-state operation of the nuclear power plant at elevated temperatures leads to creep deformation, whereas loading transients including startup and shutdown generate fatigue. A detailed understanding of the creep-fatigue interaction in Alloy 617 is necessary before it can be considered as a material for nuclear construction in ASME Boiler and Pressure Vessel Code. Current design codes for components undergoing creep-fatigue interaction at elevated temperatures require creep-fatigue testing data covering the entire range from fatigue-dominant to creep-dominant loading. Classical strain-controlled tests, which produce stress relaxation during the hold period, show a saturation in cycle life with increasing hold periods due to the rapid stress-relaxation of Alloy 617 at high temperatures. Therefore, applying longer hold time in these tests cannot generate creep-dominated failure. In this study, uniaxial isothermal creep-fatigue tests with non-traditional loading waveforms were designed and performed at 850 and 950°C, with an objective of generating test data in the creep-dominant regime. The new loading waveforms are hybrid strain-controlled and force-controlled testing which avoid stress relaxation during the creep hold. The experimental data showed varying proportions of creep and fatigue damage, and provided evidence for the inadequacy of the widely-used time fraction rule for estimating creep damage under creep-fatigue conditions. Micro-scale damage features in failed test specimens, such as fatigue cracks and creep voids, were quantified using a Scanning Electron Microscope (SEM) to find a correlation between creep and fatigue damage. Quantitative statistical imaging analysis showed that the microstructural damage features (cracks and voids) are correlated with a new mechanical driving force parameter. The results from this image-based damage analysis were used to develop a phenomenological life-prediction methodology called the effective time fraction approach. Finally, the constitutive creep-fatigue response of the material at 950°C was modeled using a unified viscoplastic model coupled with a damage accumulation model. The simulation results were used to validate an energy-based constitutive life-prediction model, as a mechanistic model for potential component and structure level creep-fatigue analysis.
ContributorsTahir, Fraaz (Author) / Liu, Yongming (Thesis advisor) / Jiang, Hanqing (Committee member) / Rajagopalan, Jagannathan (Committee member) / Oswald, Jay (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2017
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Description
Uncertainty quantification is critical for engineering design and analysis. Determining appropriate ways of dealing with uncertainties has been a constant challenge in engineering. Statistical methods provide a powerful aid to describe and understand uncertainties. This work focuses on applying Bayesian methods and machine learning in uncertainty quantification and prognostics among

Uncertainty quantification is critical for engineering design and analysis. Determining appropriate ways of dealing with uncertainties has been a constant challenge in engineering. Statistical methods provide a powerful aid to describe and understand uncertainties. This work focuses on applying Bayesian methods and machine learning in uncertainty quantification and prognostics among all the statistical methods. This study focuses on the mechanical properties of materials, both static and fatigue, the main engineering field on which this study focuses. This work can be summarized in the following items: First, maintaining the safety of vintage pipelines requires accurately estimating the strength. The objective is to predict the reliability-based strength using nondestructive multimodality surface information. Bayesian model averaging (BMA) is implemented for fusing multimodality non-destructive testing results for gas pipeline strength estimation. Several incremental improvements are proposed in the algorithm implementation. Second, the objective is to develop a statistical uncertainty quantification method for fatigue stress-life (S-N) curves with sparse data.Hierarchical Bayesian data augmentation (HBDA) is proposed to integrate hierarchical Bayesian modeling (HBM) and Bayesian data augmentation (BDA) to deal with sparse data problems for fatigue S-N curves. The third objective is to develop a physics-guided machine learning model to overcome limitations in parametric regression models and classical machine learning models for fatigue data analysis. A Probabilistic Physics-guided Neural Network (PPgNN) is proposed for probabilistic fatigue S-N curve estimation. This model is further developed for missing data and arbitrary output distribution problems. Fourth, multi-fidelity modeling combines the advantages of low- and high-fidelity models to achieve a required accuracy at a reasonable computation cost. The fourth objective is to develop a neural network approach for multi-fidelity modeling by learning the correlation between low- and high-fidelity models. Finally, conclusions are drawn, and future work is outlined based on the current study.
ContributorsChen, Jie (Author) / Liu, Yongming (Thesis advisor) / Chattopadhyay, Aditi (Committee member) / Mignolet, Marc (Committee member) / Ren, Yi (Committee member) / Yan, Hao (Committee member) / Arizona State University (Publisher)
Created2022
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Description
The relationships between the properties of materials and their microstructures have been a central topic in materials science. The microstructure-property mapping and numerical failure prediction are critical for integrated computational material engineering (ICME). However, the bottleneck of ICME is the lack of a clear understanding of the failure mechanism as

The relationships between the properties of materials and their microstructures have been a central topic in materials science. The microstructure-property mapping and numerical failure prediction are critical for integrated computational material engineering (ICME). However, the bottleneck of ICME is the lack of a clear understanding of the failure mechanism as well as an efficient computational framework. To resolve these issues, research is performed on developing novel physics-based and data-driven numerical methods to reveal the failure mechanism of materials in microstructure-sensitive applications. First, to explore the damage mechanism of microstructure-sensitive materials in general loading cases, a nonlocal lattice particle model (LPM) is adopted because of its intrinsic ability to handle the discontinuity. However, the original form of LPM is unsuitable for simulating nonlinear behavior involving tensor calculation. Therefore, a damage-augmented LPM (DLPM) is proposed by introducing the concept of interchangeability and bond/particle-based damage criteria. The proposed DLPM successfully handles the damage accumulation behavior in general material systems under static and fatigue loading cases. Then, the study is focused on developing an efficient physics-based data-driven computational framework. A data-driven model is proposed to improve the efficiency of a finite element analysis neural network (FEA-Net). The proposed model, i.e., MFEA-Net, aims to learn a more powerful smoother in a multigrid context. The learned smoothers have good generalization properties, and the resulted MFEA-Net has linear computational complexity. The framework has been applied to efficiently predict the thermal and elastic behavior of composites with various microstructural fields. Finally, the fatigue behavior of additively manufactured (AM) Ti64 alloy is analyzed both experimentally and numerically. The fatigue experiments show the fatigue life is related with the contour process parameters, which can result in different pore defects, surface roughness, and grain structures. The fractography and grain structures are closely observed using scanning electron microscope. The sample geometry and defect/crack morphology are characterized through micro computed tomography (CT). After processing the pixel-level CT data, the fatigue crack initiation and growth behavior are numerically simulated using MFEA-Net and DLPM. The experiments and simulation results provided valuable insights in fatigue mechanism of AM Ti64 alloy.
ContributorsMeng, Changyu (Author) / Liu, Yongming (Thesis advisor) / Hoover, Christian (Committee member) / Li, Lin (Committee member) / Peralta, Pedro (Committee member) / Wang, Liping (Committee member) / Arizona State University (Publisher)
Created2023