Skip to main content
SpringerLink
Log in

Lifetime and Damage Characterization of Compacted Graphite Iron During Thermo-mechanical Fatigue Under Varying Constraint Conditions

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

The cylinder head of heavy-duty fuel engines, made of compacted graphite iron, is sensitive to cracking as a result of a phenomenon called Thermo-Mechanical Fatigue (TMF) induced by subsequent start-up and shut-down cycles of the engine. Under laboratory conditions, various test setups were applied to reproduce the TMF behavior of the valve bridge areas, which are specifically prone to TMF. In these laboratory tests, various mechanical boundary conditions were applied including single and double constraints at low and high temperatures. The TMF lifetime is satisfactorily modeled based on the Paris Crack Growth Law. The reason why the law can accurately simulate the lifetime is due to the fact that this law allows for a description whereby plastically induced damage is gradually built up cycle by cycle, which eventually is reflected in the Cp parameter of the Paris equation. It was proven that the description is valid under partial constraint, full constraint, and over-constraint boundary conditions and even with varying constraint conditions at high and low temperature. Post-processing of the Paris Law model allowed defining an equivalent constraint value γ′, which is a single constraint that yields an identical lifetime as the experiment with double constraint at low and high temperature.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Abbreviations

a :

Defect size

AC:

As cast

CGI:

Compacted graphite iron

Cp :

Paris’ crack growth law factor

E:

Elastic modulus

EDX:

Energy-dispersive X-ray spectroscopy

FE:

Finite elements

f g :

Shape factor

HCF:

High cycle fatigue

KI :

Stress intensity factor

LCF:

Low cycle fatigue

LEFM:

Linear elastic fracture mechanics

m :

Paris’ crack growth law exponent factor

N :

Number of cycles

N 10 :

Number of cycles to failure criteria

N f :

Lifetime

OP:

Out of phase

r :

Sample radius at the gauge length

STDEV:

Standard deviation

TMF:

Thermo-mechanical fatigue

TSR :

Total strain range

VB:

Valve bridge

XRF:

X‐ray fluorescence analyzer

α :

Thermal expansion coefficient

γ :

Constraint

γ′:

Effective equivalent constraint

ε m :

Mechanical stain

Δε m :

Mechanical strain range

Δε p :

Plastic strain

\( {\overline {\Delta \varepsilon }_{\text{p}}} \) :

Average plastic strain constructed with Δεp values of cycles 4, 10, 20, 40 and N10

ΔT :

Temperature difference

σ :

Stress

ε th :

Thermal strain

ε E :

Elastic strain

ε total :

Total strain of the gauge length

\( {\varepsilon_{{\text{t}}{{\text{h}}_{\text{ref}}}}} \) :

Reference thermal strain

\( {\varepsilon_{{\text{total}}\_{\text{LT}}}} \) :

Total strain at minimum temperature

\( {\varepsilon_{{\text{total}}\_{\text{HT}}}} \) :

Total strain at maximum temperature

References

  1. ASM: in Metals HandBook—Fatigue and Fracture, ASM, eds., 1996 ed., 2005, p. 2592.

  2. R.G. Budynas, J.K. Nisbett, and J.E. Shigley: Mechanical Engineering Design, McGraw-Gill Interamericana, 2008.

  3. D. F. M. GmbH, J. Eng. Gas Turbines Power, 2008, vol. 130, p. 10.

    Google Scholar 

  4. S. Dawson: China Foundry, 2009, vol. 241, p. 6.

  5. S. Dawson: Compacted Graphite Iron: Mechanical and Physical Properties for Engine Design, Materials in Powertrain VDI, Dresden, 1999, vol. 1.

  6. M. B. Grieb, H.-J. Christ, and B. Plege, Proc. Eng., 2010, vol. 2, pp. 1767–76.

    Article  Google Scholar 

  7. N. Collin: Master of Science, Industrial Engineering and Management, 2014, KTH, Stockholm.

  8. V. Norman, P. Skoglund, D. Leidermark, and J. Moverare, Int. J. Fatigue, 2016, vol. 88, pp. 121-131.

    Article  CAS  Google Scholar 

  9. M. Riedler, H. Leitner, B. Prillhofer, G. Winter, and W. Eichlseder, Meccanica,2007, vol. 42, pp. 47-59.

    Article  Google Scholar 

  10. G. Pusch et al.: in Recent Trends in Fracture and Damage Mechanics, G. Hütter and L. Zybell, eds., Springer International Publishing, Cham, 2016, pp. 159–96.

  11. S. Ghodrat: Ph.D. Dissertation, Materials Science and Engineering, Delft University of Technology, Delft, The Netherlands, 2013.

  12. M. J. Dong, C. Prioul, and D. François, Metall and Mat Trans A,1997, vol. 28, pp. 2255-2262.

    Article  CAS  Google Scholar 

  13. M.C. Mattias Lundberg, R.L. Peng: Presented at the 13th International Conference on Fracture, Beijing, China, 2013.

  14. S. Ghodrat, A. C. Riemslag, M. Janssen, J. Sietsma, and L. A. I. Kestens, Int. J. Fatigue,2013, vol. 48, pp. 319-329.

    Article  CAS  Google Scholar 

  15. A. Riemslag, JTEVA,1994, vol. 22, pp. 410-419.

    CAS  Google Scholar 

  16. A. Kalra: Master of Science, 3Mi, 2016, Delft University of Technology, Delft.

  17. X. Wu, G. Quan, R. MacNeil, Z. Zhang, X. Liu, and C. Sloss, Metall and Mat Trans A,2015, vol. 46, pp. 2530-2543.

    Article  Google Scholar 

  18. C.G. Csaba Halászi, H. Dannbauer: MAGNA Powertrain, 2007, p. 14.

  19. H. J. Christ, Procedia Engineering,2013, vol. 55, pp. 181-190.

    Article  Google Scholar 

  20. G.H.S.S. Manson, and M. Hirschberg: Presented at the Symposium on Design for Elevated Temperature Environment, 1971.

  21. P. Hähner et al., Int. J. Fatigue,2008, vol. 30, pp. 372-381.

    Article  Google Scholar 

  22. ASTM: Standard Practice for Strain Controlled Thermomechanical Fatigue Testing, E2368.ASTM, 2004.

  23. T. L. Anderson, Fracture Mechanics: Fundamentals and Applications, 3 edn., CRC Press, Boca Raton, 2004, p. 640.

    Google Scholar 

  24. P. Kumar: Elements of Fracture Mechanics. McGraw-Hill, New York, 2009, p. 273

  25. H. Tada, P.C. Paris, and G.R. Irwin: in The Stress Analysis of Cracks Handbook, Third Edition, H. Tada, P.C. Paris, and G.R. Irwin, eds., ASME, New York, 2000.

  26. S. Ghodrat and L. A. I. Kestens, Steel Res. Int.,2016, vol. 86, p. 8.

    Google Scholar 

  27. H. J. Christ, A. Jung, H. J. Maier, and R. Teteruk, Sadhana,2003, vol. 28, pp. 147-165.

    Article  Google Scholar 

  28. M. J. Dong, C. Prioul, and D. François, Metall and Mat Trans A,1997, vol. 28, pp. 2245-2254.

    Article  Google Scholar 

  29. G.E. Dieter: Mechanical Metalurgy, 2nd ed., McGraw-Hill Book Co., New York, 1976, pp. 241–75.

  30. T.E. Reinton: in Norwegian University of Science and Technology, Trondheim, 2016, vol. Master.

Download references

Acknowledgments

M.Sc student Reinton Elise (TU-Delft) is acknowledged for her assistance with carrying out the experimental schedule.[30] The authors are also indebted to Dr. A.C. Riemslag for ample valuable discussions. The authors acknowledge and thank the contributions of Aslan Mohammadpour who performed Finite Elements calculations regarding temperature gradients at the sample gauge length during heating and cooling.

Funding

This research was carried out under project number F23.5.13484a. in the framework of the Partnership Program of the Materials Innovation Institute M2i (www.m2i.nl) and the Foundation of Fundamental Research on Matter (FOM) (www.fom.nl), which is part of the Netherlands Organization for Scientific Research (www.nwo.nl).

Author Contributions

Conceptualization: Edwin A. Lopez-Covaleda; Methodology: Edwin A. Lopez-Covaleda, Sepideh Ghodrat, and Leo A.I. Kestens; Formal Analysis: Edwin A. Lopez-Covaleda, Sepideh Ghodrat, and Leo A.I. Kestens; Investigation: E.A. Lopez-Covaleda; Resources: Leo A.I. Kestens; Data Curation: Edwin A. Lopez-Covaleda; Writing-Original Draft Preparation: Edwin A. Lopez-Covaleda; Writing-Review & Editing: Edwin A. Lopez-Covaleda, Sepideh Ghodrat, and Leo A.I. Kestens; Visualization: Edwin A. Lopez-Covaleda; Supervision: Sepideh Ghodrat and Leo A.I. Kestens; Project Administration: Leo A.I. Kestens; Funding Acquisition: Leo A.I. Kestens.

Conflict of interest

None

Author information

Authors and Affiliations

  1. Metals Science and Technology Group, EEMMeCS Department, Ghent University, Technologiepark 46, 9052, Ghent, Belgium

    Edwin A. Lopez-Covaleda & Leo A. I. Kestens

  2. Metal Processing group of the CRM GROUP, Technologiepark 48 B, 9052, Ghent, Belgium

    Edwin A. Lopez-Covaleda

  3. Design Engineering Department, Faculty of Industrial Design Engineering, Delft University of Technology, Landbergstraat 15, 2628 CE, Delft, The Netherlands

    Sepideh Ghodrat

  4. Materials Science and Engineering Department, Delft University of Technology, Delft, The Netherlands

    Leo A. I. Kestens

Authors
  1. Edwin A. Lopez-Covaleda
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sepideh Ghodrat
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Leo A. I. Kestens
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Edwin A. Lopez-Covaleda.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Manuscript submitted January 29, 2019.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lopez-Covaleda, E.A., Ghodrat, S. & Kestens, L.A.I. Lifetime and Damage Characterization of Compacted Graphite Iron During Thermo-mechanical Fatigue Under Varying Constraint Conditions. Metall Mater Trans A 51, 226–236 (2020). https://doi.org/10.1007/s11661-019-05522-4

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-019-05522-4

Search

Navigation