Online and Ex Situ Damage Characterization Techniques for Fiber-Reinforced Composites under Ultrasonic Cyclic Three-Point Bending.

With ultrasonic fatigue testing (UFT), it is possible to investigate the damage initiation and accumulation from the weakest link of the composite material in the very high cycle fatigue (VHCF) regime in a shorter time frame than conventional fatigue testing. However, the thermal influence on the mechanical fatigue of composites and the scatter in fatigue data for composites under ultrasonic cyclic three-point bending loading still need to be investigated. In this study, we conducted interrupted constant-amplitude fatigue experiments on a carbon-fiber satin-fabric reinforced in poly-ether-ketone-ketone (CF-PEKK) composite material. These experiments were carried out using a UFT system, which operates at a cyclic frequency of 20 kHz with a pulse-pause sequence. Various parameters, such as the CF-PEKK specimen's surface temperature, acoustic activity, and the ultrasonic generator's input resonance parameters, were measured during cyclic loading. During experiment interruption, stiffness measurement and volumetric damage characterization in the CF-PEKK specimens using 3D X-ray microscopy (XRM) were performed. The locations of damage initiation and accumulation and their influence on the changes in in situ parameters were characterized. Under fixed loading conditions, damage accumulation occurred at different locations, leading to scattering in fatigue life data. Further, the damage population decreased from the surface to the bulk of the composite material.

Stress and strain calculation method for orthotropic polymer composites under axial and bending ultrasonic fatigue loads.

Accelerated fatigue testing is one potential solution to evaluate the very high cycle fatigue behavior of composite materials within a reasonable amount of time. The ultrasonic fatigue testing methodology can be adopted to realize fatigue experiments up to 109 cycles at 20 kHz, compared to conventional fatigue experiments usually carried out between 5-50 Hz. The determination of cyclic stresses during ultrasonic loading remains to be one of the major challenges. The cyclic stresses during ultrasonic fatigue loading were investigated for a carbon fiber 5H satin fabric reinforced in Polyetherketoneketone (CF-PEKK) composite material. Two experimental setups were developed to perform ultrasonic testing under uni-axial and three-point bending loading conditions. A 3D-Scanning Laser Doppler Vibrometer (3D-SLDV) and a single-point Laser Doppler Vibrometer (LDV) were integrated into the test systems to measure the oscillation displacement of the CF-PEKK specimens during ultrasonic cyclic loading. These displacement measurements were used to calculate the resulting strains and stresses under elastic loading conditions. The experimental results were found to be in good agreement with those obtained from finite element models, providing evidence for applying the proposed method.

Measuring the Cooling Behavior of Melt Pools in L-PBF by Pyrometry.

This study aims to measure the cooling rates or, more precisely, the cooling durations of single laser tracks by pyrometry within the laser powder bed fusion (L-PBF) process. Two-color, as well as one-color pyrometers are tested within this work. Regarding the second, the emissivity of the investigated 30CrMoNb5-2 alloy is determined in-situ within the L-PBF system in order to measure temperature instead of arbitrary units. This is done by heating up printed samples and verifying the measured pyrometer signal by comparing it to values obtained by thermocouples attached to the samples. In addition, the precision of two-color pyrometry is verified for the given setup. Following the verification experiments, single laser track experiments are conducted. The obtained signals prove to be partially distorted mainly due to by-products such as smoke and weld beads arising from the melt pool. To encounter this problem, a new fitting method is presented and experimentally validated. Melt pools resulting from different cooling durations are analyzed by EBSD. These measurements show areas of extreme deformation or potential amorphization correlating with the cooling durations. The obtained cooling duration can be used for the validation of simulations as well as for the correlation of corresponding microstructure and process parameters.

In-Depth Evaluation of Ultrasonically Welded Al/Cu Joint: Plastic Deformation, Microstructural Evolution, and Correlation with Mechanical Properties.

Ultrasonic metal welding (USMW) is widely used in assembling lithium-ion (Li-ion) battery packs due to its advantages in joining dissimilar and conductive materials in the solid state. However, the welding process and mechanisms are not yet clearly understood. In this study, dissimilar joints of aluminum alloy EN AW 1050 to copper alloy EN CW 008A were welded by USMW to simulate the tab-to-bus bar interconnects for Li-ion battery assembly. Qualitative and quantitative investigations were carried out on plastic deformation, microstructural evolution, and the correlated mechanical properties. During USMW, the plastic deformation concentrated on the Al side. The thickness of Al was reduced by more than 30%; complex dynamic recrystallization and grain growth occurred near the weld interface. The mechanical performance of the Al/Cu joint was evaluated with the tensile shear test. The failure load gradually increased until a welding duration of 400 ms, and then remained almost constant. The obtained results showed that the mechanical properties were greatly influenced by plastic deformation and microstructure evolution, which provides guidance for improving the weld quality and the process in general.

Solid State Joining of a Cold Rolled Zr-Based Bulk Metallic Glass to a Wrought Aluminum Alloy by Power Ultrasonics.

Ultrasonic metal welding (UMW) enables joining in the solid state at relative low temperatures with short cycle times. This technique is of particular interest for joining metallic glasses to each other or to other materials, because crystallization of the amorphous structure can be prevented due to the low thermal loading and the rapidity of the process. In this work, UMW is applied to join one 1 mm thick sheet of a commercial wrought aluminum alloy (AA5754) and one 0.4 mm thick strip of a commercial Zr-based bulk metallic glass (AMZ4). The introduced heat of the welding process is detected with thermocouples and thermal imaging. To investigate the strength of the joint and the influence on the microstructure, mechanical tensile tests are carried out in combination with scanning electron microscopy and differential scanning calorimetry. The results show that ultrasonic metal welding is a suitable technique to join amorphous bulk metallic glasses to crystalline aluminum alloys. The metallic glass component retains its amorphous structure in the joint, and the joint strength is higher than the strength of the Al sheet. These findings will help to develop future applications of BMG-based multi-material components, including medical tools.

Influence of Pulse-Pause Sequences on the Self-Heating Behavior in Continuous Carbon Fiber-Reinforced Composites under Ultrasonic Cyclic Three-Point Bending Loads.

Several studies have been conducted in the Very High Cycle Fatigue (VHCF) regime on Carbon Fiber Reinforced Polymers (CFRP) in search of their fatigue limit beyond their typical service life, which is itself in the order of 108 loading cycles. The ultrasonic fatigue test (UFT) method has been recently gaining attention for conducting fatigue experiments up to 109 loading cycles. This can be attributed to the reduction of testing time, as the testing facility operates at a cyclic frequency of 20 kHz. The fatigue loading in UFT is usually performed in a pulse-pause sequence to avoid specimen heating and undesirable thermal effects. For this study, the pulse-pause combination of the UFT methodology was explored and its influence on the self-heating behavior of the CFRP material was analyzed. This was realized by monitoring the temperature evolution in the CFRP specimens at different pulse-pause combinations and correlating it with their final damage morphologies. From the obtained results, it is concluded that the specimen heating phenomenon depends on several variables such as cyclic loading amplitude, the pulse-pause combination, and the damage state of the material. Finally, it is proposed that the test procedure, as well as the testing time, can be further optimized by designing the experiments based on the self-heating characteristic of the composite and the glass transition temperature (Tg) of the polymer matrix.

Biomechanics of the parasite-host interaction of the European mistletoe.

The European mistletoe (Viscum album) is an epiphytic hemiparasite that attaches to its host by an endophytic system. Two aspects are essential for its survival: the structural integrity of the host-parasite interface must be maintained during host growth and the functional integrity of the interface must be maintained during ontogeny and under mechanical stress. We investigated the mechanical properties of the mistletoe-host interaction. Intact and sliced mistletoe-host samples, with host wood as reference, were subjected to tensile tests up to failure. We quantified the rough fractured surface by digital microscopy and analysed local surface strains by digital image correlation. Tensile strength and deformation energy were independent of mistletoe age but exhibited markedly lower values than host wood samples. Cracks initiated at sites with a major strain of about 30%, especially along the mistletoe-host interface. The risk of sudden failure was counteracted by various sinkers and a lignification gradient that smooths the differences in the mechanical properties between the two species. Our results improve the understanding of the key mechanical characteristics of the host-mistletoe interface and show that the mechanical connection between the mistletoe and its host is age-independent. Thus, functional and structural integrity is ensured over the lifetime of the mistletoe.

3D X-ray Microscopy of Ultrasonically Welded Aluminum/Fiber-Reinforced Polymer Hybrid Joints.

Ultrasonically welded hybrid aluminum/fiber-reinforced PEEK joints were analyzed non-destructively with an X-ray microscope. The potential and limitations of the technology as a non-destructive testing method were investigated. For a quantitative evaluation, joints with suitable and unsuitable parameters were compared. For a further comparison, geometric modifications of the joining partners were made, and the influence on the structure and process variation of the resulting hybrid joints was examined on a microscopic level. By using a tool for 3D segmentation of the composition of the joining zone, quantitative information on volume-specific proportions could be obtained and compared in relation to each other.

An Empirical Approach for the Development of Process Parameters for Laser Powder Bed Fusion.

For certain additive manufacturing technologies the choice of available materials is currently limited. The development of process parameters is especially elaborate for powder bed technologies. Currently, there is no common approach concerning the procedure and documentation. This work proposes a methodology for the initial development of process parameters for new L-PBF (laser powder bed fusion) alloys. Key elements are the examination of the laser-powder-bed interaction by single laser track experiments and an iterative design of experiment (DoE) approach for the development of volumetric parameters. Two types of single laser track experiments are presented and provide information regarding the laser track width and depth as well as the resulting surface roughness and melt pool classification. Based on the information gained, suitable process windows for a DoE study can be defined by avoiding parameter settings unsuitable for production or measurement. Gradually, input variables are identified and iterative steps reduce the process window in order to optimize the desired target values. Near-surface exposure parameters are developed by a one-dimensional parameter variation and metallographic investigations. The approach is primarily designed for the initial development of process parameters for new L-PBF alloys. However, the information gained can also be used to optimize established parameter sets regarding new target values (productivity, mechanical properties), optimize process parameters for specific components or for a microstructural design.

Ultrasonic torsion welding of ageing-resistant Al/CFRP joints: Properties, microstructure and joint formation.

Ultrasonic metal welding is a promising process for joining light metals with fiber-reinforced thermoplastics. The technique is characterized by high reproducibility, short process times, low energy input, no additional filler materials and finally the possibility of extensive process data logging. With this process, dissimilar aerospace materials are ultrasonically welded and the applied process parameters are optimized by statistical methods. A prediction of ageing resistance is possible by the evaluation of the electrical resistivity of the multi-material-joints. With the help of detailed process parameter recording and microscopic investigations, the bonding mechanism of hybrid AA5024/(GF-)CF-PEEK joints is explained and the kinematics of bonding formation is presented in detail.

Analysis of fatigue properties and failure mechanisms of Ti6Al4V in the very high cycle fatigue regime using ultrasonic technology and 3D laser scanning vibrometry.

Accelerated fatigue tests with Ti6Al4V were carried out using a 20kHz ultrasonic testing facility to investigate the cyclic deformation behavior in the Very High Cycle Fatigue (VHCF) regime in detail. Beside parameters like the ultrasonic generator power and the displacement of the specimen, a 3D laser scanning vibrometer was used to characterize the oscillation and fatigue behavior of the Ti-alloy. The course of the S-N(f) curve at the stress ratio R=-1 shows a significant decrease of the bearable stress amplitude and a change from surface to subsurface failures in the VHCF regime for more than 107 cycles. Microscopic investigations of the distribution of the α- and ß-phase of Ti6Al4V indicate that inhomogeneities in the phase distribution are reasons for the internal crack initiation. High resolution vibrometry was used to visualize the eigenmode of the designed VHCF-specimen at 20 kHz in the initial state and to indicate local changes in the eigenmodes as a result of progressing fatigue damage. Non-contact strain measurements were realized and used to determine the stress amplitude. The determined stress amplitudes were correlated with strain gauge measurements and finite element analysis.