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Technical Paper

A Comparative Study of the Fatigue Behavior of Spot Welded and Mechanically Fastened Aluminum Joints

1995-02-01
950710
The cyclic behavior of single overlap aluminum joints joined through a number of different methods has been investigated using Alcan 5754-O, an alloy that potentially could be used in structural applications. Overlap shear tests of spot welded, clinched and riveted joints are compared on the basis of their fatigue performance. The fatigue response of the spot welded joint was the baseline to which the other fasteners were compared. Test results showed an improvement of approximately 25% for both the mechanical clinch joints and aluminum rivets in fatigue strength at 106 cycles. The most significant improvement in fatigue strength of 100% was found for the self piercing rivets at 106 cycles. The failure behavior of the various joining methods is discussed as well as the surface appearance.
Technical Paper

Designing for the Effects of Corrosion on the Fatigue of Automotive Materials

2007-04-16
2007-01-0389
With the renewed current interest in high strength steel and aluminum automotive body and chassis components it has again become important to properly assess the effects of corrosion on the fatigue behavior of structures. The present work summarizes the past work on fatigue and corrosion and presents new results on current automotive materials. The Neuber plasticity correction method, used throughout fatigue software of the ground vehicle industry to account for localized plastic behavior during fatigue, was found to give a very simple and useful technique for the computation of fatigue life of materials in corrosion environments. Data is offered for many common automotive structural materials and a method is given to adapt finite element calculations to compute corrosion fatigue life.
Technical Paper

Impact of Decarburization on the Fatigue Life of Powder Metal Forged Connecting Rods

2001-03-05
2001-01-0403
A main requirement for a satisfactory function and service life of a forged powder metal connecting rod is the fatigue strength. Fatigue strength mainly depends on design, material, microstructure, and surface condition. Much work has been accomplished to optimize these factors, but still a variety of surface defects such as localized porosity, roughness, oxide penetration, decarburization, etc., can be developed during manufacturing. These surface defects impact the fatigue strength in various ways. The impact of the decarburized layer depth on the fatigue life of a forged powder metal connecting rod is the focus of this work. Several connecting rods were submitted to a Weibull test at the same loading pattern. After the fatigue tests, the connecting rods were divided into groups with different decarburized layer depths. Both Maximum Likelihood Estimates (MLE) and Rank Regression (RR) techniques were used to analyze test results from all the groups obtained.
Technical Paper

Increased Fatigue Strength of Powder-Forged Connecting Rods by Optimized Shot Peening

1995-02-01
950384
Shot peening is a commonly used surface treatment process used to improve the fatigue life of aircraft, automotive and other highly stressed structural components. This improvement is attributed to the formation of compressive residual stress on the surface layer of the material by the impingement of spherical media (shot). The compressive residual stress usually decreases the tensile stress created in the component by “in service” external forces and therefore increases the fatigue strength of the part. To quantify the improvement resulting from shot peening, the fatigue behavior of powder-forged connecting rods and laboratory test bars from the base material (2% copper steel), both in the stress-free (unpeened) and surface treated (shot peened) condition were compared. The fatigue data were correlated with the residual stress generated at the surface. The stress magnitude and depth were determined using x-ray diffraction analysis.
Technical Paper

Low Cycle Fatigue of A356-T6 Cast Aluminum Alloy - A Round-Robin Test Program

1988-08-01
881701
A round-robin low cycle fatigue test program was conducted by the SAEFDE Committee using A356-T6 cast aluminum alloy. Three different microstructures representative of three solidification rates were sought, but only two significantly different secondary dendrite arm spacings, DAS, resulted. The smaller DAS had slightly greater monotonic yieid and ultimate strengths, greater permanent deformation at fracture and better low cycle fatigue resistance. Under strain-controlled axial low cycle fatigue conditions. A356-T6 was observed to cyclicaiiy strain harden and hysteresis loops were skewed toward the compressive stress from about 1 to 10 percent. Fatigue failures usually initiated at surface or near surface porosity. About 25 percent of the 173 test specimens that were considered valid failed between the strain gage knife edges and the specimen fillet radius.
Technical Paper

Steel Powders for High Performance Automotive Parts

1994-03-01
940423
Increased use of powder-forged connecting rods in the automotive industry prompted an investigation into the suitability of powders from different suppliers for this application. Specifications developed by North American users call for ultra clean powders to enhance machinability and fatigue life. Powders from four manufacturers were each blended with graphite and lubricant, then pressed, sintered and forged to full density. Metallographic samples were prepared and evaluated for inclusion content. In addition, the powders were mixed to the composition of connecting rods, (C - 0.5%, Cu - 2% and MnS - 0.3%), and were similarly pressed, sintered and forged. Test bars were machined from the forged discs. Uniaxial fatigue tests were performed in the tension-compression mode and strain-life curves were developed. It was determined that all powders examined were very clean and were comparable in their inclusion content.
Technical Paper

Using Superposition to Calculate Critical Location Stress, Strain and Life in Vehicular Transmission Shafts of Complex Geometry Subjected to Bending and Torsion

2002-03-04
2002-01-1302
A procedure for the computation of fatigue life of shafts subjected to variable amplitude independent bending and torsion loading is described. The elastic superposition technique, followed by a Neuber plasticity correction, also allows for the initial and possibly cyclic plasticity dependent residual stress states caused by induction hardening or other surface altering processing effects. The present study documents the formation and alteration of residual stresses caused by initial induction hardening and followed by a straightening process. Sample calculations are presented for two critical finite elements of a prototype shaft, and lives are predicted using a traditional equivalent axial stress and by a new procedure that searches for and computes lives at critical angles.
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