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The purpose of this paper is to present and validate a methodology for the structural integrity assessment of components containing a variety of stress risers and subjected to static conditions.

The methodology is based on the use of the apparent fracture toughness prediction provided by the theory of critical distances (in this case, the line method), together with a well‐known, widely‐used engineering tool in structural integrity assessments: failure assessment diagrams. In order to validate the proposed methodology, an experimental programme has been conducted, testing 38 specimens made of aluminium alloy Al7075‐T651, each of them containing a certain stress riser. The comparison between the experimental results and the corresponding predictions provided by the proposed assessment methodology has also allowed the situations for which the theory of critical distances provides accurate predictions to be defined.

The results show that the methodology provides accurate results as long as the Neuber number, defined as the notch radius divided by the critical distance (L), is sufficiently low. In order to extend the validity to situations where the Neuber number is higher, it is necessary to calibrate L by using notched specimens with similar radii to those found in the defects being analysed.

The present study is part of Virginia Madrazo's doctoral thesis, an original research work.

The main aim of this study is to investigate the mixed-mode I/II failure and the cracking manner of three-dimensional (3D)-printed components made by the fused deposition modeling technique in an experimental and theoretical manner.

Acrylonitrile butadiene styrene (ABS) material and a modified printing method (that increases the adhesion and integrity between the layers and strands) are used for manufacturing the semicircular bending (SCB) test samples. In addition to precracking, the effect of additional stress concentration on the stress field is studied by introducing three small holes to the SCB fracture samples. The critical mixed-mode I/II failure loads obtained from the experiments are predicted using different stress/strain-based fracture theories, including maximum tangential stress (MTS), maximum tangential strain (MTSN), generalized form of MTS and MTSN and combination of them with equivalent material concept (EMC). The effects of plastic deformation, as well as the structural stress concentration, are considered for a more realistic prediction of mixed-mode fracture load.

The stress-based criteria are more suitable than the strain-based theories. Among the investigated fracture models, the EMC–generalized maximum tangential stress theory provided the best agreement with the experimental results obtained from 3D-printed SCB tests.

The influences of stress risers and applicability of different failure theories in cracked layered 3D-printed parts are studied on the fracture behavior of tested specimens under mixed-mode I/II.

The stress state near the notch affects fatigue damage directly, but quantifying the stress field is difficult. The purpose of this study is to provide a mathematical description method of the stress field near the notch to achieve a reliable assessment of the fatigue life of notched specimens.

Firstly, the stress distribution of notched specimens of different materials and shapes under different stress levels is investigated, and a method for calculating the stress gradient impact factor is presented. Then, the newly defined stress gradient impact factor is used to describe the stress field near the notch, and an expression for the stress at any point along a specified path is developed. Furthermore, by combining the mathematical expressions for the stress field near the notch, a multiaxial fatigue life prediction model for notched shaft specimens is established based on the damage mechanics theory and closed solution method.

The stress gradient factor for notched specimens with higher stress concentration factors (V60-notch, V90-notch) varies to a certain extent when the external load and material change, but for notched specimens with relatively lower stress concentration factors (C-notch, U-notch, stepped shaft), the stress gradient factor hardly varies with the change in load and material, indicating that the shape of the notch has a greater influence on the stress gradient. It is also found that the effect of size on the stress gradient factor is not obvious for notched specimens with different shapes, there is an obvious positive correlation between the normal stress gradient factor and the normal stress concentration factor compared with the relationship between the shear stress gradient factor and the stress concentration factor. Moreover, the predicted results of the proposed model are in better agreement with the experimental results of five kinds of materials compared with the FS model, the SWT model, and the Manson–Coffin equation.

In this paper, a new stress gradient factor is defined based on the stress distribution of a smooth specimen. Then, a mathematical description of the stress field near the notch is provided, which contains the nominal stress, notch size, and stress concentration factor which is calculated by the finite element method (FEM). In addition, a multiaxial fatigue life prediction model for shaft specimens with different notch shapes is established with the newly established expressions based on the theory of damage mechanics and the closed solution method.

The purpose of this paper is to present a methodology to predict initial crack growth behavior of crack or notch like stress raisers in AISI 316L(N) stainless steel material subjected to monotonic loading condition.

The methodology for critical crack blunting corresponding to crack initiation in crack or notch like stress raisers is based on critical plastic strain (Epc) at a characteristic distance (lc), where uniform strain (Eu) is considered as Epc and two grain diameter is considered as lc. Further crack growth is based on parabolic crack tip opening displacement (CTOD) scheme established based on coupled experimental and FEM analysis of compact tension (CT) specimen subjected to mode-I loading condition. The FEM predicted load-displacement plots is compared with experimental result of CT specimens with different a/W ratios. It has shown that the proposed methodology could account initial crack blunting appropriately and predict the fracture load and load-displacement plots for initial crack growth regime.

The results show that for crack growth with near straight crack front, experimental data from a CT specimen of particular a/W ratio coupled with plane strain 2D FEM analysis could predict load vs displacement plots for different a/W ratios when initial crack blunting is accounted appropriately with a local damage model.

The present study is a part of developing methods to analyse fracture behavior of AISI 316L(N) SS material components used for fast breeder reactor-based power plant being built at Kalpakkam, India.

This study aims to extend the application of the quality category approach in rapid fatigue assessment of complex welded structures containing defects under arbitrary loadings, following the investigation of their core data and fatigue assessment procedures based on fracture mechanics.

The analysis methods and procedures for calculating equivalent sizes of semi-elliptic cracks and initial sizes of through-width cracks at the weld toe were developed based on the life equivalence principle. Different stress concentration solutions, i.e. 2D-M_k and 3D-M_k solutions, and different bending ratios were considered. Then, approximate equations were proposed to calculate the crack size under combined stress. In addition, a procedure for calculating the fatigue life by interpolation was proposed and applied to engineering examples.

The fatigue lives of fillet and butt weld joints obtained with the 3D-M_k solution for large L/B are longer than those obtained with the 2D-M_k solution. The results of the fatigue life of the brake unit bracket show that the average error between the proposed approximation equations and the quality category approach is 1.6%.

The quality category and equivalent size curves of different stress concentration solutions under combined membrane and bending stresses are newly added, which further expands the application of the quality category approach. When the proposed fatigue life calculation methods are employed, the remaining life can be quickly derived in addition to the qualitative conclusion on the safety of the structure. These provide the necessary conditions to perform a rapid fatigue assessment adapted to engineering purposes.

Under multiaxial random loading, the material stress–strain response is not periodic, which makes it difficult to determine the direction of the critical plane on the material. Meanwhile, existing methods of constant loading cannot be directly applied to multiaxial random loading; this problem can be solved when an equivalent stress transformation method is used.

First, the Liu-Mahadevan critical plane is introduced into multiaxial random fatigue, which is enabled to determine the material's critical plane position under random loading. Then, an equivalent stress transformation method is proposed which can convert random load to constant load. Meanwhile, the ratio of mean stress to yield strength is defined as the new mean stress influence factor, and a new non-proportional additional strengthening factor is proposed by considering the effect of phase differences.

The proposed model is validated using multiaxial random fatigue test data of TC4 titanium alloy specimens and the results of the proposed model are compared with that based on Miner's rule and BSW model, showing that the proposed method is more accurate.

In this work, a new multiaxial random fatigue life prediction model is proposed based on equivalent stress transformation method, which considers the mean stress effect and the additional strengthening effect. Results show that the predicted fatigue lives given by the proposed model are in well accordance with the tested data.

The combined numerical-experimental approach has been presented. The purpose of this paper is to determine the critical rupture load of the notched components based on the cohesive zone modeling (CZM).

The 42CrMo4 steel (in normalized state) state has been tested and modeled using an eXtended finite element method (xFEM) philosophy with the CZM approach. In order to validate the numerically obtained critical load forces the experimental verification was performed.

The critical loads were determined for various notch configurations. The numerical and experimental values were compared. Based on this, a good agreement between experimental and numerical data is achieved. The relative error does not exceed 7 percent.

The presented procedure and approach is effective and simple for engineering applications. It is worth to underline that the obtained critical load values for notched components require only the static tensile test results and implementation of the presented route in numerical FEM, xFEM environment.

The presented methodology is actual and still developed. The scientific and engineering value of the presented numerical procedure is high.

The purpose of this paper is to develop basic principles of deterministic structural integrity assessment of a component with a crack- or notch-like defect by including safety factors against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.

The safety factors against fracture are calculated by demanding that the applied critical stress should not be less than the yield stress of the material for a component with a crack or a notch of the acceptable size. Structural integrity assessment of the engineering components damaged by crack- or notch-like defects is discussed from view point of the failure assessment diagram (FAD). The methodology of the FAD has been employed for the structural integrity analysis and assessment of acceptable sizes of throw-thickness notch in a plate under tension and surface longitudinal notch-like defects in a pressure vessel.

Basic equations have been presented to calculate the safety factor against fracture for critical values of the stress intensity factor, crack tip opening displacement (CTOD), the J-integral and the FAD as well as to estimate an acceptable (safe) region for an engineering component with a crack- or notch-like defect of the acceptable size. It was shown that safety factors against fracture depend on both the safety factor against plastic collapse and employed fracture mechanics criterion. The effect of crack/notch tip constraint is incorporated into criteria equations for the calculation of safety factors against fracture.

The deterministic method of fracture mechanics is recommended for structural integrity assessment of a component with a crack- or notch-like defect by including safety factors against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.

The purpose of this study is to develop an efficient numerical procedure for simulating the effect of printing orientation, as one of the primary sources of anisotropy in 3D-printed components, on their fracture properties.

The extended finite element method and the cohesive zone model (XFEM-CZM) are used to develop subroutines for fracture simulation. The ability of two prevalent models, i.e. the continuous-varying fracture properties (CVF) model and the weak plane model (WPM), and a combination of both models (WPM-CVF) are evaluated to capture fracture behavior of the additively manufactured samples. These models are based on the non-local and local forms of the anisotropic maximum tangential stress criterion. The numerical models are assessed by comparing their results with experimental outcomes of 16 different configurations of polycarbonate samples printed using the material extrusion technique.

The results demonstrate that the CVF exaggerates the level of anisotropy, and the WPM cannot detect the mild anisotropy of 3D-printed parts, while the WPM-CVF produces the best results. Additionally, the non-local scheme outperforms the local approach in terms of finite element analysis performance, such as mesh dependency, robustness, etc.

This paper provides a method for modeling anisotropic fracture in 3D-printed objects. A new damage model based on a combination of two prevalent models is offered. Moreover, the developed subroutines for implementing the non-local anisotropic fracture criterion enable a reliable crack propagation simulation in media with varying degrees of complication, such as anisotropy.

Additive manufacturing (AM) enables the production of lightweight parts with complex shapes and small dimensions. Recent improvements in AM techniques have allowed a significant growth of AM for industrial applications. In particular, AM is suitable for the production of materials shaped in lattice, which are very attractive for their lightweight design and their multi-functional properties. AM parts are often characterised by geometrical imperfections, residual porosity, high surface roughness which typically lead to stress/strain localisations and decreasing the resistance of the structure. This paper aims to focus on the study of the effects of geometrical irregularities and stress concentrations derived from them.

In this paper, several technique were combined: 3D tomography, experimental tests, digital image correlation and finite elements (FE) models based on both the as-designed and the as-manufactured geometries of lattice materials. The Digital Image Correlation technique allowed to measure local deformations in the specimen during the experimental test. The micro-computed tomography allowed to reconstruct the as-manufactured geometries of the specimens, from which the geometrical quality of the micro-structure is evaluated to run FE analyses.

Experimental and numerical results were compared by means of a stress concentration factor. This factor was calculated in three different specimens obtained from three-different printing processes to compare and understand their mechanical properties. Considering the as-designed geometry, it is not possible to model geometrical imperfections, and a FE model based on an as-manufactured geometry is needed. The results show that the mechanical properties of the printed samples are directly related to the statistical distribution of the stress concentration factor.

In this work, several techniques were combined to study the mechanical behaviour of lattice micro-structures. Lattice materials obtained by different selective laser melting printing parameters show different mechanical behaviours. A stress concentration factor can be assumed as a measure of the quality of these mechanical properties.