Proceedings

SECOND INTERNATIONAL
Structural Integrity Conference & Exhibition
(SICE - 2018)

Organized By: Under the Aegis of

Defence Metallurgical Indian Structural
Research Laboratory Integrity Society
 PROCEEDINGS

SECOND INTERNATIONAL
Structural Integrity Conference & Exhibition
(SICE - 2018)

Organized By: Under the Aegis of

Defence Metallurgical Indian Structural
Research Laboratory Integrity Society
 

 

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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

 
1 AnOverallAspectsofElectrolessNiPbasedmicroandnanoCompositecoatingsAReview
SouvikBrahmaHotaandRajsekharChakrabarti
TechnoIndiaUniversity,WestBengal
 
2 AnalysisofIrregularStructuresUnderEarthquakeLoads
E.SivaNaveen,NimmyMariamAbrahamandSDAnithaKumari
MSRamaiahUniveristyofAppliedSciences,Bangalore
 
3 Corrosionandtribocorrosionofultrafinegrainedactivepassivemetalsinsimulatedbodyfluids
G.P.Chaudhari,M.DivyaandKumarSubham
IndianInstituteofTechnologyRoorkee
 
4 Effectofchemomechanicalcouplingoncrackpropagationinanelasticbodyusingphasefield
method
Hirshikesh,RatnaKumarAnnabattulaandSundararajanNatarajan,
IndianInstituteofTechnologyMadras
 
5 EffectofconstraintandhardeningoncracktipfieldsinFCCsinglecrystal
NipalDekaandKrishnaN.Jonnalagadda
IndianInstituteofTechnologyBombay
 
6 EffectofCrackLengthandSpecimenThicknessonConstraintinCentreCrackedPlate:A
NumericalAnalysis
NagarajEkabote,AbdulKhaderKatigar,SanjeevKavaleandKrishnarajaGKodancha
KLETechnologicalUniversity,Hubballi,Karnataka
 
7 Effectoffibreoffaxisorientationonmechanicalandacousticemissionbehaviourof2.5D
C/SiCcomposite
ManishPatel,JalajKumar,PhaniS.Kiran,T.Jayakumar,SweetyKumari,SarabjitSingh,A.
Udayakuma,V.V.BhanuPrasad,D.V.V.SatyanarayanaandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
8 EffectofmicroalloyingonmechanicalpropertiesofAlZnMgCualloy:Areview
RahulSamantaandAmitavaGhatak
TechnoIndiaUniversity,WestBengal
 
9 EffectofprimaryphasefractionontensilebehaviorofIMI834alloy
AmitSingh,I.Balasundar,J.P.GautamandT.Raghu
DepartmentofmaterialsEngg.SchoolofEngineeringScienceandTechnology,Universityof
Hyderabad,Hyderabad
 
10 EffectofShapeofExplosiveChargeinFailureofRolledHomogenousArmouredPlate
PankajK.Choudha,A.Kumaraswamy,GGDuttaandKusumkantD.Dhote
ArmamentResearchandDevelopmentEstablishment,ARDE,Pune
 
11 Effectofstraingradientsincrackpropagation
BVSSBharadwajaandA.Alankar
IndianInstituteofTechnologyBombay
 



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

12 EffectofStraininducedmartensitereversalonthedegreeofsensitizationofMetastable
AusteniticStainlessSteel
SourabhShuklaandAwanikumarP.Patil
VisvesvarayaNationalInstituteofTechnology,Nagpur
 
13 EffectofthicknessonbehaviourofEglass/epoxycompositelaminatesunderlowvelocity
impact
TSreekanthaReddy,KMogulanna,KGopinadhaReddy,PRamaSubbaReddyandVemuri
Madhu
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
14 ExperimentalDeterminationofApparentFractureToughness(KINu)forAluminumSheets
MahendraGattuandBishnupriyaDehuri,
NationalInstituteofTechnology,Rourkela
 
15 FailureAnalysisOfAntiJammingLeverCap
SaiMadhavandSatyapalSingh
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
16 FatigueAnalysisofWingFuselageLugsectionofaTransportAircraft
K.Shridhar,B.S.SureshandM.MohanKumar.
BMScollegeofengineering,Bengaluru
 
17 FiniteElementAnalysisofPeriodicMetallicFoams
AnkushBorkar,SagarDeshmukh,SripriyaRamamoorthy,AlankarAlankarandShankar
Krishnan
IndianInstituteofTechnologyBombay
 
18 Influenceofcrackclosingandlocalneartipstressesoncrackgrowthlifeestimation
A.NSavkin,R.Sunder,D.S.Denisevich,A.A.SedovandK.A.Badikov
VolgogradStateTechnicalUniversity,Russia
 
19 InsituStudyoftheEffectofHydrogenonFatigueCrackInitiationandPropagationin
PolycrystallineNickel
AmanArora,J.SaiNitin,RakeshKumarandDhirajK.Mahajan
IndianInstituteofTechnologyRopar
 
20 MechanicalPropertiesofAmorphousRibbonsProcessedbyMeltSpinning
VLNiranjani,DArvindhaBabu,BhaskarMajumdarandTKNandy
DefenceMetallurgicalResearchlaboratory,Hyderabad
 
21 MechanicalpropertiesoffinegrainedequiatomicCrCoFeNiMnhighentropyalloy
Abhijit,P.SaiKarthikandK.V.Rajulapati
UniversityofHyderabad,Hyderabad
 
22 MetallurgicalEvaluationofServiceExposedThrustVectorControl(TVC)FlapsofAeroengines
SweetyKumari,RajdeepSarkar,NChittiBabu,BVNSiva,DVVSatyanarayanaandVikas
Kumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
 



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

23 Metallurgicalfailureanalysisofcomponentsusedindefencesystems
MrityunjoyHazraandSatyapalSingh
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
24 Microstructureandmechanicalpropertiescorrelationofweldjointsofahighstrengthnaval
gradesteel
PDGosavi,KKSarkar,SKKhunte,VRPawarandBBasu
NavalMaterialsResearchLaboratory,Ambernath
 
25 MicrostructureandMechanicalPropertiesofHotIsostaticallyProcessedHighStrengthNickel
BaseSuperalloy
B.Sreenu,CM.Omprakash,RajdeepSarkar,SubhradeepChatterjeeandG.AppaRao
DefenceMetallurgicalResearchLaboratory,Hyderabad

 
26 ModellingandSimulationofFatigueFailureinBoltedJointunderDifferentLoadingCondition
VishalAchwalandManojChouksey
MewarUniversity,Chittorgarh
 
27 MultifrequencyACPDtechniqueforcreepdamagemeasurementsinDSCM247alloy
C.M.Omprakash,A.Kumara,VajenderSingha,M.KamarajbandD.V.V.Satyanarayanaa
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
28 OnthestructuralandmicrostructuralaspectsofequiatomicAlCrCoFeMoNihighentropyalloy
SamanwithaKolli,K.BhanuSankaraRaoandKoteswararaoV.Rajulapati
SchoolofEngineeringSciencesandTechnology,UniversityofHyderabad
 
29 PerformanceEnhancementofColumnsbyExternalFRPStrengtheningTechnique–AReview
DarshanPatel,PurveshPatel,TejashPatel,MitaliPatel,TejendraTankandSandip
Vasanwala
MerchantInstituteofTechnology,Mehsana
 
30 QuantifyingtheResidualStrengthofTiAlloy834at600°CwithNonlinearUltrasonicNDT
Technique
B.NagarajaKowmudi,KartikPrasad,K.GopinathandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
 
31 StrainratesensitivityandRTcreepbehavioroffrictionstirweldedandelectronbeamwelded
INRAFMsteels
J.Varghese,V.L.Manugula,K.V.Rajulapati,G.M.ReddyandK.BhanuSankaraRao
UniversityofHyderabad,Hyderabad
 
32 StudyofMaterialAnisotropyonElasticandElastoPlasticBehaviorofflatSpecimens
RameshKumar,RituJ.Singh,J.Mishra,V.BalasubramaniyanandH.S.Kushwaha
AtomicEnergyRegulatoryboard,Mumbai
 
33 SynthesisandcharacterizationofequiatomicAlCrFeMoNbNihighentropyalloyforstructural
applications
VMadhuBabu,K.BhanuSankaraRaoandKoteswararaoV.Rajulapti
SchoolofEngineeringSciencesandTechnology,UniversityofHyderabad



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

 
34 SynthesisandoptimizationofSteeringmechanismofextralongsemitrailervehicletoimprove
itsstructuralintegrity.
VikrantGarud,AbhijitKulkarni,RushikeshNanawareandPravinKarunanithi
PimpriChinchwadCollegeofEngineering,Pune
 
35 UltrasonicTestinganAlternativeforRadiographyforEvaluationofPFBRBlanketPinEndPlug
WeldIntegrity
AltafAli,AnishKumar,B.KamaleshKumar,YRCMurthy,B.Ravinder,KomalKapoorandC.
PhaniBabu
NuclearFuelComplex,Hyderabad
 
36 UseofCompressionGeometrytoStudyEffectsofStoichiometryandTemperatureonFracture
ToughnessofNiAl
DeviLal,PraveenKumarandVikramJayaram
IndianinstituteofScience,Bangalore
 
37 WeightOptimizationofHousingBracketforElectricalStarterMotorusingFEA
VaratharajNeelakandan,ThulasirajanGanesanandPraveenChakrapaniRao
ComstarAutomotiveTechnologiesPvt.Ltd





SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
AN OVERALL ASPECTS OF ELECTROLESS Ni-P
BASED MICRO AND NANO COMPOSITE
COATINGS-A REVIEW
Souvik Brahma Hota1, Rajsekhar Chakrabarti2
EM-4,Sector V, Salt Lake City, Kolkata, West Bengal 700091
souvik.hota@gmail.com
Recent advancement of coating material and techniques used for coating
on metals and non-metals gained researcher’s attention and open up a
new era of electroless composite coating where wide ranges of second
phase material from micro to nano level is being used.Electroless coating
differs from its contemporary as it's does not require external electricity
and coating takes place by oxidation reduction process which gives it's a
continuous flow of chemical reactions so that the process will go on over
a period of time until the coating is completed. Therefore,it is also called
an auto catalytic process. Present paper gives a comprehensive
understanding of Electroless coating in terms of bath composition,system
for metal/alloy and different composite coatings. Various elements of EL
composite bath have been discussed. Various types of Electroless bath
and general set up for the process has also been discussed. Influence of
process parameters on various mechanical properties like hardness,wear
resistance and chemical property like corrosion resistance is also detailed
in this paper. This paper elaborates dispersion of second phase nano-
particles in Ni-P matrix with the bonding mechanism of the composite
coatings. Electroless nickel coatings possess superb tribological
properties which includes higher hardness,excellent wear resistance and
corrosion resistance. For that reason, electroless nickel has found huge
applications in aerospace, electrical, chemical, automobile and transport
industries.Variation of concentration of different micro and nano
materials in the electroless bath solution and their effect on coating
thickness,surface roughness and other mechanical properties like
hardness and wear resistance is also studied and this paper briefly
describes the current scenario of micro and nano composite coatings and
their desired future trends. The morphology, physical and mechanical
properties of Ni-P-Composite coatings have discussed with their relevant
industrial applications.
Key Words: Electroless, nanocomposite ,hardness ,wear resistance,
corrosion resistance
ANALYSIS OF IRREGULAR STRUCTURES
UNDER EARTHQUAKE LOADS
*
Siva Naveen E1, Nimmy Mariam Abraham2 , Anitha Kumari S D3
1
Post Graduate Student, 2Assistant Professor, 3Associate Professor
1,2,3
Department of Civil Engineering, M S Ramaiah University of Applied
Sciences, Peenya, Bangalore 560 058
Email: *nimmy555@gmail.com
Behaviour of a multi-storey building during strong earthquake motion
depends on structural configuration. The irregular configurations either in
plan or in elevation are recognized as the major cause of failures during
earthquakes. Thus irregular structures, especially the ones located in
seismic zones are a matter of concern. Structures generally possess
combination of irregularities and consideration of a single irregularity
may not result in accurate prediction of seismic response. The choice of
type, degree and location of irregularities in the design of structures is
important as it helps in improving the utility as well as aesthetics of
structures. Hence, the present study addresses the seismic response of
reinforced concrete structures possessing various combinations of
irregularities in both plan and elevation. Irregularities are incorporated in
different forms in nine-story three dimensional frames. A regular frame
and 54 frames with irregularities in both plan and elevation are studied
and compared. Out of these, 34 cases are of single irregularity and 20
cases are of combination of irregularities. All the frames are subjected to
seismic loads and the response of the structures is computed numerically.
It is observed that irregularity considerably affects the seismic response.
Out of five cases of single irregularity, stiffness irregularity has
maximum impact on the response and out of seven different
combinations, the structure with mass, stiffness and vertical geometric


irregularities has maximum impact on the response. The results of this
study aids in better design of irregular structures without compromising
their performance.
CORROSION AND TRIBOCORROSION OF
ULTRAFINE GRAINED ACTIVE-PASSIVE
METALS IN SIMULATED BODY FLUIDS
G.P. Chaudhari, M. Divya, Kumar Subham
Department of Metallurgical and Materials Engineering, Indian Institute
of Technology Roorkee 247667 India
Email of corresponding author: chaudfmt@iitr.ac.in
Ultrafine or nano-scale grained materials produced by severe plastic
deformation techniques offer new structural and functional properties for
orthopaedic implant applications. Most of the orthopaedic implants fail
due to combined action of wear and corrosion in the body fluids.
Therefore, in this work common implant grade stainless steel and
titanium alloys are investigated as model materials to correlate their
severely deformed microstructures and corrosion and tribocorrosion
behaviour. Underlying degradation mechanisms are highlighted.
Ultrafine-grained materials showed higher pitting corrosion resistance as
evidenced by an increase in passive range and decrease in area of the
cyclic polarization loop in Hanks’ solution and 3.5 wt% NaCl solution.
This is attributed to an increase in fraction of grain boundaries and
increased homogenization of alloys. Fall in OCP values during tribo-
corrosion experiments was much lower than the annealed samples for all
values of loads indicating better repassivation of ultrafine-grained alloys.
Coefficient of friction and total mass loss values of severely deformed
alloys are considerably better than that of annealed samples that is
attributed to the increase in hardness and ultrafine-grained microstructure.
EFFECT OF CHEMO-MECHANICAL COUPLING
ON CRACK PROPAGATION IN AN ELASTIC
BODY USING PHASE FIELD METHOD
Hirshikesh, Ratna Kumar Annabattula, Sundararajan Natarajan
Integrated Modeling and Simulation Lab, Department of Mechanical
Engineering, Indian Institute of Technology Madras, Chennai 600036.
Email of corresponding author: hsk111989@gmail.com
Interaction of chemistry and mechanics gained a lot of interest in the
recent years due to its wide range of application areas such as hydrogen
embrittlement in steel [1], Li diffusion in Lithium-Ion Batteries (LIBs)
[2], chloride diffusion in cement paste [3], bacteria growth in biofilm [4].
The mechanical behavior of such system requires the understanding of
the interaction between the diffusing species and the induced stresses in
the material. A lot of studies have been performed to establish the stress-
diffusion interactions response numerically by coupling the continuum
diffusion model with the continuum mechanics model within the
framework of thermo-elasticity [5]. As an application of the phase field
model for fracture in an elastic body, chemo-mechanical crack growth
model with the effect of the diffusive species is considered. Numerical
results show the difference of load-bearing capacity of the system with
and without the diffusive species. Diffusive species increases the load
carrying capacity of the system and delays the fracture. Temporal
evolution of the normalized concentration around the crack tip with the
crack growth is also investigated.
[1] R.A.Oriani, A mechanistic theory of hydrogen embrittlement of
steels, Berichte der Bunsengesellschaft fürphysikalische Chemie, 76
(8) (1972) 848-857.
[2] M. Zhu, J. Park, A. M. Sastry, Fracture Analysis of the cathode in
Li-Ion Batteries: A Simulation study, Journal of the
Electrochemical Society 159 (4) (2012) A492-A498.
[3] C. Page, N. Short, A. E. Tarras, Diffusion of chloride ions in
hardened cement pastes, Cemenet and Concrete Research 11 (3)
(1981) 395-406.
[4] P.S. Stewart, Diffusion in biofilms, Journal of Bactriology 185 (5)
(2003) 1485-1491.
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
[5] N. Swaminathan, S. Balakrishnan, K. George, Elasticity and Size
Effects on the Electrochemical Response of a Graphite, Li-Ion
Battery Electrode Particle 163 (3) (2016) A488-A498.
EFFECT OF CONSTRAINT AND HARDENING ON
CRACK TIP FIELDS IN FCC SINGLE CRYSTAL
Nipal Deka, Krishna N. Jonnalagadda
Department of Mechanical Engineering, Indian Institute of Technology
Bombay, India
Email of corresponding author: nipal_deka@iitb.ac.in
In the current study, the crack tip fields in the neighborhood of a
stationary mode I crack in a hardened ductile single crystal under
monotonic loading was investigated. A weakly coupled diagonal
hardening law proposed by Bassani and Wu was incorporated in the
modified boundary layer (MBL) simulation under the framework of
crystal plasticity. The effect of latent hardening on the stress and strain
fields was studied. The deformation field displayed a clear preference of
slip, over kink band, for hardened single crystals. In addition, the effect
of crack tip constraint was also examined with the advantage of T-stress
in the MBL simulation. Important observations like absence of kink band,
and presence of elastic sectors in the deformation fields near the crack
were explained. Moreover, how these interesting events for hard
materials are affected by various levels of crack tip constraint
corresponding to different test geometries and load conditions were also
elucidated. The increase of T-stress raised the number of triple slip
sectors near the crack tip whereas, the increase of LHR value made the
triple slip regions more prominent with wider angular spread. Besides, a
correlation between full 3D and 2D plane strain simulation was also
established through the utilization of T-stress term in the MBL analysis.
The present study primarily offers a comprehensive investigation of
effect of crack tip constraint and latent hardening on the crack tip fields
for hardened FCC single crystals under monotonic load.
EFFECT OF CRACK LENGTH AND SPECIMEN
THICKNESS ON CONSTRAINT IN CENTRE
CRACKED PLATE: A NUMERICAL ANALYSIS
Nagaraj Ekabote1, Abdul Khader Katigar2, Sanjeev Kavale3, Krishnaraja
G Kodancha4
1,3,4
School of Mechanical Engineering, KLE Technological University,
Hubballi.
2
Department of BVB College of Engineering and Technology, Hubballi.
krishnaraja@gmail.com
Fracture toughness of the material can be characterized by J integral, for
both linear elastic and elastic plastic analysis. Further J dominance is
dependent on the constraint present near the crack. Defining the level of
constraint near the crack is essential to achieve better structural
integrity.Here an attempt is made to study the effect of constraint
parameters, T-stress, Plastic Zone Size (PZS) and Stress Triaxiality (h) on
J dominance in Centre Cracked Plate (CCP) for various crack length (a)
and specimen thickness (B). Both 2D and 3D numerical analyses are
carried out for Interstitial Free (IF) steel material under mode I remote
loading for linear elastic conditions. Small Scale Yielding (SSY)
condition is achieved in the analysis by considering 2/3rd of yield stress of
the material as remote load. T-stress and PZS variation is observed for all
thickness considered and the mapping of T-stress and PZS along the
crack front indicated higher value for T-stress and lower value for PZSat
the middle of the specimen. The combined effect of T-stress, PZS and
Stress triaxiality along the crack front on various crack length to width
(a/W) and specimen thickness to width (B/W) have been compared and
discussed. Results reveal that the effects of these parameters on J
dominance in CCP specimen are significant and suggest the importance
of using two-parameter theories like J-T, J-h etc. The inferences drawn
out of these comparisons will be useful in assessment of real practical
problems for better structural integrity.


EFFECT OF FIBRE OFF AXIS ORIENTATION ON
MECHANICAL AND ACOUSTIC EMISSION
BEHAVIOUR OF 2.5 D C/SiC COMPOSITE
Manish Patel 1, Jalaj Kumar 1, Phani S. Kiran 1, T. Jayakumar 1, Sweety
Kumari 1, Sarabjit Singh 1, A. Udayakumar 2, V.V. Bhanu Prasad 1,
D.V.V. Satyanarayana 1 and Vikas Kumar 1
1
Defence Metallurgical Research Laboratory, Hyderabad, India-500058
2
National Aerospace Laboratory, Bangalore
Email: patelmet@dmrl.drdo.in
C/SiC composites are one of the high performance and high temperature
thermo-structural ceramic matrix composites (CMCs) which find
applications in hot section components of gas turbine, aerojet engine’s
components and hot structure based thermal protection system (such as
nose cap and leading edges of hypersonic vehicle). The mechanical
properties of these composites depend upon compositions (fibre, matrix
and interface content), manufacturing processes, fibre architectures and
resulting microstructure. Off axis loading becomes an important factor in
the composite when a composite component experiences multiaxial
strain. Off axis loading is known to have a detrimental effect on
mechanical properties of CMCs. Therefore, mechanical properties as well
as damage characteristic of a 2.5 D C/SiC composite with different fibre
orientation (0/90, 30/60 and 45/45) to loading direction, produced by
chemical vapour infiltration), have been studied in the present
investigation. The flexural strength was measured by three-point bend
test. During these tests, acoustic emission (AE) data was recorded to
ascertain localised response of composite constituents. The Young’s
modulus was measured by impulse excitation technique. The average
flexural strength and Young’s modulus for on-axis (00/900 fibre
orientation to loading direction) was found to be 254 ± 20 MPa & 57 ±
0.8 GPa, respectively. The average flexural strength was decreased by ~
33 and ~39 % for the 300/600 and 450/450 off axis orientation with
loading direction. Similarly, the average Young’s modulus was decreased
by ~ 38 and ~41 % for the 300/600 and 450/450 off axis orientation to
loading direction. AE data analysis shows that the transverse matrix
cracking saturation and interface debonding load is independent of fibre
off axis orientation to loading direction. On the other hand, it was found
that load at which fibre fracture started is dependent on the fibre off axis
orientation. The AE data were further analysed to determine the time and
strain for first cracking in these samples. This analysis was done for
different time domain and a noticeable difference was observed in these
samples. Optical micrographs of the surface show micro-cracks which are
perpendicular to fibre axis for all off axis orientation with loading
direction.
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
EFFECT OF MICRO-ALLOYING ON
MECHANICAL PROPERTIES OF Al-Zn-Mg-Cu
ALLOY: A REVIEW
Rahul Samanta, Amitava Ghatak
Techno India University, Salt Lake City, Kolkata, West Bengal – 700091,
India
Email of corresponding author: rahulsamanta1912@gmail.com
Recently with the improvement of structural materials for aerospace
technology, prime attentions have been paid to develop light weight
alloys demonstrating high strength, rational ductility, and improved
corrosion resistance property. Al-Zn-Mg-Cu alloys are extensively used
to build-up structures of aircraft and automobile due to their high strength
to weight ratio. However, the strengthening and toughening mechanisms
of the alloy are now objectively understood, researchers are keenly
interested to improve mechanical properties of the alloy with addition of
micro-alloying elements such as In, Si, Ag, Sn, Cd, etc. Mechanical
properties such as hardness, tensile and corrosion behavior for the matrix
alloy and the micro-alloyed alloys are reviewed. Cold working and heat
treatment processes are significant to advance the mechanical properties
of the micro-alloyed aluminum alloys.The effect of the micro-alloying of
Al-Zn-Mg-Cu alloys, mechanical properties like tensile strength, and
hardness increased, compared to the base alloy.These light weight micro-
alloyed aluminum compounds having the properties like great
workability and formability, high erosion protection and high
conductivity which offer these alloys for more industrial applications.
Effect of dynamic changes using light weight Al-Zn-Mg-Cu alloy in
designing and identifying the sensible necessities with the advancement
of ideas and techniques with changes in result, and setups of structure
components offers more applications in terms of industrial prospects.
Improved micro-alloyed high quality Al-Zn-Mg-Cu alloy opens a new
path in the industrial applications.
EFFECT OF PRIMARY  PHASE FRACTION ON
TENSILE BEHAVIOR OF IMI 834 ALLOY
Amit Singh a, I. Balasundar b, J.P. Gautam a,#, T.Raghu b
a
Department of Materials Engineering, School of Engineering Sciences
and Technology, University of Hyderabad, Hyderabad 500046, India
b
Near Net Shape Group, Aeronautical Materials Division,
Defence Metallurgical Research Laboratory, Hyderabad 500058, India
# Corresponding author: jaiprakashgautam@gmail.com
In the present work, the tensile behavior of IMI 834 alloy with varying
fraction of primary  (p) in the matrix of transformed  was studied at
room temperature. Variation in p phase fraction was obtained by
changing solution-treatment temperature of the alloy in (+) heat-treated
region from 1288K to 1333K. The solution treated samples were aged at
973K for 2hrs. Final microstructures consisted of various p fractions
(0.1 to 22 %), incoherent silicide precipitate (Ti,Zr)5Si3 and coherent
Ti3Al precipitates. These resulted in two kinds of microstructure which
were bimodal and acicular. The p phase fraction for bimodal
microstructure was ranging from 5 to 22 % and that for acicular
microstructure 0.1 to 3 %. Tensile test results show that, tensile strength
increased with increase in p up to ~ 15 % and then it is decreased from
~15 % to 22 % of p. The strain hardening was not observed for any
samples. The higher tensile strength for samples with p fraction up to 15
% and lower tensile strength for sample with p fraction ~15% - 20 % are
attributed to solid solution strengthening and solute partitioning effect,
respectively.
Keywords: Primary  phase, IMI 834 Ti alloy, Strain hardening, Tensile
strength


EFFECT OF SHAPE OF EXPLOSIVE CHARGE IN
FAILURE OF ROLLED HOMOGENOUS
ARMOURED PLATE
Pankaj K. Choudha a, A. Kumaraswamy b, Dr GG Duttaa, Kusumkant
D. Dhotea
a
Armament Research & Development Establishment, Dr. Homi Bhabha
Road, Pashan, Pune – 411021, India
bDefence Institute of Advanced Technology,Girinagar, Pune – 411025,
India
*E-mail: pkchoudha@gmail.com
Land based munitionsare used in defense applications. The anti-tank
munitions are used for destroying the track of tanks using blast effects.
These munitions have explosive chargesof RDX/TNT of cylindrical or
rectangular bar shape depending on the requirement of lethality and
coverage area. The bar munitions have rectangular cross section
explosive charges of 100 mm x50mm and 600 mm length used on either
side of fuze cavity to cover the tracks. The work has been carried out to
evaluate the effectiveness of these charges initiated from one end. The
cross section of the charge will change the pressure generated near the
explosive charge. Two cross sections i.e. rectangular and V shape has
been evaluated keeping the explosive weight constant. The pressure
generated in near vicinity of charge has been simulated using Ansys-
Autodyne Solver. The pressure generated from the flat charge and 'V'
shape charge have been compared. There is an enhancement of 2.4 to 3.5
times in peak over pressure and 2.5 to 4.1 times in impulseat 70 mm
distance from the cross section of the explosive charge at initiation point
and 600 mm away from the initiation pointof as shown in fig 1. Based on
these simulation results, experimental evaluation of concept was carried
out. Explosive charges were prepared of 250mmlength of both type of
cross section. The explosive qty of 1.9 kg in each case have been filled in
the polycarbonate casing of 5 mm thickness. The Rolled Homogenous
Armoured (RHA) plates of 1000 mm x 500mm x 40 mm were kept on
cement blocks and charge was kept above as shown in fig 2. The charges
were fired and failure of RHA plate from the front and rear side of plate
have been observed. In case of V shape charge, cutting has been observed
due to shape charge effect of plastic casing &failure is severe as shown in
fig 3.

EFFECT OF STRAIN GRADIENTS IN CRACK
PROPAGATION
B V S S Bharadwaja, A. Alankar
Indian Institute of Technology Bombay, Powai - 400076
bvss89@gmail.com
In the present work a finite strain non-local crystal plasticity model is
implemented via UMAT in ABAQUSTM. The main aim of this work is to
study the effect of strain gradients during crack propagation in metals.
Ashby [1970] with his experiments proved that the gradient of strains
plays a major role in the behavior of crystals when subjected to
inhomogeneous deformations. Many strain gradient models have been
proposed in past by Fleck and Hutchinson [2001], Nix and Gao [1998],
Acharya and Bassani [2000] etc. which are different from each other and
proved to be very successful in implementing the gradient effects through
material length parameters. In fact these parameters act as a bridge
between micro scale dislocations and meso scale plastic strains.
In the present work we implemented the Nix and Gao model to study the
effect of strain gradients on crack propagation. Basically we considered
FCC polycrystals in our study. How the strain gradient effects will
enhance the stresses in the near field of crack tip are shown. Shear on
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
each slip system is tracked using a power law. Statistical and
geometrically necessary dislocations are tracked separately as state
variables. Shear resistance on dislocations follows Taylor’s model. GND
evolution near crack tip is also studied.
EFFECT OF STRAIN INDUCED MARTENSITE
REVERSAL ON THE DEGREE OF
SENSITIZATION OF METASTABLE AUSTENITIC
STAINLESS STEEL
Sourabh Shukla1, and Awanikumar P. Patil2
Department of Metallurgical and Materials Engineering, Visvesvaraya
National Institute of Technology (VNIT), South Ambazari Road, Nagpur
- 440 010, Maharashtra, INDIA.
(E-mail: sourabhshukla9876@gmail.com, appatil14@gmail.com,)
Effect of reversion of strain induced martensite on degree of sensitization
(DOS) and mechanical properties of Metastable Austenitic stainless steel
(ASS) have been examined. The martensite reversion is known to be
effective in refining the grain size of metastable ASS. However,
martensitic reversal takes place only after severe cold rolling reductions.
In this study, the effect of degree of cold rolling and subsequent thermal
ageing on the microstructure, mechanical, and corrosion properties of a
metastable Cr-Mn ASS was investigated. Samples were cold worked
(20% and 40%) and then thermal aged at different temperature of 800°C
and 900°C for 2 hrs. Microstructures were subjected to optical
microscopy. Microstructural study shows that with increasing thermal
ageing temperature, strain induced martensite undergoes reversal to
austenite and is associated with grain refinement. XRD analysis has
revealed that at 20% cold work, volume fraction of martensite was 22%,
and as cold work was increased to 40%, the volume fraction of martensite
was 45%. Whereas after thermal ageing at 800°C, part of strain induced
martensite undergo reversal to austenite and only 18% martensite is left
in the matrix. On thermal ageing at 900°C, only 2% strain induced
martensite was left in the matrix. Hardness also follows the same trend as
observed for volume fraction of martensite during cold work and
subsequent thermal ageing. As the cold work percentage increases,
hardness and volume fraction increases but as thermal ageing temperature
increases, both hardness and volume fraction of martensite decrease
rapidly. Degree of sensitization (DOS) decreases with increasing thermal
ageing temperature.
EFFECT OF THICKNESS ON BEHAVIOUR OF E-
GLASS/EPOXY COMPOSITE LAMINATES UNDER
LOW VELOCITY IMPACT
T Sreekantha Reddy, K Mogulanna, K Gopinadha Reddy, P Rama
Subba Reddy*, Vemuri Madhu
Armour Division, Defence Metallurgical Research Laboratory,
Hyderabad-58
Email:rsreddy@dmrl.drdo.in ; +91-40-24588011
Fibre-reinforced composite materials have remarkable potential for use in
automobile, aerospace and defence applications where high strength,
damage tolerance and weight reduction are important design objectives.
Due to their high specific properties and stiffness composites are being
used as an alternative to steel and other light weight alloys for many
defence applications such as structural and armour systems. E-glass fiber
reinforced composite laminates are found to be more promising for
various defence applications due to their low cost, easy availability,
flexibility in design and processing. In the present study, E-glass/epoxy
composite laminates were subjected to low velocity impact using 16 mm
hemispherical impactor with the impact energy range of 50-150 J. Effect
of laminate thickness on impact parameters like peak force, maximum
displacement and damage area was experimentally evaluated. It was
found that peak force is increased with increase in impact energy up to
complete perforation and then became constant. Peak force is found to be
increased linearly with the increase in thickness at all impact energies.
Maximum displacement has decreased 50% as the thickness of the


laminate is doubled. Interaction time/contact duration also decreased due
to increased resistance with thickness. Visual inspection of impacted
laminates indicates two types of damage regions namely fibre breakage
area and delamination area. However, the extent of damage regions and
their ratio are found to be thickness dependent. Dominant failure mode
gradually changes from fibre breakage to delamination as the thickness is
increased.
Keywords: Composite laminates, Low velocity impact, Peak force,
Displacement, Damage area
EXPERIMENTAL DETERMINATION OF
APPARENT FRACTURE TOUGHNESS (KINu) FOR
ALUMINUM SHEETS
Mahendra Gattu*, Bishnupriya Dehuri
Department of Civil Engineering, National Institute of Technology,
Rourkela, Odisha, India.
Email*: g2mahendra@gmail.com
Aluminum strips of 150mm x 30mm x 3mm with single edge notch depth
(a) of 5mm, 10mm, and 15mm were prepared. These strips were tested
under tensile loading at a strain rate of 1mm/minute. The stress intensity
factor (KI) for varying notch depth was calculated using finite element
simulations. The apparent fracture toughness (KINu) values were
calculated with the peak loads obtained from the experimental data (refer
figure A). The results show the KINu/a0.5 remains constant. These tests
were followed by preparation of strips of 150mm x 50mm x 3mm with
center notch length (2a) of 5mm, 10mm, 15mm, 20mm, and 25mm.
These strips were tested under tensile loading at a strain rate of
0.2mm/minute. The stress intensity factor for center cracked geometry
was calculated using Fedderson’s secant formula and from finite element
simulations. The results of KINu are shown in figure b.
Figure A Figure B
FAILURE ANALYSIS OF ANTI JAMMING LEVER
CAP
Sai Madhav, Satyapal Singh
Scientist, Defence Metallurgical Research Laboratory, Kanchanbagh,
Hyderabad
ms.madhav@gmail.com
Failures of engineering components can occur either during
manufacturing or during service. Various aeronautical components fail in
service due to problems in material, processing and usage. These
problems arise out of various reasons. The present paper consists of a
case study of anti jamming lever cap, aeroengine component failed due
to poor processing of the material.
The study deals with the nut of the Anti Jamming Lever Cap of tail rotor
actuator of advanced light helicopter at distributor valve of hydraulic
system-2 body. A crack was observed on nut of hydraulic system body
of Tail rotor actuator which led to the leakage of the hydraulic oil from
the package. This actuator operates by two independent hydraulic
systems working simultaneously. This component is bought out from
M/s Electtronica Aster, Italy and is made of Aluminum based alloy.
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
The nut had a crack of 10 mm length starting from the top edge covering
80% length of the large dia part of the nut; the crack has nearly 0.5 mm
opening at the top. The crack in the nut was opened and observed under
optical microscope and SEM. At low magnification the banded structure
is evident. Large second phase particles are abundantly present which
are aligned in one direction. Intact portion of crack was forced opened
and had also revealed banded structure. The dimple walls are almost
horizontal in this case. The picture also shows presence large aligned
particles along with chain of small particles with them.
EDS analysis of the large aligned particles revealed that these particles
are Al-Cu precipitates precipitates in aluminium alloy matrix. EPMA
analysis further confirmed the same.
The optical micrographs of the nut material have shown elongated grains
along the working direction with second phase particles of 10-20 μ
interspersed. The second phase particles are also aligned along the
working direction. Nearly continuous chain of fine particles is seen along
with the coarse second phase particles.
It was concluded that the likely cause of failure is coarse and highly
banded microstructure of the alloy used.
FATIGUE ANALYSIS OF WING-FUSELAGE LUG
SECTION OF A TRANSPORT AIRCRAFT
K.Shridhar1, B.S.Suresh1, M.Mohan Kumar.2*
1
Department of Mechanical Engineering, B M S College of Engineering,
Bangalore- 500 019.
2
Fatigue & Structural Integrity Group, Structural Technologies Division
CSIR-National Aerospace Laboratories, Bangalore 560 017.
* Corresponding author: Email-Id: mmk@nal.res.in, Phone: +91-(0)80-
2508 6325
During the flight when the maximum lift is generated, the wings of the
aircraft will undergo highest bending moment. The bending moment will
be maximum at the root of the wing which causes highest stress at this
location. Wings are attached to the fuselage structure through wing-
fuselage attachment lug joints. Lugs are the primary structural elements
in airframe structure that are widely used in connecting different
components of the airframe The bending moment and shear loads from
the wing are transferred to the fuselage through the attachment lug joints.
Failure of lug may lead to the catastrophic failure of the whole structure.
In the pin loaded lug joint, the combination of high stress concentration
could potentially lead to appearance of the crack initiation and then crack
growth under cyclic loading. Stress intensity factor (SIF) solutions are
required for assessment of fracture strength and residual fatigue life for
defects in structures.A computational model for estimating the residual
fatigue life of attachment lugs is proposed. Initially stress concentration
effects in the loaded lug are determined by applying analytical and
numerical methods. In strength analysis, the lug is examined in the
presence of crack for stress intensity factor, which is an important
parameter for fatigue life estimation. Stress intensity factor estimation of
the lug with single through-the-thickness crack near the pin loaded hole
will be carried out. Both analytical and numerical methods will be used
for obtaining the SIF which is an important parameter for fatigue life
estimation. Fatigue crack growth life for the cracked lug was estimated
using the suitable crack growth model. Also the effect of different radius
ratios (lug geometry) on the number of cycles to failure is studied
FINITE ELEMENT ANALYSIS OF PERIODIC
METALLIC FOAMS
Ankush Borkara, Sagar Deshmukha, Sripriya Ramamoorthya,b, Alankar
Alankara,b, Shankar Krishnana
a
Department of Mechanical Engineering, Indian Institute of Technology
Bombay, 400076, India
Email: ramamoor@iitb.ac.in; alankar.alankar@iitb.ac.in


In this work, the finite element analysis of open cell foams is conducted
using BCC, FCC and A15 periodic unit cell (PUC) geometries in
ABAQUSTM/Standard. The open foam periodic unit cells are created by
subtracting the spherical pore space from a unit cube of the metal as
shown in Fig 1 (Krishnan et al., 2006). Periodic boundary conditions are
applied on opposite faces to account periodicity of unit cells while the
displacement boundary conditions are applied for constraints and uniaxial
loading. Elastic properties for all three PUC’s are estimated and
compared with the existing empirical relationships (Gibson L.J & Ashby
M. F., 1998). These configurations are also compared by varying their
respective radius of the spherical pores and hence the porosities. It was
found that BCC unit cell possess the highest strength to weight ratio in
comparison with the FCC and A15 unit cells. It is also observed that for
the BCC configuration which is similar to Kelvin cell geometry
theoretical relations under-estimates the values of elastic modulus
whereas converse behaviour has been observed for FCC and A15
configurations. Use of these periodic structures can reduce the
uncertainties in the elastic properties of the foam material as well as it can
provide the ease of controlling elastic modulus by simply varying the
position and the ratio of radius of the spherical pore.


Fig.1:Periodicunitcell(PUC)for(a)BCC(b)FCC(c)A15

References
[1] Krishnan et al., Direct simulation of transport in open-cell metal
foam, Journal of Heat Transfer, pp. 793-799, 2006.
[2] Gibson L. J and Ashby M. F., Cellular Solids: Structure and
Properties, Cambridge University Press, Cambridge., 1998.
INFLUENCE OF CRACK CLOSING AND LOCAL
NEAR-TIP STRESSES ON CRACK GROWTH LIFE
ESTIMATION
Savkin A.N., Sunder R., Denisevich D.S., Sedov A.A, Badikov K.A.
Volgograd State Technical University, Volgograd, Russia, 400005, Lenin
Avenue, 28, tfpic@vstu.ru
Currently, among other models for crack growth prediction, crack closure
models that take into account the decrease in stress intensity factor (SIF)
range associated with cyclic loading asymmetry are more popular. One of
drawbacks of these models is impossibility of taking into account the
loading history sequence.
The theory related threshold SIF range and Kth and local near-tip
stresses, induced by overloads, and postulated that the overload effect in
the near-threshold region of growth rates is caused by residual local
stresses. The proposed model applies the local stress and strain approach
to estimate stress * in the stress concentration region for fatigue
analysis. This region is characterized by local near-tip stress *, whose
amplitude is determined by cyclic inelastic reaction at crack tip. Further
development of the model is due to varying nature of the threshold SIF
range Kth.
As a basis, the Forman-Mettu formula was adopted, which describes the
fatigue crack growth curve in all three regions of fatigue crack growth
rate. The range K was determined by the peak load P of the load
history. The crack closure was taken into account by the Schijve
equation, taking into account the asymmetry of the half-cycle U = f(R),
and effective SIF was estimated by Keff = K*U. Given known SIF
range K, the value of the local stress * at distance from the crack tip r*
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
was determined for each half cycle by Neuber and Ramberg-Osgood
equations, and threshold SIF was estimated from the analytical formula of
V
th=f( ). Thus, known loading history made it possible to determine
Keff, Kmax, and Kth on each cycle for fatigue life estimation.
Mathematical modeling of fatigue crack growth life, especially in near-
threshold region of its growth, according to the Sunder’s scheme, showed
that investigated aluminum alloy 2024-T3 exhibited crack growth
sensitivity to various types of force action, including various types of
random loading.
IN-SITU STUDY OF THE EFFECT OF HYDROGEN
ON FATIGUE CRACK INITIATION AND
PROPAGATION IN POLYCRYSTALLINE NICKEL
Aman Arora, J. Sai Nitin, Rakesh Kumar, Dhiraj K. Mahajan*
Ropar Mechanics of Materials Laboratory, Department of Mechanical
Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab,
India, 140001
*dhiraj.mahajan@iitrpr.ac.in
Correlating hydrogen embrittlement phenomenon with the metallic
microstructural features holds the key for developing metals resistant to
hydrogen-based failures. In case of fatigue failure of hydrogen charged
metals, in addition to thehydrogen-based failure mechanisms associated
with monotonic loading such as HELP, HEDE etc, microstructural
features such as grain size, type of grain boundary (special/random),
fraction of special grain boundaries; their network and triple junctions
can play a complex role. The probable sites for fatigue crack initiation in
such metals can be identified as the sites of highest hydrogen
concentration or accumulated plastic strain. To this end, we have
developed an experimental framework based on in-situ fatigue crack
initiation and propagation studies under scanning electron microscope
(SEM) to identify the weakest link in the metallic microstructure leading
to failure. In-situ fatigue experiments are performed on carefully
designed polycrystalline nickel (99.99% pure) specimens (miniaturised,
shallow-notched & electro-polished) using a 10 kN fatigue stage inside
the SEM. Electron Back Scattering Diffraction (EBSD) map of the
notched region surface helps identify the distribution of special/random
grain boundaries, triple junctions and grain orientation.The specimen
surface in the shallow notched region for both the hydrogen charged and
un-charged specimens are then carefully studied to correlate the
microstructural feature associated with fatigue crack initiation sites.Such
correlation of the fatigue crack initiation site and microstructural feature
is further corroborated with the knowledge of hydrogen trapping and
grain’s elasticanisotropicityto be either the site of high hydrogen
concentration, accumulated plastic slip or both.
Keywords: In-Situ fatigue testing,SEM, EBSD,polycrystalline nickel,
hydrogen charging
MECHANICAL PROPERTIES OF AMORPHOUS
RIBBONS PROCESSED BY MELT SPINNING
V L Niranjani, D Arvindha Babu, Bhaskar Majumdar, T K Nandy
Defence Metallurgical Research Laboratory, Hyderabad, 500058,India
Email: neruleela@gmail.com
In this study, structural and mechanical properties of amorphous
[(Fe0.5Co0.5)0.75B0.2Si0.05]96Nb4 and Hf55Cu28Al12Ni5 melt spun ribbons are
presented. The ribbons were prepared by planar flow melt spinning
technique under the vaccum of 10-5 mbar. The tensile tests of the ribbons
were carried out using micro tensile test at different strain rates. Both the
alloys were found have significant strain rate dependence on fracture
strength. In both the melt spun ribbons it was observed that, with
increasing strain rate the fracture strength decreased. In case of Fe
amorphous ribbon fracture strength of 1950MPa was obtained, where as
in Hf amorphous ribbon 900MPa was observed. Detailed microscopic
studies of the fracture surface showed the formation of multiple shear
bands.


MECHANICAL PROPERTIES OF FINE GRAINED
EQUIATOMIC CRCOFENIMN HIGH-ENTROPY
ALLOY
Abhijit1, P. Sai Karthik2, K. V. Rajulapati1,*
1
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad 500046 India.
2
International Advanced Research Centre for Powder Metallurgy and
New Materials,Hyderabad 500005 India
*Corresponding author: kvrse@uohyd.ernet.in; Tel.:+91-40-23134452;
FAX:+91-40-23011087
Alloys are valuable because they can be made stronger, harder, lighter or
better than the pure elements. But these alloys also have so many
limitations in their engineering applications when we need an uncommon
combination of mechanical properties. Then a new class of novel
materials known as High Entropy Alloys (HEAs) is introduced. In past
years many alloys were prepared by vacuum arc melt casting. Often the
problem associated with this method is unwanted segregation of alloying
elements. Mechanical alloying (MA) is a widely used solid state
processing route for synthesis of advanced materials, which can easily
lead to the formation of nanocrystalline phase formation and could
increase the scope of high entropy alloys. It is a solid-state powder
processing technique involving repeated welding, fracturing, and re-
welding of powder particles in a high-energy ball mill.In the present
work, CrCoFeNiMnalloy was synthesized from the powders of individual
elements in equi atomic ratio through mechanical alloying. The milled
powder samples were collected at various milling durations. These
samples were characterized using XRD, SEM-EDS and TEM for phase
identification, structural and compositional analysis. Sintering was
performed on this milled powder using the spark plasma sintering (SPS)
at 950oC and 1000oC. Mechanical properties were determined using
microindentation and nanoindentation. This poster will present the
structure-property correlations established in this system.
METALLURGICAL EVALUATION OF SERVICE
EXPOSED THRUST VECTOR CONTROL (TVC)
FLAPS OF AEROENGINES
Sweety Kumari, Rajdeep Sarkar, N Chitti Babu, B V N Siva, D V V
Satyanarayana, Vikas Kumar
Defence Metallurgical Research Laboratory, Hyderabad 500 058, India
E-mail : sweety@dmrl.ernet.in
The flaps, of Thrust Vector Control (TVC) jet nozzle are the moving
parts in the nozzle section of fighter aircraft engine, which play a vital
role in controlling the throat area of the nozzle. The TVC flaps are made
out of a cast nickel base superalloy produced by investment casting. In
the present study, the evaluation of the metallurgical condition of TVC
flap alloy in virgin as well as service exposed for 500 h and 1000 h
condition has been carried out using both microstructural characterization
and determining the hardness of the flap alloy to assess their suitability
for continued service. During service exposure, as damage accumulates
progressively, the morphological characteristics of microstructure change
which needs to be assessed using metallographic technique.
Microstructural characterization has been carried out systematically using
optical, scanning and transmission electron microscopy in order to
ascertain any changes in the microstructure of TVC flap alloy with the
service exposure. In addition, quantification of microstructural features
such as grain size, inter-particle spacing, size, morphology and volume
fraction of Jc and carbides of the flap alloy using Image J analysis
software has also been undertaken. The microstructure of the flap alloy in
all conditions essentially exhibits dendritic structure, a characteristic of
cast nickel base superalloys. The grains are coarse and essentially
equiaxed. At higher magnification, primary, secondary and tertiary Jc as
well as coarse MC type carbides distributed randomly throughout the J
matrix have also been observed. In addition, the results on quantification
of various microstructural features indicate that there is only marginal
variation in size and morphology of various microstructural features with
service exposure upto 1000 h. Further, the marginal variation in Vickers
hardness values of the TVC flap alloy observed in different conditions
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

reinforce the idea that there is no deterioration in metallurgical condition
of the flap alloy with service exposure.
METALLURGICAL FAILURE ANALYSIS OF
COMPONENTS USED IN DEFENCE SYSTEMS
Mrityunjoy Hazra* and Satyapal Singh
Defence Metallurgical Research Laboratory (DMRL), P.O. –
Kanchanbagh, Hyderabad – 500 058, India
*
mhazra@dmrl.drdo.in, hazra.mrityunjoy@gmail.com
Metallurgical failure analysis is a method by which root metallurgical
cause(s) of failure of a failed component is/are determined so as to avoid
repetition of the same type of event in future. This is possible by
developing knowledgebase on faulty processing steps experienced by the
subject material system of the component, making it non-suitable for use
in concerned service environment. The process is executed through a
widely accepted key steps starting from visual examination and macro
photography, followed by various defect characterization techniques such
as NDT, metallography, fractography etc. DMRL deals with numerous
failure investigation cases related to diverse fields like various crucial
parts of missile systems, components from thermal power plants etc. in
addition to aeroengine parts, armour and naval weapon components
coming from three Indian Defence Services.
Two case studies, namely failures of ramp component systems of a
transport aircraft and power take off (PTO) shafts of a fighter aircraft
have been analyzed. Ramp failure happened due to torsional fatigue
initiated at fillet area of ramp shaft followed by torsional overloading. It
seems to have been occasionally supported by presence of over-tempered
microstructure at those localized areas. Each of the PTO shafts
manufactured by two separate agencies failed by fatigue cracking, which
is most likely to have been initiated at semi-circular type of (forging)
fabrication induced surface discontinuities existed on diaphragm discs.
Discontinuities with lower availability and smaller sizes in one shaft led
to somewhat increased life (466 million cycles) as compared to the life
(104 million cycles) of the other shaft.
Key words: Failure Analysis, ramp, transport aircraft, torsional fatigue,
power take off (PTO) shaft, diaphragm disc
MICROSTRUCTURE AND MECHANICAL
PROPERTIES CORRELATION OF WELD JOINTS
OF A HIGH STRENGTH NAVAL GRADE STEEL
P D Gosavi, K K Sarkar*, S K Khunte V R Pawar, and B Basu
Naval Materials Research Laboratory, Defence Research Development
Organisation (DRDO), Ministry of Defence, Additional Ambernath,
Anandnagar P.O; Thane-421 506, INDIA
*Corresponding Author Email: sarkar@nmrl.drdo.in
Low alloy steels of higher strength grades are conventionally used for
pressure hull application. Strength required range from 560 MPa to 800
MPa and plate thickness requirement is often higher (40 mm or more).
Welding of high strength steels with higher thicknesses is often a
challenge. From the view point of structural integrity challenge is not
only in obtaining defect free weld joint but also of meeting strength and
low temperature toughness requirement in both weld and HAZ. In hull
construction, different types of welding processes are used depending
upon the requirement, accessibility and criticality of the weld joints to be
produced. Conventionally, welding processes include Shielded Metal Arc
Welding (SMAW), Gas Metal Arc Welding (GMAW), Submerged Arc
Welding (SAW) & Gas Tungsten Arc Welding (GTAW). Number of
weld consumables indigenously developed for a higher strength steel
(YS~800 MPa), were used to develop the procedure, for producing weld
joints, meeting the critical structural property requirements.
Temperature (DBTT), tensile properties and quantitative metallography.
DBTT of weld joint is important from the aspect of structural integrity at
sub zero temperature. Impact toughness at -400C varied from 39 J for
SMAW process to 191 J for GTAW process. Yield strength of weld joints
varied from 534 MPa for SMAW process to 907 MPa for GTAW
process. Quantitative metallogrphy was carried out to determine volume
fraction of acicular ferrite (AF) in different welds. Heat input (HI) to
produce a weld joint varied with welding processes used. HI for SMAW
was 1.3kJ/mm while it was 2.2kJ/mm for SAW process. At HI of
1.85kJ/mm (GTAW), a higher % fraction of AF (~77%) having Impact
toughness of 191 kJ/mm at -400C
Key words: HSLA Steel, Mechanical Properties, DBTT, Acicular Ferrite,
Heat input
REFERENCES
1. S. S. Babu (2004): ‘The mechanism of acicular ferrite in weld deposits’
Curr. Opin. Solid State & Mater. Sci., pp. 267-278.
2. D.M. Viano, N.U. Ahmed, G.O. Schumann : ‘Influence of heat input
and travel speed on microstructure and mechanical properties of double
tandem submerged arc high strength low alloy steel weldments’; Journal
of science and technology of welding and joining, Vol.5, 2000, pp. 26-34.
MICROSTRUCTURE AND MECHANICAL
PROPERTIES OF HOT ISOSTATICALLY
PROCESSED HIGH STRENGTH NICKEL BASE
SUPERALLOY
B. Sreenu a *, CM. Omprakash a, Rajdeep Sarkar a, Subhradeep Chatterjee
b
and G. Appa Rao a
a
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad
500058, India
b
Department of Materials Science & Metallurgical Engineering, IIT,
Hyderabad 502285, India
* E-Mail address: sreenudmrl@yahoo.co.in
Nickel-base superalloy powder produced by inert gas atomization
technique was hot isostatically processed (HIPed) at a selected
temperature of 1190±2 °C under 120 MPa pressure for 3 h of sustaining
time. The as-HIPed alloy with full density of 8.0 g/cc was characterized
for microstructure. The as-HIPed alloy has shown fine equiaxed grains of
a varying size with an average grain diameter of 12 μm. The grain
boundaries showed the presence of carbides enriched with Cr and are
confirmed to be the M23C6 and M3C2 type carbides. Prior particle
boundaries (PPBs) are also seen in the HIPed material and these are MC
type carbides and closely associated with oxides of Ti and Hf. Tensile
properties of as-HIPed alloy were evaluated at room temperature (RT)
and 650 °C. The as-HIPed alloy exhibited yield strength (YS) and
ultimate tensile strength (UTS) of 975 and 1325 MPa respectively with
corresponding ductility of 10%EL and 8% RA at RT. With increasing the
test temperature to 650 °C, the YS and UTS of the alloy although
marginally dropped to 850 MPa and 1275 MPa respectively, there is an
improvement in ductility of 25%EL and 28%RA. The stress rupture
properties of as-HIPed alloy were evaluated at constant temperature of
650°C and 750 °C under a varied stress levels from 300 to 500 MPa. The
as-HIPed material has offered 1000 hours life under the test conditions of
(i) 650 °C/750MPa and (ii) 750°C/300MPa with a creep strain of 1.5%
and 2.2% respectively. The fractographs of the stress rupture tested
material have indicated that the failure occurred predominantly at grain
boundary and particle boundary decohesion.
Key words: Hot isostatic pressing, superalloy, prior particle boundaries.

Present study was focused on structural property correlation of weld

joints made using these indigenous consumables. Weld joints were
characterized in terms of impact toughness, Ductile Brittle Transition

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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
MODELLING AND SIMULATION OF FATIGUE
FAILURE IN BOLTED JOINT UNDER DIFFERENT
LOADING CONDITION
Vishal Achwal*, ManojChouksey**
* Research Scholar, Mechanical Engineering Department, Mewar
University, Chittorgarh, Raj., India
** Professor, Mechanical Engineering Department, Shri G.S. Institute of
Technology & Science, Indore, M.P, India.
Email: vishalachwal60@gmail.com*
This paper includes the fatigue analysis of bolted joint plates. Three
different cases of shear, bending and axial loading have been modelled
for fatigue analysis. A CAE environment is created for analysis of fatigue
life by using Hyperworks software. Result shows that the fatigue life is
maximum in bending load case when compared with the cases of shear
and axial loading. The fatigue damage is localized in bending and axial
loading test and in the shear loading test it is throughout the bolt length.
Area of maximum bolt damage is just below the head of bolt which is in
contact with the plates.
MULTI FREQUENCY ACPD TECHNIQUE FOR
CREEP DAMAGE MEASUREMENTS IN DS CM 247
ALLOY
C.M. Omprakash*a, A.Kumara, Vajender Singha, M. Kamarajb, D.V.V.
Satyanarayanaa
a
Defence Metallurgical Research Laboratory, PO Kanchanbagh,
Hyderabad, Telangana -500058, India
b
Indian Institute of Technology, Madras, India
Assessing the damage state of a component in service, operating at high
temperatures where deformation due to creep is of prime concern, is very
useful in ensuring safety of structures, assessing the remaining life and
also for life extension programs. In-situ metallographic replica technique
commonly used to assess the damage state provides only surface
information concealing damage towards the core of the component.
However, advanced techniques which provide complete state of damage
accumulation with time in service have to be explored. In the present
study Alternate Current Potential Drop (ACPD) technique has been
explored to evaluate creep strain accumulation employing multi
frequency method and EBSD was employed to quantify microstructural
damage at different depths in the creep samples of a nickel base
superalloy.Interrupted creep tests at constant load were conducted in air
at a temperature of 950°C and a stress of 250MPa.This method involves
passing a constant current of 0.2 Amps and varying frequency from 0.3 to
500 kHz through the gauge portion of the creep specimen and monitoring
the potential drop between two points within the gauge portion near the
center of the specimen. Four creep specimens were interrupted at
different strain levels (0.47, 1.368, 6.74, and 7.08) at 95°C/250MPa for
detailed microstructural study using EBSD. The correlation of creep
strain calculated using multi-frequency potential drop data obtained from
ACPD technique with that measured using LVDTs for Nickel base
superalloy DS CM247 at different depths in the creep specimen show
different strain accumulation at different depths. EBSD technique was
used to show the evidence of different levels of creep strain accumulation
at different depths in the sample with creep exposure using misorientation
profile maps.
ON THE STRUCTURAL AND
MICROSTRUCTURAL ASPECTS OF
EQUIATOMIC AlCrCoFeMoNi HIGH-ENTROPY
ALLOY
Samanwitha Kolli1, K. Bhanu Sankara Rao2 and Koteswararao V.
Rajulapati1,*
1
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad-500046


2
Ministry of Steel (Govt. of India) Chair, Mahatma Gandhi Institute of
Technology, Hyderabad 500075, India
*
kvrse@uohyd.ernet.in
Advancement in the technology has always challenged the field of
material science for the development of the new and specialised
materials. High entropy alloys (HEAs) are one of such recent
developments posing wider possibilities owing to their unique and
exceptional properties compared to that of conventional materials. Out of
the vast possible compositions of the HEAs, the ones that would give
exceptional high temperature properties (high melting point, high
temperature strength and stability) making them suitable for elevated
temperature applications, have to be developed. These alloys can
therefore substitute the currently used Ni-based superalloys which exhibit
temperature limitations by undergoing thermal softening above
600oC.The present work involves synthesis of equiatomic
AlCrCoFeMoNi HEA through mechanical alloying using high-energy
ball milling followed by characterization of the powders employing X-ray
diffraction (XRD)andelectron microscopy (SEM, TEM) techniquesfor
crystal structure or phase identification and microstructural analysis. The
milled powders were consolidated using Spark Plasma Sintering (SPS) at
varying temperatures. The sintered pellets were further characterized
using XRD and SEM for identification of phases and microstructural
changes. Vickers hardness test and nanoindentation were carried out to
test the mechanicalbehaviour of the material.
Key words: high entropy alloys, mechanical alloying, microstructure,
single phase, melting point
PERFORMANCE ENHANCEMENT OF COLUMNS
BY EXTERNAL FRP STRENGTHENING
TECHNIQUE – A REVIEW
1
Darshan Patel, 1Purvesh Patel, 2Tejash Patel, 3Mitali Patel, 4Tejendra
Tank, 5Dr Sandip Vasanwala
1
Research Scholar, Merchant Institute of Technology & Engineering,
Mehsana
2
Ph.D Research Scholar, Applied Mechanics Department, SVNIT, Surat
3
Assistant Professor, Gujarat Forensic Sciences University, Gandhinagar
4
Head of Department, Civil Engineering, Indus University, Ahmedabad
382 115
5
Professor, Applied Mechanics Department, SVNIT, Surat
1
darshandvkrvarahi@gmail.com
Retrofitting and strengthening of existing Reinforced Concrete structures
is rapidly becoming one of the integral segments in construction and
structural engineering practices, owing to various situations that
necessitate the capacity enhancement of structural members. Structural
deterioration owing to many parameters is the root cause for
understrength of RC elements, and amongst all, Environmental
Deterioration being one of the most prominent factors. FRP composites
are widely used for structural strengthening and rehabilitation in
developing countries and are mostly adopted for old deteriorated
structures. FRP composite are also widely used as jacketing material, to
strengthen axially loaded reinforced concrete Columns. The significance
of these activities also increases with the insufficient capacity of
structures which previously were designed, using old design codes.
However, no Codal provisions are developed in India till date for FRP
composites, to be used as jacketing material. Moreover, no well-defined
method for confinement of RC columns using FRP Composite material
has been established in India. This owes to lack of adequate research in
this segment. Researchers have proposed various mechanisms and
materials for external strengthening of RC columns, and each mechanism
has its own set of advantages, accompanied by its limitations. This
manuscript determines research gaps in the field of external strengthening
of RC columns using FRP composites and suggests measures for future
research, to establish FRP composites as a feasible material for
strengthening axially loaded RC columns by overcoming its limitations.
Efforts have been made to lay down emphasis on the failure modes of
externally strengthened RC columns using FRP composites.
8

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
QUANTIFYING THE RESIDUAL STRENGTH OF
Ti-ALLOY 834 AT 600°C WITH NONLINEAR
ULTRASONIC NDT TECHNIQUE
B. Nagaraja Kowmudi, Kartik Prasad, K. Gopinath and Vikas Kumar
Defence Metallurgical Research Laboratory, Hyderabad 500 058, India
E-mail : bnagarajak@gmail.com
The rotating aeroengine components which operate at elevated
temperatures are prone to fatigue damage. This lead to reduction in the
life span of the components considerably. In-service assessment of the
damage state in these components are important for ensuring safe
operation, predicting the remaining life. Fatigue deformation is associated
with synergistic effect of both microstructural changes and strain
accumulation. In order to quantify the evolution of fatigue damage, ‘E'
parameter was measured on the Low Cycle Fatigued (LCF) samples by
using nonlinear ultrasonic technique (NLU).
In this investigation LCF tests were carried out under strain controlled
mode at 600°C with total strain amplitude of 1.0 % under completely
reverse loading conditions. One sample was tested till fracture while three
samples were interrupted at 10%, 50% and 80% of the fatigue life. The
samples so obtained were analyzed using NLU and subsequently pulled
in tension up to failure at 600°C. NLU measurements have been carried
for these samples also. The results show the linear relationship of the beta
parameter with cumulative plastic strain under cyclic loading conditions
and work hardening parameter under tensile deformation condition
respectively. The residual strength (fatigue pre-deformed yield strength)
of the alloy was observed to be decrease with respect to increase in
accumulated plastic strain and ‘E' parameter.
Keywords :Nonlinear Ultrasonic; ‘’ parameter; Cumulative plastic stain;
Work hardening; Ti-alloy 834.
STRAIN RATE SENSITIVITY AND RT CREEP
BEHAVIOR OF FRICTION STIR WELDED AND
ELECTRON BEAM WELDED IN-RAFM STEELS
J. Varghese1, V. L. Manugula2, K. V. Rajulapati1,*, G. M. Reddy3, K.
BhanuSankara Rao4
1
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad 500046 India
2
Mahatma Gandhi Institute of Technology, Hyderabad 500075 India
3
Defence Metallurgical Research Laboratory, Hyderabad 500050 India
4
Ministry of Steel (Govt. of India), MGIT, Hyderabad 500075 India
*kvrse@uihyd.ernet.in
Reduced activation ferritic martensitic steel is a highly promising steel
for the applications in first wall and test blanket module of fusion
reactors. Their stability in neutron irradiation environments has made
them to be within the acceptable specifications for the structural materials
in the International Thermonuclear Experimental Reactor (ITER)
program.Several countries have designed their own compositions for
RAFM steels and India specific Reduced activation ferritic martensitic
steel (IN-RAFM) was also developed by India.
Joining of RAFM steels is a challenging process as the joining method
should avoid the formation of -Ferrite which can be deleterious during
the structure’s service time. Fusion based metal joining methods have
their inherent solidification related defects and the chances to form -
Ferrite. Friction stir welding (FSW) which is a solid state welding process
has been proved to be promising with its microstructural and mechanical
properties. Electron Beam Welding (EBW) which is another low heat
input joining technique which implies a thinner Heat affected zone
(HAZ).
Nanoindentation is a method to study the hardness and mechanical
properties of materials at very small length scales which involves the
penetration of a nanometer sized tip in to the sample surface and
measuring the load-displacement behavior. In this study the two phased
(ferrite and martensite) structure is subjected to nanoindentation process
to study the strain rate sensitivity (SRS) and room temperature creep


properties along with nano hardness and elastic modulus. The two phases
are observed to show different mechanical properties which could be
correlated to the bulk behavior of the material.
Keywords: IN-RAFM, FSW, EBW, Nanoindentation
STUDY OF MATERIAL ANISOTROPY ON
ELASTIC AND ELASTO PLASTIC BEHAVIOR
OFFLAT SPECIMENS
Ramesh Kumar, Ritu J. Singh,J. Mishra, V. Balasubramaniyan, H. S.
Kushwaha
Atomic Energy Regulatory Board, Mumbai-94, India
Email of corresponding author: kramesh@aerb.gov.in
During pilgering or extrusion processes, specific texture may develop in
the material due to limited number of slip systems available. Texture
developed on the material is also controlled to obtain desirable
mechanical properties. Texture results in development of mechanical
properties with certain directionality. In this work, the effect of
orthotropic anisotropy is investigated on the stress field. In an orthotropic
material, anisotropy is in three directions i.e. rolling (RD), transverse
(TD) and normal (ND) direction. In design of a component, the stress
analysis often assumes isotropic behviour of the metal considering that
isotropic behviour gives conservative results. However, under certain
conditions more realistic material model is needed e.g. in failure analysis.
Therefore, in this work the effect of isotropic and orthotropic material
model on elastic and elasto plastic deformation of flat specimens will be
explored. The effect will be investigated on uniaxial rounded or notched
specimen made of Zr 2.5% Nb. Simulation of Nakazima test is carried
out to benchmark the results obtained in orthotropic material model.
SYNTHESIS AND CHARACTERIZATION OF
EQUIATOMIC AlCrFeMoNbNi HIGH ENTROPY
ALLOY FOR STRUCTURAL APPLICATIONS
V. Madhu Babu1, K. Bhanu Sankara Rao2, Koteswararao V. Rajulapati1*
1
School of Engineering sciences and technology, University of
Hyderabad, Hyderabad-500046
2
Ministry of Steel (Govt. of India) Chair, Mahatma Gandhi Institute of
Technology, Hyderabad 500075, India
* kvrse@uohyd.ernet.in
The high entropy alloys (HEAs) have created new interest in materials
design because of their probable improved mechanical properties in
comparison to many conventional alloys. The main concept involved in
HEAs is high entropy which is associated with the number of principal
elements as the possible motive for the single phase solid solution
formation. As per the Gibbs free energy of mixing, competition between
the configurational entropy and mixing enthalpy would decide phase
formation in HEAs.
In the present work, AlCrFeMoNbNi alloy was synthesized using
mechanical alloying (MA) to take advantage of grain refinement and
extended solubility limits. The alloy AlCrFeMoNbNi system was
prepared from individual elemental powders of purity greater than 99%
and with the equiatomic ratios using high energy ball milling. Structural,
morphological and compositional characterizations were carried out on
milled powder samples using X-ray diffraction (XRD) and scanning
electron microscopy (SEM- EDS) techniques. Compaction of powder
samples AlCrFeMoNbNi was done using the spark plasma sintering
(SPS) to have advantage of nanocrystalline nature of full dense sintered
sample formation. Crystal structure, microstructure, grain size and
density measurements were performed on the sintered samples.
Mechanical properties of sintered AlCrFeMoNbNi system were
determined by using microindentation and nanoindentation techniques.
Key words: High entropy alloys, high energy ball milling, spark plasma
sintering, nanoindentation
9

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
SYNTHESIS AND OPTIMIZATION OF STEERING
MECHANISM OF EXTRA-LONG SEMI-TRAILER
VEHICLE TO IMPROVE ITS STRUCTURAL
INTEGRITY
Vikrant Garud1; Abhijit Kulkarni2; Rushikesh Nanaware3; Pravin
Karunanithi4
123
Pimpri Chinchwad College of Engineering Pune India
4
VRDE, Ahmednagar India
Email of corresponding author: vicky_garud100@yahoo.co.in
The paper discusses about synthesis and optimization of structural
integrity of steering mechanism system of Semi-Trailer or Articulated
vehicle with medium off-road capability and good maneuverability. The
practical difficulty lies with current steering system is pin joint of tie rod
mechanism sheared off at higher articulation angles and the magnitude of
errors in angle turned by wheels and ideal angles are up to 110. Research
and development efforts with VRDE, Ahmednagar initiated to synthesize
and optimize the steering mechanism to avoid shearing of tie rod pin
joints and to lower the magnitude of errors in angle turned by wheels less
than 70 using genetic algorithm with help of MATLAB and Validation
(Simulation) of optimized structural integrity of steering mechanism
carried out with the help of ADAMS to have excellent. Results of
optimization shows reduction in errors (Deformation) of tie rod link by
96% which is sufficient to avoid tie rod link failure. Also magnitude of
errors in angle turned by wheels of optimized steering mechanism is 60
ULTRASONIC TESTING AN ALTERNATIVE FOR
RADIOGRAPHY FOR EVALUATION OF PFBR
BLANKET PIN END PLUG WELD INTEGRITY
Altaf Ali, Anish Kumar 1, B. Kamalesh Kumar, YRC Murthy, B.
Ravinder , Komal Kapoor, C. Phani Babu
Nuclear Fuel Complex, Hyderabad-500062
1
Indira Gandhi Centre for Atomic Research, HBNI, Kalpakkam-603102
Email of corresponding author: altafali@nfc.gov.in
Radial blanket pins of Prototype Fast Breeder Reactor (PFBR) are made
by encapsulating Deeply Depleted UO2 (DDUO2) pellets in a D9
austenitic stainless steel clad tube. The ends of the tubes are sealed by
TIG welding of end plugs at both the ends. This is a critical weld as any
failure will lead to spread of radioactivity in sodium coolant circuit of
PFBR. At present, integrity of these welds is ensured by 100%
radiography by using double wall single image full compensating block
tangential radiography method.
The present work aims at understanding the nature of defects encountered
in the end plug welds and developing an ultrasonic testing methodology
in lieu of radiography for qualification of the end plug welds. Typical
defects have been examined by metallography and statistical analysis of
weld zone has been carried out. A detailed analysis on various parameters
affecting detection of tight lack of penetration (LOP) defects in
radiography has also been carried out. An ultrasonic testing technique
based on B-scan imaging in pulse-echo mode has been explored for
inspection of end plug weld. Testing has been carried out with a highly
damped spherically point focused 20 MHz transducer to produce 450
shear wave in weld joint area. End plug welds with different types of
natural defects have been generated by varying different TIG welding
parameters. Ultrasonic testing and radiography of the same have been
carried out. LOP has been detected with good sensitivity and ultrasonic
testing results show good correlation with radiography. The paper
provides the details of the above study carried out.


USE OF COMPRESSION GEOMETRY TO STUDY
EFFECTSOF STOICHIOMETRY AND
TEMPERATURE ON FRACTURE TOUGHNESS OF
NiAl
Devi Lal, Praveen Kumar and VikramJayaram
Department of Materials Engineering,Indian institute of Science,
Bengaluru 560012
E-mail: dl.material13@gmail.com
Development of hard materials is generally driven by increasing the
hardness to the modulus ratio. However, in practice, these materials often
fail by crack propagation and hence it is imperative to study their fracture
behaviour to accurately assess the lifetime of the components comprising
these materials. Since compression fracture geometry shows stable crack
growth, it is useful for studying crack propagation and associated
processes, such crack bridging, microstructural and compositional in
homogeneity induced variation of fracture toughness along crack path,
etc.In addition, due to the ease of performing tests and fabricating
specimen, this geometry has recently gained significant attention for
studying fracture behaviour of hard coatings. We have further developed
some mechanistic details of the compression fracture geometry that
makes it suitable for testing brittle and miniaturized samples. We have
prepared compression fracture samples from two composition of NiAl
alloys, havingcompositionsNi-50Al, Ni-40Al. Herein, 20 mm diameter
disks of NiAl of desired composition were arc melted and homogenized.
Fracture samples were prepared from the cast alloy using electro-
discharge machining, followed by femto-second pulse-laser machining
for creating a sharp notch. Room temperature fracture toughness of Ni
rich alloys are found to be higher than stoichiometric NiAl. It is believed
that improved fracture toughness in Ni-rich inter metallic are due to stress
induced E2 to L10 martensitic transformation or due to presence of ܰ݅ଷ Al
at grain boundries. There inter metallic shows ductile to brittle transition
at around 500ºC. So, Fracture toughness will be compared from room
temperature to 700 ºC to better understand their failure during service.
WEIGHT OPTIMIZATION OF HOUSING
BRACKET FOR ELECTRICAL STARTER MOTOR
USING FEA
Varatharaj Neelakandan *1, Thulasirajan Ganesan2, and Praveen
Chakrapani Rao4
*1nvaratha@comstarauto.com; 3gthulasi@comstarauto.com and
4
cpraveen@comstarauto.com
Starter motor is an electric motor which provides mechanical motion to
start the internal combustion engine. The electric starter ensures that
anyone could easily start and run an internal combustion engine of any
vehicle car. Housing bracket in starter motor are supporting whole starter
assembly and it is used to mount starter on the engine so housing bracket is
the major component of starter motor assembly. Housing bracket
strength and weight has been continuously a concern which may lead to
operational cost high and durability life. The important causes of higher
weight gain is overdesign, customer demand, casting feasibility and the
operating conditions. This paper presents the design optimization
methods for robust design to meet the customer demand as well as to
align operating conditions. In the optimization of housing bracket, finite
element analysis software used for calculating the stress and fatigue
analysis and then the weight was optimized. The optimized new housing
bracket was proposed for new starter projects to capture new business and the
design was implemented to reduce cost in productionized starters.
10
 

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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session1A:StructuralIntegrityI
Chairman:GMadhusudhanReddy,DMRL
SessionCoordinator:CMOmprakash,DMRL
16001627 InvitedTalk:Roleofstressstateonthestructuralintegrityofweldedstructures
SSuresh,PSGcollegeofTechnology,Coimbatore
16391651 LaserHybridweldingofInconel617forAdvancedUltraSuperCriticalBoiler(AUSC)
Applications
MohdAqeel,G.Padmanabham,K.V.PhaniPrabhakarandJ.PGautam
InternationalAdvancedResearchCentreforPowderMetallurgyandNewMaterials,
Hyderabad
16511703 EstimationofresidualstressesdevelopedinSS304L/Zr2.5%Nbjoints
V.SrikanthandA.Laik
BhabhaAtomicResearchCentre,Bombay
17031715 StructuralIntegrityAssessmentofaPropellanttankinpresenceofWeldingResidual
Stresses
V.Viswanath,A.K.Asraff,P.Jayesh,SureshMathewThoma,KrishnaKumarand
R.Muthukumar
IndianSpaceResearchOrganisation,Thiruvananthpuram
17151727 NumericalstudyontheresidualstressdistributionsinGTAweldeddissimilarmetal
components
Ch.VijaySai,KSatish.Velaga,BiswanathSen,B.P.C.RaoandA.Ravisankar
IndiraGandhiCentreforAtomicResearch,Kalpakkam
17271739 CharacteristicsofStrainInducedMartensiticTransformationinWeldedJointswith
theStructureofMetastableAustenite
Yu.Korobov,O.Pimenova,M.Filippov,M.Chadiev,N.Ozerets,S.Mikchailov,S.
Morozov,Yu.DavidovandM.Razikov
UralFederalUniversity,Russia
17391751 MicrostructuralevolutionofbrazedTijointusingTi20Zr20Cu50Ni10metallicglass
ribbonasfiller
P.RamaRao,BhaskarMajumdar,K.AnilBhatnagarandK.Muraleedharan
CSIRCGCRI,Kolkata
17511803 Theeffectofgraphitesizeontensilepropertiesandhydrogenstoragecapabilityof
ferriticductilecastiron
TakuyaYoshimoto,TakashiMatsuoandTomohiroIkeda
FukuokaUniversity,Japan
18031815 SurfaceModificationStudiesonZrB220v/oSiC1w/oB4C0.1w/oCfComposite
JitenDas,JJanardhanaReddy,VSrinivas,ManishTakandVVBhanuPrasad
DefenceMetallurgicalResearchLaboratory,Hyderabad
18151827 FailureAnalysisofMetallicArmouredElectroOpticMechanicalCablesInUnderwater
TowedSonarSystems
V.KiranGovind,N.AnshathHussain,V.PGopalakrishnanNairandM.SabuSebastian
NavalPhysicalandOceanographicLaboratory,Kochi


 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
ROLE OF STRESS STATE ON THE STRUCTURAL
INTEGRITY OF WELDED STRUCTURES
 fusion zone possibly due to cooling rates experienced by the two zones.
Prof. Dr. S. Suresh
GM, CoE welding
PSG college of Technology, Coimbatore
drsuresh.srinivasan@gmail.com
Structural integrity or fail safe service performance for the whole design
life is the aim of every engineered component or structure. The Structural
integrity of a welded structure is often influenced by a) Presence of peak
stresses & stress raisers that are associated with fabrication processes b)
Relative brittleness of the weld & heat affected zones near the weld
regions c) Tri-axial tensile residual stress field that exist in the weld
regions and overall weldment geometry d) complex geometry/design
configurations resulting in plane strain conditions e) limitation with
respect to direct evaluation of the mechanical property (toughness and
ductility) of the production welds f) the uncertainties or limitations in the
Non destructive methods employed g) the presence of acceptable
discontinuities that may grow in service etc,. In recognition of this,
International standards organization has declared welding as a special
process & recommends use of ISO-IEC 3834 standard to ensure the
performance of a welded structure.
Amongst the above mentioned factors, the stress state near the weld and
HAZ due to aggregate effect of the above factors has a major influence
on service performance. The stress state can often become very complex
and not easily amenable for calculations by traditional design analysis
methods due to complex geometry features. Experimental methods are
often used to determine the stress state in critical structures by measuring
stress concentrations, discontinuity stresses, residual stress near the weld
toe regions etc by using suitable transducers under controlled or
simulated loading conditions. The results coupled with evaluation of the
compliance to theories of elasticity, failure analysis theories etc., can
provide us valuable information and measures to ensure structural
integrity of critical welded structures.
In this paper the role of stress related factors on structural integrity,
experimental evaluation of stress state in some new and retrofitted
structures using electrical strain gauges, determination of the safety of the
critical structures by analysis of the experimentally measured stress data,
are presented.
LASER HYBRID WELDING OF INCONEL 617 FOR
ADVANCED ULTRA SUPER CRITICAL BOILER
(A-USC) APPLICATIONS
Mohd Aqeel, G. Padmanabham1, K.V. Phani Prabhakar2, J.P Gautam3
1, 2
Centre for Laser Processing of Materials, International Advanced
Research Centre for Powder Metallurgy and New Materials (ARCI),
Hyderabad, India
3
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad, India
Email: mohdaqeel180@gmail.com

Advanced ultra super critical (A-USC) boilers are aimed at increasing the
efficiency of coal-based power generation (>50%). However, advanced
materials are needed that could withstand higher temperatures of 700 to
7600C and pressures upto 25-35 MPa. High temperature nickel-based
superalloy, such as Inconel 617 (UNS N06617) is considered as a
candidate material due to its excellent oxidation resistance, superior
mechanical properties and high creep resistance. In the present work,
CO2 Laser-MIG hybrid (LHW) welding of 10 mm thick Inconel 617
plates was performed. Influence of different welding speeds on weld
penetration and the effect of MIG arc and CO2 Laser sources on the
microstructure were analyzed. Near full penetration could be obtained at
low welding speed welds. Welding defects such as laser-induced porosity
and lack of sidewall fusion observed in laser fusion zone were due to the
fluctuation of the laser beam and beam offset respectively.


Segregation of secondary elements such as Cr and Mo are found to be
more at interdendritic region of MIG fusion zone compared to laser
Mo content in the interdendritic region increases with decrease in
welding speed due to the formation of M6C carbides. Secondary dendritic
arm spacing (SDAS) value increases as the welding speed decreases. The
results obtained from X-ray diffraction (XRD) analysis reveals that the
high welding speed welds produce more number of M23C6 carbide peaks
compared to low welding speed welds. Laser-hybrid weldability studies
on fusion behaviour, microstructure, microhardness of Inconel 617 will
be presented.
Keywords: Inconel 617, A-USC boilers, Laser Hybrid welding,
Microstructure, elemental segregation
ESTIMATION OF RESIDUAL STRESSES
DEVELOPED IN SS 304L / Zr-2.5%Nb JOINTS
V. Srikanth* and A. Laik
Materials Science Division, Bhabha Atomic Research Centre,
Mumbai 400085, India
Email of corresponding author: voonas@barc.gov.in
Joints between stainless steel (SS) and zirconium based alloys have
various applications in nuclear technology [1]. Since mechanical integrity
of these joints under reactor operating conditions for the reactor life time
viz. 40-50 years is vital, the qualification criterion for these joints should
be very critical. The large difference in thermal coefficient of expansion
of Zr-based alloys and SS leads to generation of residual stresses at the
joint interface, which can have deteriorating effect on the bond integrity
and mechanical properties of the joint [2]. Therefore, a proper estimation
of these stresses is essential for its qualification. One of the accepted
ways of mitigating such high residual stresses is by using suitable ductile
interlayers between the joining materials. In the present work, the
magnitude, nature and distribution of the residual stresses have been
estimated using finite element method (FEM). Simulations were
performed using axisymmetric model to evaluate the residual stress field
generated while cooling SS304L/Zr-2.5%Nb joint from 1273 K to
ambient temperature. The stress fields were calculated assuming elasto-
plastic behaviour of the joining materials. The SS part of the joint was
found to experience a maximum radial tensile stress of about 296 MPa,
and a maximum shear stress of 55 MPa at the SS/Zr-2.5%Nb interfacial
region. The maximum compressive stress in axial direction was found to
be 92 MPa. Similar simulations were also performed by introducing Ni
and Ti interlayers of thickness 200 m each between SS304L and Zr-
2.5%Nb. The maximum radial tensile stress on the SS side was found to
be 243 MPa and a maximum shear stress of about 74 MPa near SS/Ni
interface, while the maximum compressive stress in axial direction was
55 MPa. Therefore, it can be seen that a reduction in residual stress levels
can be achieved upon incorporation of Ti and Ni interlayers.
Key words: residual stress, elasto-plastic, tensile.
[1] M.A. Chaudhary, J. Nucl. Mater., 301 (2002), 118-121.
[2] H. I. Shaaban and F. H. Hammad, J. Nucl. Mater., 71 (1978), 277-
285.
STRUCTURAL INTEGRITY ASSESSMENT OF A
PROPELLANT TANK IN PRESENCE OF
WELDING RESIDUAL STRESSES
V. Viswanath, A. K. Asraff, Jayesh. P, Suresh Mathew Thomas, Krishna
Kumar.R, Muthukumar R
Liquid Propulsion Systems Centre, Valiamala P.O,
Thiruvananthapuram- 695 547
v_viswanath@lpsc.gov.in
Upper stage of India’s new generation launch vehicle makes use of
cryogenic propellants with liquid hydrogen (LH2) and liquid oxygen
(LOX) as fuel and oxidizer respectively. The propellants are stored in
tanks fabricated of Aluminum alloy AA2219 and contain various
11

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
openings. As carrying out proof test at operating environment was not
feasible, the tanks were subjected to proof pressure test at room
temperature (RT). During the RT proof pressure test of LOX tank, high
strains greater than 8000PH were recorded by gauges at three locations
where weld rework had been undertaken. From structural analysis, it was
observed that maximum welding residual stress of 95N/mm2 exists at
these locations. From stress analysis point of view, positive margins
were observed with respect to failure of the tank even in presence of these
residual stresses.
However, since the tank would be operating at cryogenic temperature,
though there is an increase in the yield and ultimate strengths of the tank
material, there is a reduction in ductility (lower percentage elongation).
Therefore, evaluation of structural integrity of the hardware from fracture
point of view is of paramount importance. A study was undertaken to
investigate the influence of residual stresses in integrity of the tank in
presence of minimum detectable crack sizes [1]. Location where
maximum strains were observed, post proof test, was considered for
fracture evaluation. Directional stresses at location of interest were
predicted through detailed finite element analysis. Subsequently,
generalized Failure Assessment Diagram was drawn based on Elasto-
Plastic fracture mechanics principles [2, 3] and margin against ultimate
ensured.
References:
Anonymous, ‘Nondestructive Evaluation Requirements for Fracture
Critical Metallic Components’, NASA STD 5003, 2008
Anonymous, ‘Guide to Methods for Assessing the Acceptability of Flaws
in Metallic Structures’, BS 7910: 2005, 2005
T. L. Anderson, ‘Fracture mechanics Fundamentals & applications’, CRC
Press, 2011
NUMERICAL STUDY ON THE RESIDUAL STRESS
DISTRIBUTIONS IN GTA WELDED DISSIMILAR
METAL COMPONENTS
Ch. Vijay Sai, Satish K. Velaga, Biswanath Sen, B.P.C. Rao, A.
Ravisankar
Indira Gandhi Centre for Atomic Research, Kalpakkam,
Tamil Nadu-603102
vijaysai@igcar.gov.in
Residual stresses are inherently self-balanced stresses that arise due to
non-uniform development of Eigen strains during processes like welding.
Tensile residual stress in weld joints have a detrimental effect on the
structural integrity and life of an engineering component, as it
exacerbates the effects of fatigue, corrosion and increases crack growth
rate leading to fracture. Hence, its correct estimation and minimization is
a pre-requisite to qualify a component for durable service in severe
environments e.g. in nuclear power plants. Dissimilar weld joints are
inevitably fabricated to provide the structural and functional continuity
whenever an equipment in a process line is fabricated. A typical and
relevant example is the weld joint between Modified 9Cr-1Mo steel (P91)
and AISI type stainless steel 304 L which finds application in nuclear
power plants and process industries.
While several methods exist to estimate stress distributions on a
component, Computer aided numerical simulation provides detailed
information of the magnitude and distribution of residual stress in the
component. This paper describes a numerical study carried out for
evaluation of residual stress occurring in dissimilar butt weld joints
between P91 and SS304 plates and circumferentially welded pipes. This
covers sequential coupled thermo-metallurgical and mechanical FEM
time-step analysis using three-dimensional models. The model predicted
residual stresses are compared with measured residual stresses arising in
weld joints of P91 and SS304L.


CHARACTERISTICS OF STRAIN-INDUCED
MARTENSITIC TRANSFORMATION IN WELDED
JOINTS WITH THE STRUCTURE OF
METASTABLE AUSTENITE
Yu. Korobov, O. Pimenova, M. Filippov, M. Chadiev, N. Ozerets, S.
Mikchailov, S. Morozov, Yu. Davidov, M. Razikov
Ural Federal University, 19 Mira str. Ekaterinburg, Russia, 620027
yukorobov@gmail.com
Welded joints of medium-carbon steel were performed by GMAW.
Economically alloyed cored wire based on the Fe-C-Cr matrix, providing
a welded joint structure of a metastable austenite, was used as a
feedstock. Phase transformations during crystallization and subsequent
thermal and deformational influences under loading were studied. For
this purpose, the results of electron microscopic studies, dilatometric and
magnetometric measurements were analyzed. As shown, the structure
contains an increased amount of metastable austenite, -ferrite and high-
strength carbon-chrome martensite. Welded joints were intensively
hardened at local impact due to strain-induced martensitic transformation.
At the same time, the joints were marked by high resistance against the
formation of cold cracks. It was shown that these features were resulted
from the heterophase dissipative structure formed in the conditions of the
thermal-deformation cycle inherent in a welded joint. As reviewed, the
test conditions used are typical for various applications.
MICROSTRUCTURAL EVOLUTION OF BRAZED
Ti JOINT USING Ti20Zr20Cu50Ni10 METALLIC
GLASS RIBBON AS FILLER
P. Rama Rao*1, 4. Bhaskar. Majumdar2Anil K. Bhatnagar1, 3, and, K.
Muraleedharan4
1
School of Engineering Sciences & Technology
University of Hyderabad, Hyderabad 500046, INDIA
2
Defence Metallurgical Research Laboratory (DMRL)
Kanchanbagh, Hyderabad – 500 058, India
3
School of Physics, University of Hyderabad, Hyderabad 50046, India
4
CSIR-Central Glass and Ceramic Research Institute, Kolkata– 700032
*Corresponding author: panugothu.ramarao@gmail.com
Metallic glasses of Ti20Zr20Cu50Ni10in the form of hard ribbon were
produced by the standard melt-spinning technique on copper roller wheel
in air. Vacuum brazing using these ribbons were done to join two plates
of Ti alloy at 990oC for 10 min. The main aim of the present work was to
study the use of the metallic glass ribbons as brazing material for titanium
based alloys. Since the microstructure during crystallization of these
metallic glasses is expected to influence the strength of brazing joints,
microstructure characterization is very important. Here we present the
results of characterization of the ribbons with Ti20Zr20Cu50Ni10
composition as well as the brazed sample after joining two Ti-plates.
Both as-spun and heat-treated ribbons were characterized by X-ray
Diffractometry (XRD), Field-EmissionScanning Electron Microscopy
(FESEM), Transmission Electron Microscopy (TEM) and the energy
dispersive X-ray spectroscopy (EDX) attached to both TEM and FESEM.
The as-prepared ribbons showed amorphous nature when examined on
both surfaces by XRD and as was also verified by TEM imaging and
diffraction observation. TEM study of heat treated (753 K, 30 min.)
ribbon showed formation of nanocrystalline microstructure comprised of
equi-axed grains having sizes in the range of about 50-200 nm. Electron
diffraction analysis in the TEM suggested the presence of two phases,
viz., cubic Ti2Ni and(Ti, Zr)2Ni phases.
12
 
SeccondInterna
ationalStructturalIntegrittyConferencce&Exhibitio 018) PROCEEDING
on(SICE– 20 GS

oint and good mechanical properrties at elevated temperature but also

po
ex
xhibits reasonablyy good oxidation resistance at abou ut 1500 oC. Althoough
thee composite exxhibits linear oxxidation kineticss initially, it shhows
paarabolic oxidationn kinetics after thhe formation of protective
p oxide scale
s
as the oxidation progresses.
p Initiaal linear oxidatio
on behaviour off the
omposite can be mitigated by aallowing the com
co mposite to form m the
protective oxidatioon scale by a suiitable surface mo odification techniique.
Soome initial trails have
h been carriedd out by subjectin
ng the composite with
a various
v combinattion of laser pow wer density and exposure
e time usiing a
dioode laser at ARCI, Hyderabad iin order to obtaiin a protective oxide o
scale on the compposite surface. T The composite was w found to forrm a
Figg.1 Interfacial miccrostructure ofTi// Ti20Zr20Cu50N
Ni10 / Tijoint brazzed protective SiO2-Z ZrO2 mixed oxiide scale when it was exposedd to
at 990°C for
f 10min. ~220W/mm2 powerr density for aboout 30 s. The ox xide scale appearrs to
haave submicron grain
g size distribuution with an average
a grain sizze of
Keyywords: Metallicc glass, Brazing, Scanning eleectron microscoopy, ~11
m. Although it i appears that thhis mixed protecctive oxide scale will
Eneergy dispersive sppectroscopy. heelp in reducing oxidation rate of the compossite substantiallyy by
su
uppressing initiaal linear oxidatiion kinetics, a systematic oxidaation
stu
udies of bare as well
w as surface trreated composite are to be carriedd out
in order to confirmm this.
TH
HE EFFECT OF GRAPHIITE SIZE ON
N TENSILE
PR
ROPERTIES AND HYDRROGEN STOR RAGE
CA
APABILITY FA
AILURE AN
NALYSIS OF METALLIC
C ARMOUREED
OF
F FERRITIC DUCTILE CAST
C IRON ELECTRO-OPPTIC MECH
HANICAL CA
ABLES IN
UNDERWATE
U ER TOWED SONAR SYS
STEMS
Tak kuya Yoshimoto1, Takashi Matsuuo2,3 and Tomohiroo Ikeda4
1
Grraduate School off Engineering, Fuukuoka Universityy, Japan Kiiran Govind V, Anshath
A Hussain N, Gopalakrishnnan Nair VP, Sabuu
2
Deepartment of Mecchanical Engineerring, Fukuoka Unniversity, Japan Seebastian M
3
Institute of Materiaals Science and Technology, Fukuuoka University, Naaval Physical andd Oceanographic L
Laboratory, Thrik
kkakkara, Kochi--21
Japaan kirrangovind@npol.drdo.in
4
R&&D center, HINO ODE, Ltd., Japan
E-mmail of correspondding author:tmatssuo@fukuoka-u.aac.jp Soonars, which dettect the presencee of enemy subm marines under water
w
thrrough active orr passive meanss, are one of the most impoortant
Ducctile cast iron (D DCI) is one of prospective matterials used for the co
onstituents of Annti-Submarine W Warfare (ASW) systems.
s Amongg the
hyddrogen equipmennts because off low-cost, goodd workability and a diffferent classes off sonars availablee, towed array son
nar systems, fitteed on
formmability. The widde range of mechhanical propertiess of DCI is obtainned booard naval ships, have proven to bbe the most fruitfu ul in ASW operattions
by controlling micrrostructural factoors such as graaphite size, voluume as they can be deplloyed to variable depths, can accom mmodate more no: n of
fracction of graphite, matrix structure and so on. Thereefore, it is importtant sennsors and are leaast affected by shhip noise. In toweed sonar systemss, the
to find
f out an optimal microstructuraal condition that is
i less susceptiblee to acoustic projector array
a and receiveer array are towed
d behind a ship using
u
hyddrogen embrittlem ment. In this studdy, the effect of graphite
g size on the a combination
c of ellectro-optic mechhanical (EOM) toow cables - negatiively
hyddrogen storage caapability and thee hydrogen-inducced ductility losss of buuoyant metallic armoured
a cable aand neutrally buooyant fibre armooured
ferrritic DCI was inveestigated. caable- the former for
f depth control and latter for dep pth maintenance. Any
faiilure in these cabbles can affect thee performance off the sensor arrayy and
Sevveral kinds of ferrritic DCIs with a different graphitte diameter of abbout caan even result in loss of the towed system to sea.
10
m – 30
m weere used for the tensilet test and thhe hydrogen conttent
meaasurement. Hydroogen charging waas performed prioor to the tensile test t Du uring a series of sea
s trials of towedd array sonar systems, it was obseerved
by soaking a specim men in thiocyannate ammonium solution. Then, the thaat the metallic armoured
a cable had lost its cirrcularity and beccame
tenssile test was perrformed in air ata room temperatture. The hydroggen flaattened during deeployment and reetrieval from shipp. This may be duue to
conntent of a specimeen was measured by a thermal desoorption analyzer. thee extreme radial forces acting onn the cable whille passing througgh a)
It was
w found that thhe amount of hyddrogen stored in DCI was dependdent rollers located at winch
w spooler annd b) main fairllead comprising of 5
on the graphite sizee. As the graphitte diameter increeased, the hydroggen rollers located at aft
a end of ship, which causes permanent changees in
conntent sharply incrreased at a certaiin graphite diam meter, and it becaame caable’s internal connfiguration.
nearrly constant irreespective of increase in graphite diameter. In otther
worrds, there was thee critical graphitee diameter that siignificantly changged Too verify the caause and study the effects of such flatteningg on
the hydrogen storaage capability. The ductility was decreased by funnctionality and liife of the cable, ccyclic load testing
g studies were caarried
hyddrogen, and the hydrogen-induced
h d ductility loss waas dependent on the ou
ut at factory afterr simulating the aactual deploymen nt-retrieval condittions
hyddrogen content. Therefore,
T the hyddrogen embrittlemment of DCI becaame as that in the ship i.e
i bending diameeter and angle of approach. Tests were w
rem
markable when thee graphite size waas larger than the critical value. alsso conducted to simulate an ideeal condition meeting m the minimmum
beending diameter specifications. Both indigenou usly developed and
im
mported cable sam mples were chosen as test samp ples for performmance
co
omparison. The teests were conductted for 100 cycless for 2 ton load.
SU
URFACE MO ODIFICATIOON STUDIESS ON ZrB2- Du uring the tests, it was observed thaat severe flattenin
ng of armour and core
20vv/oSiC-1w/oB
B4C-0.1w/oCf COMPOSIT
TE caable resulting in failure of electrrical & optical liines had occurreed in
inddigenous cable samples. The iimported cable samples showedd no
flaatness or failure of lines, but onlly minor opening g up of armour wires
w
Jiteen Das, J Janardhhana Reddy, V Srrinivas, Manish Tak1, V V Bhanu
aft
fter all three tests.. Based on the reesults, steps were taken to improvee the
Prassad
raddial load bearingg capacity of the indigenous cablee. Modifications werew
Deffence Metallurgiccal Research Labooratory, Hyderabaad
1 maade in a) core cabble sheath materiial b) core cable sheath
s thickness & c)
Addvanced Researchh Centre International, Hyderabad
armmour wire materrial and an improoved indigenous cable c was develooped,
Email of the corresponding author: daasjiten@rediffmaail.com
wh hich has withstoood all the above teests and is now reeady to be inducteed to
thee system for sea trials.
t
ZrB
B2-20v/oSiC-1w/ooB4C-0.1w/oCf Composite show ws excellent fractture
tougghness (6 MPa.m m1/2) at room temperature
t as well
w as at elevaated
tem
mperature. It is a suitable
s material for nose tip and wing leading eddges
of a hypersonic vehiicle. This compoosite not only posssesses high meltting

13

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session1B:CompositeMaterialsandStructuresI
Chairman:VVBhanuPrasad,DMRL
SessionCoordinator:MLVMahesh,DMRL
16001627 InvitedTalk:FractureToughnessandStrengthoftheInterfaceofanIntrinsicHybrid
Laminate
RobertBrandt,UniversityofSiegen,Germany
16271639 Quasistaticcompressionbehaviorofglassfilledepoxycomposites
SarthakS.Singh,P.ChakrabortyandR.Kitey
IndianInstituteofTechnologyKanpur
16391651 DevelopmentofInhouseUnidirectionalCarbon/epoxyPrepregsandits
CharacterizationforAerospaceApplications
P.R.KrishnaMohan,MAnilKumar,SivagouthamKumarandP.M.Mohite
IndianInstituteofTechnologyKanpur
16511703 InSitu3AxisDefectGrowthScannerforCFRPCompositesSubjecttoTestingUnder
StaticandCyclicLoading
K.Ramesh,H.Mahesh,M.Murali,H.P.Chandru,A.SomayyaandR.Sunder
BangaloreIntegratedSystemSolutionsPvt.Ltd,Bangalore
17031715 EvaluationofFractureToughnessofAl6082Al2O3/Al2SiO5MetalMatrixcomposites
usingTaguchiMethod
PuneethN,SatheeshJ,GJNaveen,SatyajeetMallaandSurajSTendulkar
VivekanandaCollegeofEngineeringandTechnology,Puttur
17151727 Effectofspecimenwidthandcracklengthonthefracturepropertiesofglass/epoxy
laminatedcomposites
A.SatyanarayanaandM.Gattu
NationalInstituteofTechnology,Rourkela
17271739 Mixedmodecohesivelawestimationofcompositejointsmadeoftoughenedepoxy
adhesive
MohdTauheedandNaresh.V.Datla
IndianInstituteofTechnologyDelhi
17391751 Matrixcrackinginpolymermatrixcompositeunderbiaxialloading
NJagannathan,SGururajaandCMManjunatha
CSIRNationalAerospaceLaboratories,Bangalore
17511803 ComparativeStudyoftheBehaviourofCFRPandGFRPLaminatesinaplatespecimen
usingmodifiedvirtualcrackclosuretechnique(MVCCT)
ShubhaJavagal,J.RajuandKattaVenkataramana
NationalInstituteofTechnologyKarnataka,Surathkal
18031815 Designingtheinterphaseincarbonfiberpolymercompositesusingcarbonnanotubes
HarpreetSinghBediandPrabhatK.Agnihotri
IndianInstituteofTechnologyRopar
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
FRACTURE TOUGHNESS AND STRENGTH OF
THE INTERFACE OF AN INTRINSIC HYBRID
LAMINATE
R Brandt and A B Busch
University of Siegen, Germany
robert.brandt@uni-siegen.de
Unidirectional glass fibre reinforced plastic (U-GFRP) represents itself as
an excellent lightweight structural material due to its high tensile strength
ܴ௠ and its low density ߩ. A major drawback, however, is the relative
weakness of the matrix under more complex loading conditions
comprising a multi-axial state of stress. Therefore, a local hybridization
of U-GFRP by adding a layer of high strength steel seems to be an
adequate measure to enhance the robustness of the material. First, the
material testing program sets the focus on the investigation of the strength
of the interface between both constituents of the hybrid material, which
can be widely adapted by means of surface treatments. Hence, the energy
release rate ‫ܩ‬ூ , the static shear strength ߬௦ as well as the cyclic shear
strength ߬௦ǡ௖௬௖௟௜௖ of the considered interfaces have been determined at
room temperature RT and at an elevated temperature of ܶ ൌ ͺͲι‫ܥ‬. The
results show up that primers, such as silane, are leading to a good
adhesion between the constituents. However, the scattering of the
measured values is still high. Furthermore, a fibre bridging effect is
apparent which leads to an increase of the energy release rate ‫ܩ‬ூ with the
growth of the length ܽ of the crack. A power law is well suited to
describe this strengthening and its exponent ݊ serves as a further measure
to describe the strength of the interface. Generally, ageing of the material
and straining at an elevated temperature harm the performance of the
intrinsic hybrid material.
QUASI-STATIC COMPRESSION BEHAVIOR OF
GLASS FILLED EPOXY COMPOSITES
Sarthak S. Singh1, P. Chakraborty2, R. Kitey3
1
Ph.D Student, 2Assistant Professor, 3Associate Professor
Department of Aerospace Engineering, IIT Kanpur-208016, India
Email of corresponding author: sarthak@iitk.ac.in
Rigid particle reinforced polymer composites are used in several
engineering applications, ranging from in MEMS and bio-medical
devices to aerospace and civil structures. The functionality and the
reliability of theses equipments invariably depend upon the mechanical
and fracture response of composites. In general the composites’
mechanical characteristics are enhanced by varying the shape, size,
distribution and volume fraction of fillers. In current investigation, quasi-
static compression experiments are conducted to elucidate the effect of
filler shape and volume fraction on the mechanical behavior of glass filler
reinforced epoxy composites.
The epoxy matrix is prepared by mixing DGEBA (Diglycidyl Ether of
Bisphenol A) resin with TETA (Tri-ethyl Tetra amine) hardener in a ratio
of 10:1 by weight. Two glass filler variants, spherical particles with 34
μm average diameter and milled fibers with an average length and
diameter of 200 μm and 16 μm, respectively, are uniformly embedded
into the matrix. The filler volume fractions are varied from 0 % to 10 %
at a step of 2.5%. The cylindrical samples of 8 mm diameter and 6 mm
height are fabricated to prepare the test specimens. Quasi-static
compression experiments are conducted by loading the samples in
displacement control mode at a crosshead speed of 1 mm/min.
Stress vs. strain curves exhibit linear elastic regime followed by strain
softening, a plateau region and strain hardening characteristics. While the
yield stress in spherical particle composites remains nearly constant at all
volume fractions, the post-yield plateau stress shows increasing trend
with increasing filler volume fraction. On the contrary, the yield strength
as well as the post-yield stress is observed to be increasing with increase
in the filler content of milled-fiber reinforced epoxy. In all cases milled-
fiber composites exhibit higher yield and post-yield stress values when
compared to the spherical particle counterpart. To get more insight into
the influence of filler shape on the deformation mechanisms a
computational study is performed where a set of inclusions surrounded by


the polymer matrix is modeled and the materials’ deformation response to
the compressive loading is analyzed by conducting a two dimensional
elasto-plastic finite element simulations.
DEVELOPMENT OF IN-HOUSE
UNIDIRECTIONAL CARBON/EPOXY PREPREGS
AND ITS CHARACTERIZATION FOR
AEROSPACE APPLICATIONS
P. R. Krishna Mohan, Anil Kumar. M, Sivagoutham Kumar, P. M.
Mohite
Department of Aerospace Engineering, Indian institute of Technology
Kanpur UP 208016.
Email of corresponding author: prkmohan@iitk.ac.in
The main objective of this work is to develop an in-house Unidirectional
Carbon/Epoxy prepreg manufacturing technology suitable for Aerospace
applications. Modifications were made to the existing in-house prepreg
manufacturing facility to improve the quality of prepregs.
Characterization techniques were carried out to assess the quality of
prepregs. Tests have been performed at both prepreg and at laminate
level. To quantify the cure extent of epoxy (B-stage curing) and fibre
volume fraction in the prepreg, SDT (Simultaneous differential scanning
calorimetry and thermogravimetric analysis) is used. We have performed
plasma surface treatment on carbon fibres to improve surface roughness
and induce functional groups that would improve adhesion between
carbon fibres and epoxy resin during prepreg manufacturing. To know the
effect of plasma on carbon fibres, we have conducted FTIR for
identifying required functional groups on treated and untreated fibres.
Test performed at laminate level includes matrix digestion test to quantify
the fibre volume fraction, SDT to identify proper cure and determine the
service temperatures. In accordance with ASTM D2734, void volume
fraction is estimated. A 0° laminate is prepared and tension test is
performed to quantify modulus and the strength. Tension tests on ± 45°
and 90° laminates are also planned to check proper impregnation
(fibre/matrix interfacial bonding strength) by measuring shear modulus,
and transverse strength and modulus respectively. Tensile tests are
planned in accordance with ASTM D3039. A short beam shear test is also
planned in accordance with ASTM D790 to determine interlaminar shear
strength that reveals the proper impregnation. The characterization of
UD prepreg has given an in-depth insight of prepreg manufacturing
technology and therefore, contributed in making a good quality in-house
prepregs.
References:
1. R. Banks, A. Mouritz, S. John, F. Coman, R. Paton, Development of a
new structural prepreg: characterisation of handling, drape and tack
properties, Composite structures (2004) 169–174.
2. Kulkarni, A. P. (1995). Modifications in unidirectional prepreg making
machine and characterization of products. Master's thesis, IIT Kanpur.
IN-SITU 3-AXIS DEFECT GROWTH SCANNER
FOR CFRP COMPOSITES SUBJECT TO TESTING
UNDER STATIC AND CYCLIC LOADING
K. Ramesh, H. Mahesh, M. Murali, H.P. Chandru, A. Somayya1 and R.
Sunder
BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author, E-mail:
somayya@biss.in, Mob: +91-9880-432-322

Carbon Fiber Reinforced Polymers or Plastics (CFRP) have found wide
and increasing applications in aerospace given their light weight and
superior mechanical properties. Whilst their design, stress analyses and
manufacturing have steadily improved over the years, aerospace
composites are grossly under stressed by comparison to their metallic
counterparts. This is in large measure due to the lack of sufficient
understanding of how defects may grow in composites under service
loading. Damage kinetics in fatigue is much better understood in metals.
14

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
Defects in CFRP composites are as a rule internal and not subject to
visual tracking. Available NDT techniques such as ultrasound typically
demand bench conditions. No method was commercially available to
permit uninterrupted and automated tracking of damage growth in CFRP
specimens during the course of mechanical testing. Such testing can
proceed for several days if cyclic loading is involved because of
limitations on test frequency when working with composites.
The present paper describes an on-line scanner developed at BISS for
real-time NDT monitoring and recording of damage growth in CFRP
laminates under static and cyclic loading. The scanner employs precision
3D eddy-current probe positioning, followed by signal processing to
build a picture of growing damage as well as posttest analysis to
characterize fatigue damage growth.
EVALUATION OF FRACTURE TOUGHNESS OF
AL6082-Al2O3/Al2SiO5 METAL MATRIX
COMPOSITES USING TAGUCHI METHOD
1 2 3 4
Puneeth N , Satheesh J , G J Naveen , Satyajeet Malla , Suraj S
Tendulkar5
1
Assistant Professor, Department of Mechanical
Engineering,Vivekananda College of Engineering and
Technology,Puttur, Karnataka, INDIA,2Professor, Department of
Mechanical Engineering, SJB Institute of Technology, Bengaluru,
Karnataka, INDIA, 3Assistant Professor, Department of Mechanical
Engineering,Sambhram Institute of Technology, Bengaluru,
Karnataka,INDIA,4UG Student,Department of Mechanical Engineering,
Vivekananda College of Engineering and Technology, Puttur, Karnataka,
INDIA, 5UG Student, Department of Mechanical Engineering,
Vivekananda College of Engineering and Technology, Puttur, Karnataka,
INDIA
1
(puneeth0015@gmail.com), 2(satheeshsjbit@gmail.com),
3
(gj_naveen@yahoo.co.in), 4(satyajeetmalla@gmail.com),
5
(9869sujan@gmail.com)
Conventional Monolithic materials are limited in gaining a proper
combination of toughness, hardness, density, stiffness and strength.
Application of Metal Matrix Composites (MMC’s) in areas such as
automotive, aerospace, marine etc. are the most promising materials and
gaining extensive response in the present day scenario. These materials
are economical with high performance comparatively. Due to its low
fracture toughness as compared to metals; Metal Matrix Composites are
most often usedin critical applications. Evaluation of the plane strain
fracture toughness using specimen geometries and notches by various
researchers for the application of Linear Elastic Fracture Mechanics have
been benchmarked.
In the present work, evaluation of fracture toughness of Al6082 based
Al2O3/Al2SiO5 particulate composites is fabricated using Stir casting
method. Input parameters such aswt. % of Al2O3, stirring speed and stir
time on the hardness, tensile strength, impact strength and fracture
toughness of cast Al6082/Al2O3/Al2SiO5composites is investigated by
Taguchi method.
Taguchi’s L9 orthogonal array shows wt. % of Al2O3 is a higher
influential factor for experimental design. Three process parameters i.e.
wt. % of Al2O3 (3, 6, 9), stirring speed (150, 200, 250 rpm) and stirring
time (5, 10, 15 min) are used to fabricate samples of MMC’s comprising
of each factorwith 3 levels. Microstructural characterization via SEM is
used to have a visual observation on distribution of Al2O3 particles in Al
6082 matrix.
Keywords: - Al6082,Al2O3 and Al2SiO5 particulates, Stircasting, Fracture
Toughness, Scanning Electron Microscope.


EFFECT OF SPECIMEN WIDTH AND CRACK
LENGTH ON THE FRACTURE PROPERTIES OF
GLASS/EPOXY LAMINATED COMPOSITES
A.Satyanarayana, M.Gattu
Department of civil engineering, NIT Rourkela, Odisha
E-mail: aalasatyanarayana@gmail.com
This paper investigates the effect of different strain rates and crack length
on the fracture behavior of glass/epoxy composite laminates. The strain
rates are considered from 1 to 1000 mm/min and crack length considered
from 0 to half the width of the specimen, by maintaining crack length-
width ratio (a/W) between 0 to 0.5. The tensile test results show that with
the increase of strain rate there is an increase in nominal fracture stress,
stress intensity factor and fracture energy of the material.
MIXED-MODE COHESIVE LAW ESTIMATION OF
COMPOSITE JOINTS MADE OF TOUGHENED
EPOXY ADHESIVE
MohdTauheed and Naresh. V. Datla
Department of Mechanical Engineering, IIT Delhi, HauzKhas, New
Delhi, India 110016
Email of corresponding author:Mohd.Tauheed@mech.iitd.ac.in
Joining composites using adhesive bonding is attractive because they
reduce the weight of structure and allow to join complex shapes. These
benefits encourage use of composite adhesive joints in aerospace and
automotive industries. However, composite adhesive joints are seldom
used for primary structures because of our limited understanding of their
failure, especially under mixed-mode loads. Predicting the failure of
composite joints is challenging because the failure can occur cohesive in
adhesive, interfacial between adhesive/adherend, or within the composite
adherend. Moreover, these failures depend on the specimen geometry,
loading conditions, surface treatments, and environmental conditions.
Recent studies showed that cohesive zone approach can be used to
reliably predict failure, but most of these studies are limited to failure
under mode I loads and further for brittle epoxy adhesives. In this study,
traction-separation laws (TSL) were extracted for composite joints made
of toughened adhesive by applying the Digital Image Correlation
technique. These TSLs were used for strength prediction of composite
joints subjected to mixed-mode loading.
Composite adhesive joints were made of carbon fiber/epoxy composite
adherend and Araldite 2015 epoxy adhesive. Initially, a suitable surface
pre-treatment was established to be lateral sanding with 220 grit
sandpaper followed by acetone cleaning. Mode I and mode II fracture
testing were conducted using the double cantilever beam and end notch
flexural specimens, respectively. From these fracture tests, TSLs were
extracted by using a direct method based on the digital image correlation
technique. These TSLs were used in a finite element (FE) model of a lap
shear joint modelled in ANSYS 14 to predict the failure strength. This FE
predicted failure strength reasonably agreed with the experimentally
determined failure strength of the toughened adhesive joint.
MATRIX CRACKING IN POLYMER MATRIX
COMPOSITE UNDER BI-AXIAL LOADING
N Jagannathan1, S Gururaja2, CM Manjunatha1
1
CSIR-National Aerospace Laboratories, Bangalore, India
2
Department of Aerospace Engineering, Indian Institute of Science,
Bangalore, India
Email of corresponding author: njagan@nal.res.in
A model to predict the matrix crack evolution in a continuous fiber
polymer composite laminate under in-plane bi-axial static loading has
been presented in the current work. Oblique co-ordinate based shear lag
analysis was used to estimate the stress distribution inside the cracked
[0/90]s cross-ply T300/934 CFRP laminate. Weibull probability
distribution has been considered to account for the variation in ply
15
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

transverse strength. Size dependent strength due to variation in ply
thickness has been accounted by appropriate volume scaling based
Weibull scale factor. The Weibull parameters have been estimated using
a master ply crack evolution data. By applying incremental stress to the
laminate, using the probabilistic variation of transverse strength and the
stress at a material point, the new crack location has been identified using
Hashin matrix cracking criterion. The reciprocal of the normal distance
between two cracks has been termed as crack density. The crack density
evolution for cross ply laminates with increase in applied loading has
been estimated for various bi-axial ratios (Fig. 1) and compared with the
data available from the literature. Good correlation is found to exist
between the literature evolution data and current simulation predictions.
the critical value, GC. Depending on the external loading and material
properties, Total strain energy release rate, GT (GT=GI+GII+GIII) has been
used to predict growth of delamination. The onset of delamination growth
is determined by plotting the values of (GT/GC) across various
delamination sizes along the thickness of the plate.
DESIGNING THE INTERPHASE IN CARBON
FIBER POLYMER COMPOSITES USING CARBON
NANOTUBES

Harpreet Singh Bedi, Prabhat K. Agnihotri*

3.5
Simulation, H yy =0 Mechanics of Advanced Materials Laboratory, Department of
Mechanical Engineering, Indian Institute of Technology Ropar,
3 Simulation, H yy /H yy =3
Rupnagar, Punjab, India-140001. prabhat@iitrpr.ac.in
Simulation, H yy /H yy =1
2.5
Crack Density, 1/mm

Data , H yy =0 Experiments are conducted to quantitatively assess the effect of carbon

Data , H yy /H yy =3
nanotubes (CNTs) on the interfacial properties in carbon fiber (CF)/epoxy
2 composites by directly growing CNTs on the surface of CF. Wetting
Data , H yy /H yy =1 behavior of fiber fabric and single fiber filaments with epoxy matrix
1.5 before and after CNT grafting is investigated through contact angle
measurements. An improvement in wettability is observed after the
1 incorporation of CNTs on the fiber surface. Effect of wettability on the
size and properties of interphase is studied through well designed micro-
0.5 mechanical tests on single fiber composites processed with unsized and
CNT grafted carbon fibers. While nanoindentation testing is performed
0 for quantitative determination of interphase size and stiffness, single fiber
0 0.5 1 1.5 pull-out and micro-debond tests are used to evaluate the interfacial shear
Laminate Axial Strain, % strength (IFSS) in unsized carbon fiber/epoxy and CNT grafted carbon
fiber/epoxy composites. Consistent with the wettability analysis, CNT
Fig.1. Crack density evolution in a [0/90]s CFRP laminate under different
grafting enhances the size, stiffness and IFSS of CF/epoxy composites. In
bi-axial static loading, Data- Montesano, John, and Chandra Veer Singh.
addition, it is shown that even though larger CNT growth time on the
"Predicting evolution of ply cracks in composite laminates subjected to
surface of carbon fiber provides thicker interphase region but tends to
biaxial loading." Composites Part B: Engineering 75 (2015): 264-273.
degrade the stiffness of interphase and IFSS of CNT grafted carbon
fiber/epoxy multiscale composites. Scanning electron microscopy (SEM)
analysis of pulled-out and debonded fibers reveals different interfacial
failure mechanism in the presence and absence of CNTs on the surface of
A COMPARATIVE STUDY OF THE BEHAVIOR OF CF. The present study quantitatively show the presence of an interphase
CFRP AND GFRP LAMINATES IN A PLATE region surrounding the carbon fiber after CNT grafting on their surface.
SPECIMEN USING MODIFIED VIRTUAL CRACK The existence of interphase is important from the structural integrity of
composites view point as it eliminates the unwanted stress concentration
CLOSURE TECHNIQUE (MVCCT) at the fiber/polymer interface by gradually transforming the properties
from highly stiff fiber to comparatively weaker matrix. Moreover, the
Shubha Javagal1*, J. Raju2, Katta Venkataramana3 present study provides us a tool to design the interphase in hybrid
1
M.Tech (Research), Department of Civil Engineering, National Institute composites as per the requirement of a specific application.
of Technology Karnataka, Surathkal 575025 (Email:
shubha.javagal@gmail.com)
2
Principal Scientist, Structural Technologies Division, CSIR-National
Aerospace Laboratories, Bangalore-560017 (Email:
jrajuiyer@gmail.com)
3
Professor, Department of Civil Engineering, National Institute of
Technology Karnataka, Surathkal 575025 (Email: ven.nitk@gmail.com)

The applications of polymer composites in aircraft industry have

exponentially increased in the recent years due to their high strength to
weight ratio. Presence of delaminations in composites is inevitable which
affects the structural stability due to reduction in structural stiffness and
strength. The degradation of a structural component depends on the
geometric characteristics of delamination, nature of loading and material
characteristics. Damage tolerance study is thus essential to determine the
extent of degradation of the structure due to the presence of delamination.
The present paper brings about a comparison between the behaviour of
Carbon Fibre Reinforced Polymer (CFRP) and Glass Fibre Reinforced
Polymer (GFRP) which are subjected to circular delaminations of varying
diameters.

A constant compressive load is applied on a quasi-isotropic square plate

specimen of dimensions 200mm x 200mm with a thickness of 2.88mm of
both CFRP and GFRP configurations. The circular delamination is
introduced at the centre of the plate and its diameter and position along
the thickness direction are varied. Using ABAQUS codes of practice,
Strain Energy Release Rate (SERR) is computed using the principles of
Modified Virtual Crack Closure Technique (MVCCT). Delamination
propagates when the computed mixed mode Energy Release Rate exceeds

16

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session1C:StructuralHealthMonitoring
Chairman:SGopalakrishnan,IISc,Bangalore
SessionCoordinator:MPhaniSuryaKiran,DMRL
16001627 InvitedTalk:ConditionMonitoringofMetalsandFiberReinforcedPolymer
CompositesunderFatiguebyOpticalandAcousticMeans
SergeyPanin,InstituteofPhysicsofStrengthofMaterials,Russia
16391651 IntegratedVibroAcousticanalysisandEmpiricalModeDecompositionforfault
diagnosisofgearsinawindturbine
VamsiInturi,GRSabareeshandVaibhavSharma
BITSPilani,Hyderabadcampus
17031715 StrainBasedHealthMonitoringforFlutterInvestigationinLPCompressorof
DevelopmentalAeroEngineUsingHighSpeedRotatingTelemetrySystem.
S.Gangabhavani,K.Banumathy,OwaisMajidKamili,K.VishwanathandJ.Chitra
GasTurbineResearchEstablishment,DRDO,Bangalore
17271739 Detectionofsubtledamageinstructuresthroughsmartsignalreconstruction
K.LakshmiandA.RamaMohanRao
CSIRStructuralEngineeringResearchCentre
17511803 HighFrequencyDynamicMagneticShapeMemoryAlloyResponses
KrishnenduHaldar
IndianInstituteofTechnologyBombay

 



 
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on(SICE– 20 GS

CO
ONDITION MONITORIN
M NG OF META
ALS AND resspect to market share, size and ttechnological dessign. Generally, windw
turrbines are subjeccted to harsh operrating conditionss which further yields
y
FIB
BER REINFO
ORCED POLLYMER COMMPOSITES to damage of the critical
c componeents. Hence, healtth monitoring off key
UN
NDER FATIG TICAL AND ACOUSTIC
GUE BY OPT C co
omponents is a viital task which prredicts the damag ge severity and gives
g
MEEANS thee flexibility to plan
p the maintennance tasks. Win nd turbine conddition
mo onitoring is a maajor area of intereest in recent yearrs aiming to impprove
Pannin S.V.1,2, Eremmin A.V.1, Sunderr R.2,3, Burkov M.V.
M 1,2, Byakov thee life of the machine compoonents simultaneeously reducing the
A.VV.1, Lyubutin P.S S.1, Titkov V.V.1 op
perational and maintenance
m cost.. Gearbox in wind turbines hass the
1
Institute of Strengthh Physics and Maaterials Science, 2/4
2 Akademichesskii larrgest share of dow wntime among aall other componeents affecting direectly
pr., Tomsk 634055, Russia thee cost of operatioon and maintenance.
2
Toomsk Polytechnicc University, 30 Lenina
L pr., Tomskk 634050, Russiaa
3
Baangalore Integrateed System Solutioons, 497E 14th Cross
C 4th Phase In this current investigation, an atttempt has been made
m to diagnosee the
Peeenya Industrial Arrea, Bangalore 5660058, India geear faults by using Empiriccal Mode Deccomposition (EM MD)
svp@ispms.ru meethodology. Twoo condition monnitoring techniqu ues such as vibraation
an
nalysis and acousstic signal analyssis are integrated and the experim ments
Thee present study is i devoted to thhe investigation of o deformation and a aree performed on a laboratory sccaled three-stage gearbox havingg the
fraccture processes off various structurral materials under cyclic loadingg by speed ratio of 1:488. Local gear fauults such as tooth h chip and tooth root
meaans of optical andd acoustic techniqques. Optical metthod is based on the craack are seeded annd the response iss recorded in the form of vibrationn and
Diggital Image Correllation technique being
b aimed to obbtain strain patterrns. acoustic signals. EMMD analysis is immplemented and the t statistical feattures
Theeir study is of parrticular importancce for fatigue cracck growth in mettals. aree extracted fromm the acquired ddata. The repressentative featuress are
This approach is further
f improvedd for calculating fracture mechaanic ideentified using a decision tree alggorithm and thesee are classified using
u
paraameters as well as to monitor crack tip propagation (opening) ussing paattern recognitionn techniques – Support Vector Machine (SVM M) to
maccroscale observattion (at resolutionn 0.5 μm/px). Thee acoustic techniqque disstinguish between the healthy annd faulty classes. The challengess and
is based
b on the ultrasonic Lamb wavees probing with the t view of realizzing thee potential advanntages are also diiscussed in this paper
p to establishh the
Struuctural Health Monitoring (SHM)) systems. The opperation principlee of focus of integrated condition monitooring systems.
the proposed acousstic approach is based on the analysis a of receivved
acouustic signals (prropagating through the specimenn gauge length) by Keeywords: Wind turbine gearboox, condition monitoring,
m vibraation
commputation of a widde range of inform mative parameterrs. an
nalysis, acoustic signal
s analysis and Empirical mode decomposition..

ST
TRAIN BASE
ED HEALTH
H MONITOR RING FOR
FL
LUTTER IN
NVESTIGATIION IN LP COMPRESSO
C OR
OF
O DEVELOP PMENTAL A
AERO ENGINE USING
HIGH
H SPEED
D ROTATING
G TELEMET TRY SYSTEM
M
S. Gangabhavani +, K. Banumathyy, Owais Majid Kamili,
K K
.V
Vishwanath, J. Chitra.
Gaas Turbine Reseaarch Establishmennt, Bangalore - 56
60093
+ Email:
E gangabhavvani@gtre.drdo.iin/ s.gangabhavan ni@gmail.com
Straain field in
alumminum alloy wiith Thhis study is conceerned with the vibbratory strain meaasurement on fann first
wellded joint prior to Received acoustic signal patttern staage rotor blades for health monitoring of an aero engine under testing
fraccture. Threee with emphaasized S0 Lamb wave
w mode. ussing high speed rotating
r telemetrry system. Strainn gages were useed to
proppagating crackks meeasure the blade vibratory strains experienced by the t blades duringg Fan
are seen. Flu utter Evaluation Tests. Rotating T Telemetry System m provided the means
m
forr transmitting thhe strain data froom rotating blad des to stationary data
Ressults of experim mental and theorretical studies aimed
a at condittion acquisition systemss. During the enngine tests condu ucted in a groundd test
monnitoring of high strength
s aluminum m and titanium alloy specimens with
w faccility, the strain records revealedd high strains exp perienced by the Fan
wellded joints as well
w as carbon anda glass fiber reinforced polym mer firrst stage rotor blades
b due to nnon-integral eng gine order excitaation
commposites subjecteed to static and cyclic loading are
a described in the diaagnosed as flutterr. The strain leveels were too high for the safe operaation
papper. The evolutionn patterns of infoormative parametters (computed frrom off the engine. As part of the fluttter mitigation, in ntroduction of caasing
acouustic and optical data) and stain gauging during meechanical testing are treeatment was usedd as one of the aapproaches. Afteer the introductioon of
illusstrated. The com
mbined use of the t optical and acoustic techniqques caasing treatment, the
t engine was ttested and it waas observed that high
makkes it possible tot realize a com mplex way of daata acquisition thhus strrain levels observved earlier had rreduced considerrably. The strain data
avooiding shortcominngs of each techhnique. The com mbined sensing and a acquired through the t telemetry sysstem therefore no ot only helped inn the
monnitoring allows one to more thoroughly studdy and understaand deetection and idenntification of fluutter but also provided
p vital innputs
proccesses of damagee accumulation, crack growth and fracture. reggarding the efficacy of casing treatment in flu utter suppressionn. In
ad
ddition, the paperr also highlights tthe importance of o Rotating Telem metry
Syystem in non –coontact data transsmission resulting in excellent siignal
quuality, no wear annd tear, and minim mum inspection and maintenancee. All
INTEGRATEDD VIBRO-AC
COUSTIC ANNALYSIS AN
ND theese features are of vital importaance in online heealth monitoring and
safety assessment of o developmental aero-engines.
EM
MPIRICAL MODE
M DECOOMPOSITIOON FOR
FA
AULT DIAGN
NOSIS OF GEARS
G IN A WIND
W
TU
URBINE

Vammsi Inturi, Sabarreesh G R, Vaibhhav Sharma

Deppartment of Mechhanical Engineering, BITS Pilani, Hyderabad
Cammpus, Telangana,, India
p200160025@hyderaabad.bits-pilani.acc.in

Oveer the last few yeears, wind turbinee technology has experienced a raapid
grow
wth among the other
o renewable power
p developinng technologies with
w

17

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

DETECTION OF SUBTLE DAMAGE IN

STRUCTURES THROUGH SMART SIGNAL
RECONSTRUCTION
K. Lakshmi , A. Rama Mohan Rao
CSIR-SERC, Taramani, Chennai-600113
lakshmik@serc.res.in

The primary function of structural health monitoring (SHM) is the

process of extractingthe damage features from the measured rawdata,
recorded using sensors on the structure of interest.The efficiency of SHM
techniques lies in their capability to detect early damage in its incipient
stage. The early damage alters the dynamic characteristics of only a few
Fig1. (a) (b)
modal responses but in a feeble manner. Isolating these modal responses,
hidden in the overall raw response, for damage diagnosis, is a real
challenge to the SHM community.In order to handle this issue, an (a) Quasi-static magnetization constitutive behavior and (b) simulated
improved version of Empirical Mode Decomposition(EMD) is employed eddy current for a 1D actuated bar at 25 Hz frequency and 6% strain.
in this paper. EMD decomposes the measured response signals into
mono-component signals, called intrinsic mode functions (IMFs). The [1] OHandley. Journal of Applied Physics, 83(6):3263–3270, 1998.
mixed modes in EMD are handled using Intermittency criteria in the [2] I Karaman, B Basaran, HE Karaca, AI Karsilayan, and YI
proposed EMD. Once the IMFs are extracted from the raw signal, the Chumlyakov. Applied Physics Letters, 90(17):172505, 2007.
IMFs (signal components) which possess the valuable information of [3] K. Haldar, G. Chatzigeorgiou, and D. C. Lagoudas. European Journal
incipient damage called ‘critical IMFs’, are isolated using an automated of Mechanics - A/Solids, 54:53–73, 2015
algorithm. At this stage, the presence of damage gets exposed. To
determine the spatial location of damage, these critical IMFs are
combined to reconstruct a new signal with enriched information on
minor/incipient damage. ARMAX model is employed on the new signal
with enriched damage information. A distance measure, based on the
subspace angles of ARMAX models is used as a damage indicator.
Numerical simulation studies are carried out to evaluate the capability of
the proposed damage diagnostic algorithm, in identifying the early
incipient damage like small cracks,using the output-only dynamic
signatures (signals) with measurement noise.Experimental studies are
also carried out to complement the numerical simulation studies
demonstrate its practical application.The investigations presented in this
paper clearly reflect that the proposed damage diagnostic technique using
the smart reconstruction of teh measured raw signal is capable of
detecting the incipient subtle damages in the structures.

HIGH FREQUENCY DYNAMIC MAGNETIC

SHAPE MEMORY ALLOY RESPONSES
Krishnendu Haldar
Department of Aerospace Engineering, Indian Institute of Technology
Bombay, Mumbai 400076, India.
Email of corresponding author: krishnendu@aero.iitb.ac.in

Magnetic Shape Memory Alloys (MSMAs) are best known for their
unique ability to produce Magnetic Field Induced Strains (MFIS) up to
10% under a magnetic field [1]. Some of the commonly used MSMA
material systems are NiMnGa, FePd and NiMnX, where X=In,Sn,Sb. The
unique magneto-mechanical coupling makes MSMAs promising
materials for multifunctional structures, actuator and sensor applications
[2]. The coupled MSMA behaviors can be modeled by considering the
material as an electromagnetic continuum.

In this work, the dynamic effect of MSMAs is taken into account in the
modeling. Most of the modeling approaches consider quasi-static
magneto-mechanical processes and time dependent components from the
Maxwell equations are discarded. However, for a high frequency (~
1kHz) MSMA response, which is one of the key potential application for
this material, the magneto-mechanical coupling mechanism becomes
more complex. A systematic study is performed to capture the dynamic
responses of MSMA in terms of, e.g., the influence of eddy current and
Joule heating.

When a body deforms at high frequency in a magnetic field, a generic

material point moves with a high velocity and the motion creates an
induced electric field. The MSMA system becomes electro-magneto-
mechanically coupled in the dynamic regime. Such a coupled system is
studied based on experimentally verified quasi-static MSMA constitutive
behavior [3].

18

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

 

Session1D:OxidationandCorrosionResistantCoatings
Chairman:DipakKumarDas,DMRL
SessionCoordinator:Md.ZafirAlam,DMRL
16001627 InvitedTalk:ThermalBarrierCoatingsLifetimeAssessment
VincentMaurel,MinesParisTech,France
16271652 InvitedTalk:RoleofPhaseStabilityindurabilityofZirconiaThermalBarriermaterials
ASGandhi,IndianInstituteofTechnologyBombay
16521704 Performanceofglassceramicsasbondcoatinthermalbarriercoating(TBC)system
SumanaGhosh
CSIRCentralGlass&CeramicResearchInstitute
17041716 DevelopmentofnewTBCmaterialswithenhancedCMASinfiltrationresistance
throughatmosphericplasmaspraying
G.Sivakumar
InternationalAdvancedResearchCentreforPowderMetallurgyandNewMaterials,
Hyderabad
17161728 Frictionalcontactandwearalongvirtualinterfaces
BasavaR.Akula
MinesParistechParis,France
17281740 SurfaceAlloyingofTitaniumDiboride(TiB2)andSiliconCarbide(SiC)onAluminium
Al5052usingElectricDischargeProcessing
SandeepDas,RandhirKumarRaman,N.DevaraniandShrikrishnaN.Joshi
IndianInstituteofTechnologyGuwahati
17401754 InfluenceofsubstratepropertiesonthedeformationbehaviorofTiNcoatingunder
cyclicimpacttesting
PSureshBabu,MSusmithaSrikantha,VKrishna,LVenkatesh,GRaviChandraand
DSrinivasaRao
InternationalAdvancedResearchCentreforPowderMetallurgyandNewMaterials,
Hyderabad
17541806 Highspeednanomechanicalpropertymappingofthermalbarriercoating
B.Vignesh,P.SudharshanPhaniandG.SivaKumar
InternationalAdvancedResearchCentreforPowderMetallurgyandNewMaterials,
Hyderabad

18061818 InfluenceofShotPeeningParametersonSurfacePropertiesofTi6Al4VUsing
TaguchiTechnique
R.K.Kumar,P.SampathKumaran,S.Seetharamu,S.AnandKumar,T.PramodandG.J.
Naveen
IndianInstituteofTechnologyJammu
18181832 HightemperaturecorrosionstudiesonbareandNi20%CrcoatedInconel825super
alloyinNa2SO4V2O5environmentat900°C
S.M.Muthu,D.Raghul,N.ArivazhaganandM.Arivarasu
VelloreInstituteofTechnology,Vellore
18321844 HotcorrosionstudyofbareandPtaluminide(PtAl)coatedNibasesuperalloy
CM247LC
MaheshK.Kumawat,Md.ZafirAlamandDipakK.Das
DefenceMetallurgicalResearchLaboratory,Hyderabad



 
SeccondInterna
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TH
HERMAL BA
ARRIER COA
ATINGS LIF
FETIME PE
ERFORMAN NCE OF GLA
ASS-CERAM
MICS AS BON
ND
AS
SSESSMENT
T COAT IN THE
ERMAL BAR ATING (TBC)
RRIER COA
SY
YSTEM
V Maurel
M
MINNES ParisTech, PSL
P Research Unniversity, Su
umana Ghosh
Cenntre des Matériaux, UMR 7633, BP P87 91003 Evry, France Biio-ceramics and Coating
C Division,, CSIR-Central Glass
G and Ceramicc
vinccent.maurel@minnes-paristech.fr Reesearch Institute, Kolkata, India
Em
mail of corresponnding author: sum mana@cgcri.res.in
n
Onee of the major challenges for coatingsc on supeeralloys is to keep
adhherence during aging,
a where dam mage is mostly driven by therm mo- Thhe performance of o a thermal barrieer coating (TBC)) system consistinng of
mecchanical fatigue (TMF). On the other o hand, the methodology
m of the ytttria stabilized zirconia (YSZ) top coat, glass-cerramic bond coatt and
evaluation of the interfacial
i toughhness should be consistent withh in nicckel base superaalloy substrate wwas investigated in terms of theermal
servvice loading. Thhe aim of this paper p is to conssider the impact of properties such ass oxidation resisstance, thermal shock
s resistance and
miccrostructure evoluution on adherennce properties thrrough a mechaniical theermal gradient prroperties. Glass-cceramics was appplied as bond coaat on
analysis of the relevvant damage mecchanisms limitingg the lifetime of the thee nimonic alloyy substrate (nim monic–AE 435) by the conventiional
TBC C system. To achhieve this goal we w take advantagge of microstructture en
namelling techniqque. YSZ (8Y2O33–92ZrO2) was applied
a as the top coat
analysis coupling opptical microscopyy, SEM, EBSD annd 3D measuremeents on
nto the glass-ceraamic bond coat bby air plasma sprraying technique. The
by both
b Xray compuuted tomographyy and FIB analyssis for TMF loadding bo
ond coat thickness and top coat thickness were maintained to about a
[1-22]. On the other hand mechanicaal tests are perfoormed to determ mine 10
00±10 m and 400±104 m, resppectively. Figure 1 shows the typpical
adhhesion properties.. Recently, the use u of LAser Shhock Adhesion Test T cro
oss-sectional miccrostructure of thhe TBC system. Static oxidation test,
(LA
ASAT) has show wn its capability for both rankinng different coatting theermal shock test and thermal graddient measuremen nt were conductedd for
soluutions and evaluaating the evolutioon of a given coatting as a functionn of thee present TBC syystem.
aginng [1-2]. The linkk between differeent length scales involved in damage
mecchanisms is anallyzed by FEA includingi both explicit
e meshing of Oxxidation of bond coat governs thee lifetime of a TBBC system. Thereefore,
heteerogeneities (rouughness, grains..) and post-processsing FEA modell to TGGO layer formatiion and its thickkening should be controlled to reduce
estimate life to spallaation function off aging influence for
f TMF loading.. thee bond coat oxiddation induced TTBC degradation. Static oxidationn test
Refferences forr prolonged duraation showed no TGO layer betw ween the top coatt and
[1] Sallot, et al (22015). Metallurgiical and Materiaals Transactions A, thee bond coat of the TBC system. AAs glass-ceramic bond
b coat is basically
46(10), 4589-4600. ox
xide based, bond coat oxidation did not occur duriing thermal exposure.
[2] Maurel, V., et al (2013). Oxidatioon of metals, 79(33-4), 313-323. Thhermal shock testt exhibited high thhermal shock ressistance of the preesent
[3] Guipont, et al (22010). J. of Biom medical Materialls Research Part A, TBBC system. The thermal graddient was measu ured by noting the
95(44), 1096-1104. tem
mperature differrential between the coating su urface and subsstrate
[4] Sapardanis, et al (2016). Surface and Coatings Technology, 291, 430- su
urface. The lineaar behaviour of the thermal grad dient of the coaating-
4433. ubstrate system was observed with respect to the coating temperaturee.
su
[5] Soulignac, et al (2013) Surface and Coatings Teechnology, 237, 95-
1044.
[6] Courcier, C., et al
a (2011). Surface and Coatings Technology,
T 205((13-
14),, 3763-3773.

TopCoat
RO
OLE OF PHA
ASE STABIL
LITY IN DUR
RABILITY OF
O
ZIR
RCONIA TH
HERMAL BAARRIER MA ATERIALS BondC
Coat

Ashhutosh S. Gandh hi Substraate

Deppartment of Metallurgical Engineeering and Materiaals Science
Indiian Institute of Teechnology Bombbay, Mumbai 4000076
aganndhi@iitb.ac.in

Zircconia based oxidde ceramic coatings are now integgral to advanced gas
turbbines, whether foor aviation or forr power generatioon. These thermaally
100μm
insuulating coatings prolong
p the life off hot-section mettallic componentss by
keepping them at reelatively low tem mperatures in thhe presence of evere
incrreasing turbine innlet temperatures. Thermal barriier coatings (TBCs)
are exposed to therrmal cycling up to temperatures estimated to reach
~12250°C. The mosst successful TB BCs are based on the metastaable Fig. 1. Typiccal cross-sectionaal microstructure of TBC system
tetraagonal zirconia (t’) solid solution, stabilised by onne or more oxidess of
raree-earth elements such as Y, Ybb, La, Gd, Nd, etc. Low therm mal
connductivity and higgh fracture toughnness are the most important attribuutes
of the
t successful TBCs.
T We have shown that the fracture toughnness DEVELOPMEENT OF NEW
W TBC MATTERIALS
channges as the mettastable t’ phase transforms by precipitation of the WITH
W ENHAN
NCED CMAAS INFILTRA
ATION
cubbic phase. The behaviour of the rare-earth stabilised zircoonia
RESISTANCE
R E THROUGHH ATMOSPHHERIC
commpositions has beeen compared wiith the conventioonal yttria stabiliised
zircconia compositionn. It is seen that the phase transfo formations are fasster PL
LASMA SPR
RAYING
in compositions withw larger ionic radii of the stabiliser catioons.
Indeentation fracturee toughness hass been correlateed with the phhase G.. Sivakumar
trannsformations. Raaman spectroscoopy studies havve been used for Intternational Advannced Research Ceenter for Powder Metallurgy and New
N
idenntifying toughenning mechanism ms like ferroelasstic toughening or Materials,
M
trannsformation toughening. A compplementary line of o research workk is Baalapur P.O., Hydeerabad, INDIA.
undder progress wherrein Raman and X-ray X diffraction techniques are used
u Emmail: gsivakumarr@arci.res.in
for measuring the rooom temperature stress developed in TBCs. The long-
termm goal is to combbine the phase trannsformations, fraacture toughness anda Thhe beneficial rolee of high temperaature thermal barrrier coatings in land-
l
resiidual stress measuurement results to develop predicctive non-destructtive baased and aeroengiine gas turbines aallows the enginees to operate at hiigher
expperimental tools for assessing thhe structural inteegrity of in-servvice eff
fficiency and power.p Yttria-sstabilized-zirconiaa (YSZ) coatings,
TBC Cs. deeposited through either atmospherric plasma sprayiing (APS) or elecctron

19

 
SeccondInterna
ationalStructturalIntegrittyConferencce&Exhibitio 018) PROCEEDING
on(SICE– 20 GS

beam physical vapoor deposition (E EB-PVD) techniqques, predominanntly [3] M. Glitterle, A.

A Popp, M.W. Gee, W.A. Walll, Finite deformaation
connstitute the pressent day thermaal barrier coatinng (TBC) system ms. friictional mortar contact
c using a semi-smooth Newton
N method with
How wever the appliccability of YSZ based coatings are limited up to co
onsistent linearizaation, Int. J.Num
m. Meth. Engng.,V
Vol. 84 (5), pp. 543-
12000°C, beyond whhich the perform mance of the material
m significanntly 57
71, 2010.
deteeriorates owing tot the formationn of unstable phaases, densificatioons,
insttant reactivity with CMAS, whichh collectively acccelerates the coatting
spalllation.
SU
URFACE AL LLOYING OF TITANIUM M DI-BORID
DE
Lannthanum cerate (L LC) is one of the promising candiddate, by virtue off its
highh melting point, low
l thermal condductivity and com mparable co-efficiient
(T
TiB2) AND SIILICON CARRBIDE (SiC) ON
of thermal expansioon (CTE) with bond coat. Prelliminary studies on ALUMINIUM
A M Al 5052 USIING ELECTRRIC
infiltration of silicatteshave shown thhat LC was founnd to be effectivee in DISCHARGE PROCESSIN NG
arreesting through forrmation of La-appatite phase. How wever, REO dopaants
are essential with LC to managee the CTE valuues at intermediiate Saandeep Das1, Ranndhir Kumar Ram man2, N. Devaranni3, and Shrikrishnna
mperature zones. In order to qualiify LC based maaterials for the next
tem n N.. Joshi4*
genneration TBCs,it is essential to undderstand the role of
o REO dopants that
t 1
Dumka
D Engineerinng College, Dumkka 814101, Jharkkhand
can manage the CTE E values and alsoo, provides improoved thermal cyclling 2,4
Department of Mechanical
M Engineering, Indian Insstitute of Technology
perfformance and CMASC infiltratioon resistance. Accordingly, various Gu uwahati, Guwahaati 781039, Assam m
REO Os doped LC weere synthesized too obtain spray grrade powders whhich 3
Farm Machinery and
a Power Engineeering, College of Agricultural
werre plasma sprayyed to generatee test coupons and free-standding En ngineering & Post Harvest Technoology (CAEPHT)), Central
speccimens and comppared with zirconate based TBCs. Ag gricultural University, Ranipool, S
Sikkim
Em mails: 1das.sandeeep539@gmail.com, 2randhir.ramaan21@gmail.com,
3 4
dev.ngangkham@gmail.com, snj@ @iitg.ac.in
* Corresponding
C A
Author
FR
RICTIONAL CONTACT AND WEAR
R ALONG
In Al 5052 alloy, aluminium is m mainly alloyed with
w magnesium and
VIRTUAL INT
TERFACES hromium. It has a wide range of important ap
ch pplications in maarine
strructures, aircraft,, heat exchangerrs, fuel lines and
d tanks industryy. To
Bassava R. Akula haave a long life off these applicatioons, they need paarts made up of high
MINNES ParisTech, PSL
P Research Unniversity, Center des
d Matériaux, strrength-to-weight ratio materials with excellentt surface properrties.
CNRS UMR 7633, Reequired surface properties
p viz. hhardness, corrosio
on resistance cann be
BP 87, 91003 Evry, France. obbtained by using various treatmennts such as therm mal, thermo-chem mical,
fran Tech, Safran Group, 78772 Magny-les-Hameau
Safr M ux, France. plaating and coatingg, and implantatioon. This paper prresents a fundameental
basaava-raju.akula@mmines-paristech.ffr, stuudy on alloying of industrial useeful materials viiz. titanium di-booride
basaava-raju.akula@ssafrangroup.com.. (T
TiB2) and silicon carbide (SiC)) on Al 5052 alloy a using elecctric-
disscharge based suurface treatment.. Electric discharrges are obtainedd by
Wear is a complex innterfacial phenommenon resulting from
f relative mottion ussing electric disccharge machine (EDM). The alloying powderss are
betwween contacting bodies, and maanifests itself inn material removval. miixed and an electtrode is formed uusing powder meetallurgy method. The
Acccurate representaation of contact tractions while accounting for the prepared electrodee is used in EDM M machine to trransfer the electtrode
conntinuously evolvinng geometrical chhanges due to weear, poses numeriical maaterial onto the Al
A substrate. Exteensive experimen nts have been caarried
challenges. The commmonly encounteered complexitiess with the numeriical ouut to transfer TiB B2-SiC on Al50052 substrate, an nd suitable rangees of
treaatment of wearr include: remeeshing procedurees to capture the process parameterss viz. tool polariity, composition of alloying mateerial,
geoometrical changees and field rem mapping of hisstory variables. An peeak current and pulse on timee have been fou und out. System matic
appproach mitigating these complexities is elaborated inn this work. ch
haracterization off alloying thickneess and measurem ment of hardnesss has
beeen performed. The
T cross-sectionaal thickness afterr alloying is anallysed
Herre we extend thee existing method of embedded interfaces for tyying ussing optical micrroscopy and is ffound to be in the t range of 90 μm.
probblems to treat frictional contacct and wear prroblem in 2D [1]. Ennergy Dispersivee X-ray (EDX)) spectrometry shows a signifi ficant
Com mbining this metthod with the surrface-to-surface contact
c formulatiion, peercentage of titaniium, silicon, carbbon and moderatee percentage of boron
b
resuults in a simplifi
fied numerical frramework to treaat contact probleems traansferred during the alloying proocess. Results co oncluded that eleectric
alonng virtual interfaaces [2, 3]. An energy-based wear
w law is usedd to disscharges can be used as an ecoonomical and effficient alternativve to
deteermine the progression (wear deppth) of these virtuual interfaces in the achieve desired surrface properties on industrial parts.
bulkk; no remeshing is needed. In adddition to handling surface evolutiion,
thiss computational scheme ensures accurate repressentation of surfface
tracctions, which iss essential for wear simulatioon. The methood’s
perfformance in termms of convergennce and accuracyy will be presentted. IN
NFLUENCE OF SUBSTR
RATE PROPE
ERTIES ON
Appplications of the method to the disk-blade frettinng problem will be
disccussed.
THE DEFORM
MATION BEEHAVIOR OF TIN
COATING UN
NDER CYCLLIC IMPACT
T TESTING

P Suresh Babu, M Susmitha Srikaantha, V Krishna, L Venkatesh, G RaviR

Chhandra and D Srinnivasa Rao
Intternational Advannced Research Ceentre for Powder Metallurgy and New
N
Materials
M (ARCI)
Baalapur (PO), Hyderabad-500005, T Telangana, India
Emmail: pitchuka@aarci.res.in

TiiN coatings have been extensivelyy used to enhancee the cutting tooll life.
In addition, these coatings
c also fouund in other appliications like artifficial
REF FERENCES joiints, surgical insstruments, plasticc injection moldds and dental alloys.
[1] J.D. Sanders, T..A. Laursen, M.AA. Puso, A Nitscche embedded mesh
m Diifferent applicatioons use differentt substrate materiials. Hence it is very
metthod, Comput.Meech., Vol. 49 (2), pp. 243–257, 20112. essential to undersstand the deformaation and fracture behavior of TiN N as
[2] N. Sukumar, T. T Belytschko, Arbitrary
A brancheed and intersectting funnction substrate properties. Furrther, material cu utting is a com mplex
craccks with the exttended finite eleement method, Int.
I J. Num. Meeth. process where cuttting tool experieence tensile, com mpression and fattigue
Enggng.,Vol. 48, pp. 1741-1760, 20000. typpe stresses durring cutting opeeration. Nano-im mpact testing whichw
repplicate the millinng operation and llow cyclic fatigu
ue processes are being
b

20


SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
used widely in the recent years to assess the properties especially the
fracture and deformation behavior of thin hard coatings. A strain rate up
to 102 to 103 can be achieved during the impact testing. Hence, an
attempt has been made to understand the influence of substrate properties
on the TiN coating deformation. The fracture behavior of TiN coating
deposited by cathodic-arc physical vapor deposition (CA-PVD) on
different substrates having wide range of hardness and elastic modulus
values tested under cyclic impact will be discussed in the present talk. It
is observed that the hardness and elastic modulus of substrate influence
significantly on the deformation behavior of TiN coating. In impact
testing, delamination and chipping of coating is observed on high elastic
modulus substrate and cracking and bending of coating is noticed on soft-
substrate materials.
HIGH SPEED NANOMECHANICAL PROPERTY
MAPPING OF THERMAL BARRIER COATING
B. Vignesh, P. Sudharshan Phani* and G. Siva Kumar
International Advanced Research Centre for Power Metallurgy & New
Materials (ARCI), Balapur P.O., Hyderabad, 500005
* Corresponding author: spphani@yahoo.com
The mechanisms of failure and prediction of coating life remains the key
objective of research in thermal barrier coating (TBC) systems. Coating
failure is often attributed to several complex phenomena such as the
formation of a thermally grown oxide (TGO) layer, spinel formation in
the top coat, degradation of bond coat, densification of top coat etc., The
objective of the current work is to track & analyze all of these
phenomenon by measuring the mechanical response at submicron scale.
Novel high speed nanoindentation experiments, wherein a typical
indentation test takes less than 1 second, are carried out to measure the
local mechanical property of the TBC which comprises of a YSZ top coat
and NiCoCrAlY bond coat deposited by Atmospheric Plasma Spray
(APS) on a Ni-based super alloy substrate. The samples are subjected to
different levels of thermal cycling to study the degradation and determine
the life of the coating. A typical optical micrograph and the
corresponding hardness map of the bond coat comprising of close to 1000
indents after 5 thermal cycles is shown in Fig.1(a) and Fig.1(b)., while a
similar map at the bond coat / top coat interface after 100 cycles
comprising of 10000 indents is shown in Fig. 1(c) and Fig. 1(d). The
maps clearly demonstrate the strong correlation between the
microstructure and the hardness. A novel algorithm for deconvolution of
the large experimental data set (more than 100000 data points) to
determine the contribution of individual phases will also be presented
which can be gainfully used to understand the underlying mechanisms
and ultimately enable predictive modelling of the life of TBCs.
Fig. 1. Optical micrograph and corresponding hardness maps of bond
coat after 5 cycles ((a) & (b)) and bond coat-top coat interface after 100
cycles ((c) & (d)).


INFLUENCE OF SHOT PEENING PARAMETERS
ON SURFACE PROPERTIES OF Ti-6Al-4V USING
TAGUCHI TECHNIQUE
R.K. Kumar1, P. SampathKumaran2, S. Seetharamu3, S. Anand Kumar4,
T. Pramod5, G.J. Naveen6
1Central Power Research Institute, Bangalore
2,3
National Design and Research Forum, Bangalore
4
Indian Institute of Technology Jammu, J&K
5
The Energy and Resources Institute, Bangalore
6
Sambhram Institute of Technology, Bangalore
Email of corresponding author: anand.subramaniyan@iitjammu.ac.in
The titanium alloy especially Ti-6Al-4V material is used in aviation
industry such as engine parts, air frames etc. The main advantage of using
Ti-6Al-4V alloy is to combat chemical attack in corrosive and hash
environment as well as fatigue resistance under cyclic loading conditions.
This investigation mainly focuses on how to improve the fatigue
resistance of a component thereby the life improvement is envisaged. In
this regard, one of the methods employed is shot peening process, which
is a surface phenomenon and introduces compressive residual stress so
that the properties like stress corrosion cracking, fatigue and wear
resistance gets enhanced. The shot peening effect is generally noticed in
springs, turbine blades, dovetail joints, gears etc. wherein vibration is the
main factor responsible for fatigue damage.
The design and experimental work involves the various shot peening
parameters such as impact angle, coverage area, Almen intensity levels
affecting the surface roughness as well as surface and sub-surface
residual stresses. Further, design of experiments involving Taguchi
technique have been discussed at length. The shot peening parameters
have been correlated with residual stress and surface roughness
parameters. It is also observed that microstructure of the titanium alloy is
having the features to support the fatigue properties. Finally the work has
been summarized to arise at optimization of these parameters to achieve
higher residual stress from the point of higher fatigue life.
Keywords: Shot Peening, Design of Experiments, Almen Intensity,
Residual Stress, Surface Roughness.
HIGH TEMPERATURE CORROSION STUDIES ON
BARE AND Ni-20%CR COATED INCONEL 825
SUPER ALLOY IN Na2SO4-V2O5 ENVIRONMENT
AT 900°C
S.M.Muthua, D.Raghula, N.Arivazhagana, M.Arivarasub*
aSchool of Mechanical Engineering, VIT University,
Vellore-632014, India.
bCentre for Innovative Manufacturing Research, VIT University,
Vellore-632014, India.
* Corresponding author, Tel. :+91-9488982584, Fax: +91-416-2243092
E-mail address:arivarasu.m@vit.ac.in
The aim of the present study is to compare the hot corrosion behavior of
bare and Ni-20Cr coated Ni based super alloy Inconel 825 in molten salt
environment of Na2SO4-60%V2O5 at 900°C for 50 cycles. Ni-20Cr
coating is performed on super alloy Inconel 825 by high velocity oxy fuel
(HVOF) coating of thermal spray method. During hot corrosion study,
weight change measurement is taken at end of each cycle to obtain the
corrosion kinetics by thermo gravimetric technique. Surface morphology,
chemical analysis and phase identification of the corrosion products are
evaluated by scanning electron microscope, energy dispersive
spectroscopy and X-ray diffraction method. Cross sectional analysis is
performed on the hot corroded specimens to obtain oxide layer thickness
and depth of corrosion attack. Elemental distribution of the cross
sectioned hot corroded specimens were analyzed using X-ray mapping
analysis. Ni-20Cr coated specimen shows the better corrosion resistance
than bare specimen. Oxide scale cracks and spallation were observed on
uncoated specimen after 50 cycles.
21
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

HOT CORROSION STUDY OF BARE AND Pt-

ALUMINIDE (PtAl) COATED NI-BASE
SUPERALLOY CM247LC

Mahesh K. Kumawat, Md. Zafir Alam, Dipak K. Das

Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad
Email: mahesh.kgp.iit@gmail.com

Ni-base superalloy components are used in the hot sections of aero-gas

turbine engines. These alloys possess good high-temperature strength, but
are prone to structural degradation during service at high temperatures
due to oxidation and hot corrosion. Pt-aluminide (PtAl) coatings are
known to provide good oxidation resistance to the superalloy
components. However, the hot corrosion resistance of the PtAl coatings
has not been well reported in the open literature. The present study
examines the hot corrosion behavior of the directionally solidified (DS)
CM247 LC superalloy in the uncoated condition and after application
with a ~100 μm thick PtAl coating. The test specimens were spray coated
with Na2SO4 salt and exposed at 950°C in air for 200 h. The uncoated
alloy exhibited significant scale formation and dimensional instability,
which was unlike that of the intact coated samples. Detailed
microstructural characterization was carried out using scanning electron
microscopy and electron probe microanalysis to assess the extent of
degradation in the samples. The effectiveness of the coating, and the
benefit of Pt contained in the coating, against hot corrosion damage of the
superalloy are elucidated.

22

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

 

Session1E:FatigueandFractureI
Chairman:SVKamat,DRDO
SessionCoordinator:AtulKumar,DMRL
16001627 InvitedTalk:EffectsofVacuumlikeEnvironmentonSmallInternalCrackGrowth
ProcessesinVeryHighCycleFatigue
TakashiNakamura,HokkaidoUniversity,Sapporo,Japan
16271639 Influenceofretrogressionandreageingheattreatmentonthefatiguecrackgrowth
behaviorof7010aluminumalloy
MSNandana,KUdayaBhatandCMManjunatha
NationalInstituteofTechnology,Surathkal
16391651 EffectofhydrogenonshortcrackpropagationinSA508Gr.3Cl.Ilowalloysteelunder
cyclicloading
RajwinderSingh,AmanjotSingh,PawanK.SinghandDhirajK.Mahajan
IndianInstituteofTechnologyRopar
16511703 InterlaminarfracturetoughnessofshortfiberreinforcedGFRPlaminates
K.Chawla,S.RaychaudhuriandR.Kitey
IndianInstituteofTechnologyKanpur
17031715 EffectofnotchorientationonfracturebehaviouroftexturedZr2.5Nbmaterial
PritiKotakShah,AshwiniKumar,B.N.RathandJ.S.Dubey
BhabhaAtomicResearchCentre,Mumbai
17271739 DeterminationofJinitiationtoughnessusingprecrackedsmallpunchtestspecimens
TaslimShikalgar;B.K.DuttaandJ.Chattopadhyay
HomiBhabhaNationalInstitute,Mumbai
17391751 AGeneralizationofNeuber’sRulefortheAssessmentofLocalStressesandStrains
inStressConcentrationZonesforaWideRangeofAppliedStrains
NikolayA.MakhutovandDmitryO.Reznikov
MechanicalEngineeringResearchInstitute.RussianAcademyofSciences,Russia
17511803 Cracksizedependencyofshearmodefatiguethresholdinbearingsteelsubjectedto
continuoushydrogencharging
Y.Akaki,TMatsuo,Y.NishimuraandS.Miyakawa
FukuokaUniversity,Japan
18031815 Anewsemianalyticalapproachforobtainingcracktipstressdistributionsunder
variableamplitudeloading
A.NSavkin,DenisevichD.S,K.ABadikovandA.ASedov
VolgogradStateTechnicalUniversity,Russia




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
EFFECTS OF VACUUM-LIKE ENVIRONMENT ON
SMALL INTERNAL CRACK GROWTH
PROCESSES IN VERY HIGH CYCLE FATIGUE
 Rajwinder Singh1, Amanjot Singh1, Pawan K. Singh2, Dhiraj K.
T Nakamura and F Yoshinaka
Division of Mechanical and Space Engineering,
Hokkaido University, Sapporo
nakamut @eng.hokudai.ac.jp
In recent years, very high cycle fatigue (VHCF) has become serious
issues in the field of mechanical engineering. The VHCF phenomenon is
mainly characterized by an internal fracture in cycles over 107–108. This
type of fracture has been observed not only in ferrous metals but also in
Ti alloys. Especially in Ti-6Al-4V, a remarkable decrease of fatigue
strength is evident in internal fractures compared with surface fractures.
However, the mechanism of internal fracture is not yet fully understood.
The internal cracks seem to propagate through a vacuum-like
environment that is shut off from the air. In other words, the effects of
oxidation or gas adsorption on crack growth could be almost ignored in
the internal crack. On the basis of this concept, we conducted small crack
growth tests in air and high vacuum to clarify the effects of vacuum
environment on crack propagation. In addition, we applied a micro
computed tomography (μCT) technique using synchrotron radiation to
observe the internal crack growth non-destructively. By comparing the
crack growth process in vacuum with those of internal crack detected by
μCT, the effects of vacuum-like environment on small internal crack
growth processes were investigated.
INFLUENCE OF RETROGRESSION AND RE-
AGEING HEAT TREATMENT ON THE FATIGUE
CRACK GROWTH BEHAVIOR OF 7010
ALUMINUM ALLOY
M S Nandana1, K Udaya Bhat1*, C M Manjunatha2
1
Department of Metallurgical and Materials Engineering
National Institute of Technology Karnataka, Surathkal,
Mangalore-575025, India
2
Structural Technologies Division, CSIR-National Aerospace
Laboratories,
Bangalore-560017, India
*Email of corresponding author:udayabhatk@gmail.com
Aluminum alloys are widely used in aircraft structural components where
light weight, high strength and good corrosion resistance are the primary
requirements. These alloys are generally used in peak-aged (T6)
condition in which they are susceptible for stress corrosion cracking. In
recent years, retrogression and re-ageing (RRA) treatment on aluminum
alloys is carried out to enhance their corrosion resistance maintaining the
ultimate tensile strength. The aim of this work was to study the influence
of RRA treatment on the fatigue crack growth rate (FCGR) behavior.
The 7010 aluminum alloy was heat treated to two different conditions
i.e., T6 and RRA. The microstructures of these alloys were characterized
by using TEM. Standard CT specimens were prepared and FCGR tests
were carried out by using a 100 kN servo-hydraulic test machine as per
ASTM standard. The constant amplitude FCGR tests were carried out at a
stress ratio, R = 0.5 using sine wave loading pattern at 10 Hz. Crack
length was monitored by following compliance technique.
Microstructural studies show that RRA treated alloy contain fine and
densely populated precipitates in the matrix along with coarsened and
discontinuous precipitates in the grain boundary. The fatigue crack
growth rate was observed to reduce and threshold stress intensity factor
(Kth) was increased in RRA treated alloy compared to the T6
conditioned alloy. The mechanisms in reducing the fatigue crack growth
rate in the RRA treated alloy is attributed to the microstructural changes.
Increase in the Kth and reduction in fatigue crack growth rate of RRA
treated alloy is beneficial in enhancing the fatigue crack growth life of the
structural components in aerospace applications.


EFFECT OF HYDROGEN ON SHORT CRACK
PROPAGATION IN SA508 Gr.3 Cl.I LOW ALLOY
STEEL UNDER CYCLIC LOADING
Mahajan1*
1
Ropar Mechanics of Materials Laboratory, Department of Mechanical
Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab,
India, 140001
2
Reactor Safety Division, Bhabha Atomic Research Centre, Mumbai,
India, 400085
*dhiraj.mahajan@iitrpr.ac.in
The effect of hydrogen on short crack propagation under cyclic loading in
SA508 Gr.3 Cl.I low alloy steel is investigated. This low alloy steel is
used in manufacturing of pressure vessels installed in Indian nuclear
power plants. During operation these pressure vessels are subjected to
continuous supply of pressurized hot water at 600 K and hence are
susceptible to hydrogen embrittlement. In past, research has been
conducted on the effects of hydrogen embrittlement on long fatigue crack
propagation in this material but, the mechanistic understanding and
correlation of hydrogen embrittlement with microstructural features in the
material can be understood well by studying the effect of hydrogen
embrittlement on short fatigue crack propagation. Short fatigue cracks are
of the order of 10 μm to 1mm and unlike long cracks these short cracks
strongly interact with the microstructural features in the material such as
grain/phase boundaries. The effect of hydrogen embrittlement on short
crack propagation is studied by artificial hydrogen charging of the
material through electrochemical process. The single edge notched (SEN)
specimens with an initial notch of the order of 80 to 100 μm are used to
study the short crack propagation. The short cracks in hydrogen charged
samples initiated from the notch at lower number of loading cycles as
compared to the uncharged notched samples for the same value of applied
stress range () (refer Fig. 1a). After initiation the short fatigue crack in
hydrogen charged samples propagated at higher rate as compared to
uncharged samples (refer Fig. 1b). This dissimilarity in crack propagation
behavior is due to the difference in the interaction of short fatigue crack
with the microstructural features for a hydrogen charged and uncharged
material.
unch
ch
unch
ch
(a) (b)
Fig. 1 Comparison of (a) short crack growth ‘a’ with
number of loading cycles ‘N’ and (b) short crack
growth rate ‘da/dN’ with crack length ‘a’ in hydrogen
charged and uncharged SA508 Gr.3 Cl.I low alloy steel
INTERLAMINAR FRACTURE TOUGHNESS OF
SHORT FIBER REINFORCED GFRP LAMINATES
K. Chawla, S. Raychaudhuri2, R. Kitey3
1
Ph.D. Student, Department of Civil Engineering, Indian Institute of
Technology, Kanpur.
2
Associate Professor, Department of Civil Engineering, Indian Institute of
Technology, Kanpur.
3
Associate Professor, Department of Aerospace Engineering, Indian
Institute of Technology, Kanpur.
Corresponding author: komalc@iitk.ac.in
23

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
Continuous fibre reinforced polymer composites have wide range of civil
and defence applications. Due to their high specific strength and high
specific modulus they are particularly used in fabricating light weight
structures. Although the laminates have excellent in-plane properties,
they are often susceptible to interfacial failure during common operating
conditions. Therefore, to enhance the reliability of laminated structures
enhancement of interlayer characteristics has always been a topic of
research. In current investigation the glass fiber reinforced epoxy
laminates are embedded with short fibers and double cantilever beam
(DCB) experiments are conducted to characterize their interfacial fracture
behaviour.
The laminates are prepared by hand layup technique where four layers of
1250 GSM unidirectional glass fiber cloths are stacked together in a
mould. Another set of laminates is fabricated by reinforcing short fibers
of average length and diameter, 6.5 mm and 16
m, respectively, into the
epoxy prior to coating the fiber cloth with the matrix. In both cases the
laminates are vacuum oven cured along with a calibrated pressure. The
reinforced laminate are prepared by embedding short fibers into the
matrix upto 3% volume fraction. Test samples of dimension, 150 mm x
25 mm x 3.5 mm, are machined from the laminates with pre cracks of
length varying from 30 mm to 50 mm. Double cantilever beam test in
combination with modified beam theory is employed to determine
interlaminar fracture toughness (GIc). The reinforced laminates exhibit
higher GIc values when compared to the unreinforced counterparts. The
maximum influence is observed in the 2% volume fraction case where the
initial and stead state GIc show more than 30% and 15% enhancement,
respectively.
EFFECT OF NOTCH ORIENTATION ON
FRACTURE BEHAVIOUR OF TEXTURED Zr-2.5Nb
MATERIAL
Priti Kotak Shah*, Ashwini Kumar, B. N. Rath, J. S. Dubey
Post Irradiation Examination Division
Bhabha Atomic Research Centre
*Email: pritik@barc.gov.in
Zr-2.5Nb pressure tubes are used as primary pressure boundary material
in Indian Pressurised Heavy Water Reactors (PHWRs). Due to presence
of strong tangential basal pole texture the mechanical properties of the
pressure tube are different along axial and circumferential directions. As
pressure tube see higher hoop stress, most of the fracture studies have
been carried out on pressure tubes having axial notch or crack. However,
in practice, flaws may be present in material in any orientation. Hence,
fracture studies have been carried out on textured Zr-2.5Nb pressure tube
to evaluate its fracture properties along axial and transverse directions.
Tests were carried out using compact tension (CT) specimens from room
temperature to 300°C. Load normalisation technique was used for the
analysis of the test data and fracture surfaces of the tested specimens
were studied under Scanning Electron Microscope. This paper compares
the toughness values and fractographic features for cracks growing in
these two different directions of textured Zr-2.5Nb pressure tube.
DETERMINATION OF J-INITIATION
TOUGHNESS USING PRE-CRACKED SMALL
PUNCH TEST SPECIMENS
Taslim Shikalgar1, 2*, B. K. Dutta1**, J. Chattopadhyay1, 2
1
Homi Bhabha National Institute, Anushakti Nagar, Mumbai 400094,
India
2
Reactor Safety Division, Bhabha Atomic research Centre, Trombay,
Mumbai 400085, India
*taslim_mtech@yahoo.com, **bkdutta@barc.gov.in
Determination of fracture properties is important to assess the in-service
degradation of nuclear structural materials subjected to thermal and
irradiation conditions and to calculate residual life of the component. The
pre-cracked small punch test is an alternative method for the

determination of fracture properties in case of limited availability of
materials, which is insufficient for conducting conventional standard
tests. In this paper, pre-cracked small punch test specimens (denoted as p-
SPT) are used to obtain the fracture J-initiation toughness of nuclear
structural steel 20MnMoNi55 and T91. The size of p-SPT specimen is 10
x 10 x 0.5 mm and wire EDM technique is used to generate through
thickness crack profile from centre of one side to a point just passing the
centre of specimen, producing a crack length to specimen width ratios
(a/W) are 0.4 and 0.45. The tests are conducted to get load v/s
displacement data. Elastic plastic finite element analysis of p-SPT
specimen is carried out and numerically obtained load v/s displacement
data are compared with experimental results. This analysis also helped to
compute J-integral near the crack tip as a function of load. J-initiation is
calculated using two different approaches using p-SPT specimens: First
approach is based on applied J-integral being equal to initiation toughness
(JIC) and second approach is based on micromechanical Gurson-
Tvergaard-Needleman model to know the load at which crack is initiated.
Computed J-initiation using micromechanical GTN model has good
matching with the value quoted in the literature which shows the viability
of the method. The methodology described in this paper has potential to
determine fracture initiation toughness of aged nuclear materials using
pre-cracked small punch tests.
A GENERALIZATION OF NEUBER’S RULE FOR
THE ASSESSMENT OF LOCAL STRESSES AND
STRAINS IN STRESS CONCENTRATION ZONES
FOR A WIDE RANGE OF APPLIED STRAINS
Nikolay A.Makhutov, Dmitry O.Reznikov
Mechanical Engineering Research Institute. Russian Academy of
Sciences.
101990, 4 Maly Kharitonievsky lane, Moscow, Russia
Email: mibsts@mail.ru
Nouber rule is an approximate analytical method relating local elastic-
plastic stresses and strains at the notch root to those estimated elastically.
It allows determination of the relationship between stress and strain
concentration factors
K V K H
 (1)
2
1
K t
where KV , K H - stress and strain concentration factors, Kt theoretical stress
concentration factor. Eq. (1) provides adequate assessments of local
stresses and strains at the notch root in the range of limited plastic strains
(range II, Fig 1). However the accuracy of assessments obtained using eq
(1) reduces dramatically as soon as applied strains move to the range III.
 1 – Pseudo elastic states
2 – Stress-strain curve
)N
- Neuber’s conversion rule
according to (1)
)GN - Generalized Neuber’s
conversion rule according to (2)
I – range of elastic strains
II – range of limited plastic
strains
III – range of large plastic strains
Fig.1 Stress strain conversion rules for different strain ranges
A generalization of Neuber rule was proposed enabling assessment of the
material response to extreme loading when maximum local strains may
H
approach ultimate fracture strain values f (fig. 1 range III).
KV K H
F ( K t , V n , m)
K t2 
where V n - nominal strength, m - strain hardening exponent of the
power low stress-strain relationship V K H m . The following
interpolation function was proposed:
1
(1m)¬ª1Vn VT 1 Kt ¼º
§ V ·2
F(Kt ,Vn,m) ¨ T ¸
© KtVn ¹ 
24

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

The developed phenomenological model fits well to the experimental near-tip stress at each load step. The calculated results obtained by new
data in the broad range of plastic strains and proved to be useful in model are validated with the traditional approach (Ramberg-Osgood
predicting the structural response of structural components subjected to stress-strain relationship and Massing hypothesis)n
extreme loading regimes. instantaneous resistance of crack tip surface layers to failure under
atmospheric conditions in case of Al2024-T3 alloy for constant amplitude
loading after tensile and comprehensive overloads (Fig.1).

CRACK SIZE DEPENDENCY OF SHEAR-MODE

FATIGUE THRESHOLD IN BEARING STEEL
SUBJECTED TO CONTINUOUS HYDROGEN
CHARGING

Y. Akaki1, T Matsuo2, 3, Y. Nishimura4 and S. Miyakawa4

1
Graduate School of Engineering, Fukuoka University
8-19-1 Nanakuma, Jonan-ku, Fukuoka 814-0180, Japan
2
Development of Mechanical Engineering, Fukuoka University
8-19-1 Nanakuma, Jonan-ku, Fukuoka 814-0180, Japan
3
Institute of Materials Science and Technology, Fukuoka University
8-19-1 Nanakuma, Jonan-ku, Fukuoka 814-0180, Japan
4
Materials Engineering R&D Division, DENSO CORPORATION, Japan
1-1 Syowa-cho, Kariya, Aichi 448-8661, Japan
Email of corresponding author: tmatsuo@fukuoka-u.ac.jp
Fig.1 Simulated near-tip stress response to varying degree of underload
Premature delamination failure, characterized by white structure flaking
following 50 % tensile overload
(WSF) or white etching crack (WEC), often occurs in rolling element
bearings substantially reducing its durability. It is known that this failure
References
is associated with the evolution and invasion of hydrogen into material
1. Sunder R. Characterization of threshold stress intensity as a
during operation as well as with the shear-mode (Mode II and Mode III)
function of near-tip residual stress: theory, experiment, and
crack growth under cyclic shear stress and heavy compressive stress. In
applications. Mater PerformCharact (ASTM J) 2015;4(2):105–130.
order to ensure the integrity of rolling element bearings, it is important to
2. SunderR., DaniewiczSteven R., Dean S. W. Unraveling the
clarify the effect of hydrogen on the shear-mode fatigue crack growth
behavior, especially near the threshold level. Science of Variable Amplitude Fatigue. J ASTM Int 2012;9(1):1–32.

In our previous study, the effect of hydrogen on the shear-mode fatigue

crack growth behavior was investigated by applying a hydrogen-charge to
a bearing steel specimen with a shear-mode crack. Consequently, it was
shown that the threshold stress intensity factor (SIF) range for shear-
mode fatigue crack growth is significantly reduced by hydrogen. In the
previous study, however, the change in threshold SIF range was
investigated only for a crack with a surface length of about 900
m. It is
known that in the region of small fatigue crack of sub-millimeter in
length, the threshold SIF range depends on crack size. Therefore, to
understand the critical condition for delamination failure in bearings, it is
important to investigate the crack size dependency in the presence of
hydrogen. In this study, correspondingly, the threshold SIF range for
different crack lengths is investigated using a continuous hydrogen
charging technique, and the crack size dependency of a shear-mode crack
on the fatigue threshold condition under the influence of hydrogen is
discussed.

A NEW SEMI-ANALYTICAL APPROACH FOR

OBTAINING CRACK-TIP STRESS
DISTRIBUTIONSUNDER VARIABLE-AMPLITUDE
LOADING

Savkin A.N., Denisevich D.S., Badikov K.A., Sedov A.A.

Volgograd State Technical University,
Lenin Avenue 28, 400131, Volgograd
e-mail address: sopromat@vstu.ru

Near threshold fatigue crack response is extremely sensitive to load

history [1,2]. It is associated with the influence of near-tip stress
oninstantaneous resistance of crack tip surface layers to failure
underatmospheric conditions. The paper deals with computational aspects
of stress and strain distributions at the crack tip. A new approach is
proposed to obtain near-tip stress under variable amplitude loading. The
method considers a combination of standard rules for determining local
strains (Linear rule, Neuber rule, ESED method, etc.) and well-known in
Finite Element Analysis (FEA) return mapping algorithm in context of
nonlinear mixed hardening material model. Iterative procedure based on
Newton-Raphson method is proposed to calculate plastic variables and

25

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session1F:FatigueandFracture–II
Chairman:NEswaraPrasad,DMSRDE
SessionCoordinator:VLNiranjani,DMRL
16001627 InvitedTalk:Deformationanddamagemechanismsunderthermomechanicalfatigue
oftype316LNausteniticstainlesssteelanditswelds
NageshaA,IndiraGandhiCentreforAtomicResearch,Kalpakkam
16271639 Experimentalandnumericalinvestigationsoflowcyclefatiguebehaviorofcryorolled
AA5754
PankajKumarandAkhilendraSingh
IndianInstituteofTechnologyPatna
16511703 Influenceoffrettingonfatiguestrengthofmodified9Cr1Mosteel
V.Shiva;SunilGoyal,R.Kannan,R.SandhyaandA.K.Bhaduri
IndiraGandhiCentreforAtomicResearch,Kalpakkam
17031715 Evaluationofstatic,lowcyclefatigueandfracturemechanicspropertiesthrough
miniaturespecimens
H.RamakrishnaandR.Sunder
BangaloreIntegratedSystemSolutionsPvt.Ltd.,Bangalore
17151727 LasershockpeeninginducedfatiguelifeofSS316LNstainlesssteel
PardhuYella,K.V.Rajulapati,K.BhanuSankaraRao,G.VaraprasadReddy,R.
SandhyaandP.PremKiran
UniversityofHyderabad,Hyderabad
17271739 EffectofColdDeformationonPittingCorrosionandCorrosionFatigueBehaviorof
AusteniticStainlessSteelinAcidifiedChloridemedium
PoonguzhaliandS.Ningshen
IndiraGandhiCentreforAtomicResearch,Kalpakkam
17391751 FatigueDamageEvaluationofRivetedJointsunderTensionCompressionCyclic
LoadingwithAcousticEmissionApproximateEntropyApproach
S.KalyanaSundaram,V.R.RanganathandM.R.Bhat
CSIRNationalAerospaceLaboratories,Bangalore
17511803 CyclicmeanstressrelaxationbehaviourofP91steel:Experimentsandconstitutive
modelling
BimalDasandAkhilendraSingh
IndianInstituteofTechnologyPatna
18151827 EffectofAluminideCoatingonIsothermalandThermomechanicalFatigueBehavior
ofNearTitaniumAlloy
E.HariKrishna,KartikPrasad,ChandrakantParlikar,D.K.DasandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
DEFORMATION AND DAMAGE MECHANISMS
UNDER THERMOMECHANICAL FATIGUE OF
TYPE 316LN AUSTENITIC STAINLESS STEEL
AND ITS WELDS
A Nagesha, T Suresh Kumar, GV Prasad Reddy, R Kannan and R
Sandhya
Scientific Officer G
IGCAR, Kalpakkam
nagesh@igcar.gov.in
Thermomechanical fatigue (TMF) studies were carried out on the base
metal and weld joints of 316 LN austenitic stainless steel in different
temperature intervals in the range, 573 to 873 K under inphase (IP) and
outofphase (OP) cycling conditions. A constant strain rate of 6.4u10–5
s–1 and mechanical strain amplitudes ('Hmech/2) in the range r0.25 to
r0.6% were used for the tests. Isothermal low cycle fatigue (IF) tests
were concurrently conducted at the maximum temperatures (Tmax) of
TMF cycles to understand the difference in the cyclic stress response
(CSR) and damage behaviour under isothermal and TMF cycling. A clear
difference in the evolution of CSR between the base metal and weld joint
was observed, depending on the mean temperature and strain-temperature
phasing employed during TMF. The overall CSR displayed by the weld
joint was seen to be higher than that of the base metal. The location of
crack initiation was found to shift from the base metal to the weld zone,
with an increase in the Tmax of TMF cycling. Influence of long-term
thermal ageing on the TMF response of the weld joint was also
investigated. Cyclic lives under IP TMF were observed to be lower than
those exhibited by OP TMF and IF cycling in both the base metal and the
weld joint in all the temperature ranges which clearly established the non-
conservatism associated with the traditional design approach that relies
on the IF database. The role of creep in the life reduction under IP TMF
was clearly brought out.
EXPERIMENTAL AND NUMERICAL
INVESTIGATIONS OF LOW CYCLE FATIGUE
BEHAVIOR OF CRYOROLLED AA 5754
Pankaj Kumar, Akhilendra Singh
Indian Institute of Technology Patna, India
Email: akhil@iitp.ac.in
The influence of cryogenic forming on low cycle fatigue properties are
investigated for Al-Mg (AA 5754) alloy. AA 5754 is rolled at liquid
nitrogen temperature (cryorolling) for maximum of 40% thickness
reduction. Post annealing heat treatment is performed to alter the
material’s properties of the cryorolled (CR) alloy. Annealing of
cryorolled alloys are performed at 250oC for 2 hours. A series of uniaxial
strain controlled low cycle fatigue (LCF) tests at room temperature are
conducted to evaluate fatigue parameters for the CR and annealed
cryorolled (ACR) alloys. The low cycle fatigue test for both alloys are
evaluated at three different strain amplitudes from 0.4% to 0.6%. The
strain rate of 0.5×10-3 sec-1 is kept constant in all the LCF tests.
Significant improvement in tensile strength and ductility is observed for
ACR alloy. Cryorolled alloys show mild hardening in the initial cycles
followed by noticeable cyclic softening at all strain amplitudes during
low cycle fatigue (LCF) tests. The hysteresis loops and fatigue lives have
been investigated for both CR and ACR alloys. The extended finite
element method (XFEM) has been utilized to simulate the tensile curve
from crack initiation to final fracture of the specimens. Heaviside
function and asymptotic crack tip enrichment functions are used for
modelling of the tensile specimen. Finite Element Method (FEM)
coupled with Chaboche kinematic hardening cyclic plasticity model is
used for simulating hysteresis loop obtained during LCF test. Numerical
results signify that Chaboche kinematic hardening model has excellent
capability to successfully trace the experimental hysteresis loops of Al-
Mg alloy. The present study presents good match between simulations
and experimental results.


Fig. 1 Uniaxial Fig. 2 Tensile peak Fig. 3
tensile curve for stress vs number of Experimental and
cyrorolled and cycles at various simulated
annealed strain amplitudes hysteresis loop at
cryorolled AA for cryorolled AA 0.6% strain
5754 5754 amplitude for
cryorolled AA
5754
References
[1] Lee Y, Shin D, Park K, Nam W. Effect of annealing temperature on
microstructures and mechanical properties of a 5083 Al alloy deformed
at cryogenic temperature. Scr Mater 2004;51:355–59.
[2] Singh D, Rao PN, Jayaganthan R. Microstructures and impact
toughness behavior of Al 5083 alloy processed by cryorolling and
afterwards annealing. Int J Miner, Metall Mater 2013 20:759–69.
[3] Pathak H, Singh A, Singh I. Fatigue crack growth simulations of bi-
material interfacial cracks under thermo-elastic loading by extended
finite element method. Eur J Comput Mech 2013;22:79–104.
[4] Kumar P, Singh A. Investigation of Mechanical Properties and
Fracture Simulation of Solution-Treated AA 5754. J Mater Eng Perform
2017;26:4689-706.
INFLUENCE OF FRETTING ON FATIGUE
STRENGTH OF MODIFIED 9Cr-1Mo STEEL
V. Shiva1*, Sunil Goyal2, R. Kannan2, R. Sandhya2, A. K. Bhaduri2
1
Homi Bhabha National Institute – 400094, India
2
Indira Gandhi Centre for Atomic Research – 603102, India
*Email of corresponding author: shiva.vankudoth@gmail.com
Fretting is the surface phenomena in which two materials are contact each
other and sliding action between them causes the enhancement of surface
damage. If one of the components experiences fatigue load, then the
phenomenon is known as fretting fatigue. Fretting action reduces the
fatigue strength of materials. In Prototype Fast Breeder Reactor (PFBR),
fretting action is observed in steam generator tubes. The tubes of steam
generator are made up of modified 9Cr-1Mo steel and are supported by
strips of aluminized Inconel 718 alloy. The flow induced vibration and
thermal fluctuations causes the cyclic loading on steam generator tubes
and the relative movement between the strip and tubes causes the fretting
action. In order to understand the fretting behavior with fatigue load, an
experimental set-up has been established in-house. The proving ring and
contact pads are designed based on JSME standard (JSME S015-2009).
The fretting fatigue study has been carried out on modified 9Cr - 1Mo
ferritic steel at room temperature and at different stress ratios of 0.1, 0.3
and 0.5 at a contact pressure of 110 MPa. The contact pads were made of
modified 9Cr-1Mo steel. Fretting fatigue life increased with decrease in
maximum stress for all stress ratios. Fretting fatigue life was found to
increase with R ratio for a given maximum stress. At a stress ratio of 0.1,
fretting fatigue limit reduced to 36 % compared to plain fatigue
condition. Scanning electron microscopy also has been carried out to
understand microstructural features of the fractured specimens.
EVALUATION OF STATIC, LOW-CYCLE
FATIGUE AND FRACTURE MECHANICS
PROPERTIES THROUGH MINIATURE
SPECIMENS
H. Ramakrishna1 and R. Sunder
BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author,
E-mail: hebbarrk@biss.in, Mob: +91-9880-432-322

26

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
The study of deformation and fracture of materials through static loading
yields information on resistance to failure in terms of yield strength and
fracture toughness. Fatigue behaviour of materials as a process of
progressive damage leading to cracking and failure is obtained under
cycling loading. ASTM specifies the standard size specimens and test
setups for carrying out these experiments.
In some of the high-performance industries such as nuclear power plants,
Aerospace and thermal power plants, extraction of standard sized
specimens for evaluation of static and cyclic properties to yield
information on residual life of critical components is not practical. These
constraints necessitate obtaining such information by conducting
mechanical testing on miniature specimens. The literature reports many
attempts made on testing of miniaturised specimens, but, do not establish
standard specimen design, dimension and method of testing; the case to
case testing of such specimens is arbitrary.
In this project, an attempt has been made to obtain a spectrum of
mechanical properties: a) Tensile strength, Tensile modulus, yield
strength, peak stress, percentage of elongation, b) Fracture toughness c)
Fatigue crack growth rate and d) Low cycle fatigue properties on low
carbon steel/miniature specimens. These results have been compared with
results obtained on standard specimens; also the differences in the
properties have been pointed out. The modification in the test setup,
specimen geometry, grips and fixtures, and strain measuring devices have
also been described.
LASER SHOCK PEENING INDUCED FATIGUE
LIFE OF SS316LN STAINLESS STEEL
Pardhu Yella1, K. V. Rajulapati1*, K. Bhanu Sankara Rao2, G.
Varaprasad Reddy3, R. Sandhya3, P. Prem Kiran4
1
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad 500 046, India.
2 and the number of cycles to failure and critical cracking potential
Ministry of Steel (Govt. of India) Chair, Mahatma Gandhi Institute of
Technology, Hyderabad 500075, India.
3
Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, India.
4
Advanced Centre for Research in High Energy Materials (ACRHEM),
University of Hyderabad, Hyderabad 500 046, India
E-mail: kvrse@uohyd.ernet.in
To extend the life of a nuclear reactor, the best way is to engineer the
surface of critical components of the reactor, as most of the associated
failures are fatigue related. There exists numerous methods in literature to
engineer the surface, among them laser shock peening has shown an
enhanced performance due to its good directionality and precise coverage
even onto the critical parts of the components. Under fully reversed stress
controlled fatigue tests in the range of 200-300 MPa, the fatigue
behaviour of virgin and laser peened 316LN stainless steel have been
conducted at 298K. All the tests were conducted below 107 cycles, a
triangular wave form of loading with a constant frequency of 5 Hz has
been employed. Whereas for the test to run out, the number of cycles to
failure 107 were conducted at 60 Hz. These studies have clearly revealed
that the fatigue life is dependent on metallurgical condition of the
material and stress amplitude employed. A detailed analysis is made on
the cyclic stress-strain curves which were recorded while fatigue loading
for both virgin and peened states. A detailed study on fatigue crack
initiation and propagation was generated by observing the fractured
surface and surface of the specimens, which are subjected to fatigue
loading. The peened material showed better fatigue strength and life at
low stress amplitudes pertaining to high cycle fatigue regime. Peened
samples exhibited lower density of surface cracks in comparison with
untreated samples measured using acetate replica images. The improved
fatigue resistance of peened material is attributed to the presence of
residual compressive stresses and their effect in controlling the crack
initiation and propagation.


EFFECT OF COLD DEFORMATION ON PITTING
CORROSION AND CORROSION FATIGUE
BEHAVIOR OF AUSTENITIC STAINLESS STEEL
IN ACIDIFIED CHLORIDE MEDIUM
Poonguzhali, S. Ningshen
Corrosion Science and Technology Division
Indira Gandhi Centre for Atomic Research
Kalpakkam – 603 102, India
*Corresponding author: apoongs@igcar.gov.in
+91-44-27480121
Nitrogen is one of the most important alloying elements in alloy steels
and even in small amounts can improve their properties. Because of its
favorable properties, high performance nitrogen containing austenitic
stainless steels are currently being developed for advanced application
that require high strength along with better corrosion and wear resistance.
The present study investigate the effects of cold work (CW) on the
microstructure and corrosion fatigue (CF) resistance of AISI Type 316
LN stainless steel containing 0.11 wt. % nitrogen using microscopic,
electrochemical and surface analytical methods. Potentiodynamic anodic
polarization experiments carried out in two chloride concentrations (1M
NaCl) and (5M NaCl + 0.15 M Na2SO4 ) indicated that pitting potential
(Epit) and passivity range drastically decreased with increase in chloride
concentration and increased deformation from 0 to 20% CW. In 5 M
NaCl + 0.15 M Na2SO4, corrosion resistance (Rp) decreases with
increase in deformation rate due to increased susceptibility of the passive
film towards dissolution due to increase in dislocation density. CF
behaviour of AISI Type 316LN SS with 0.11 wt.% nitrogen was studied
in acidified 5 M NaCl + 0.15M Na2SO4 solution at a stress ratio of 0.5
and a frequency of 0.1 Hz with varying mean stress and open circuit
potential was monitored throughout the failure of the specimen. Based on
in-situ electrochemical measurements during corrosion fatigue tests, the
shift in potential indicates the crack initiation process. The S-N curve of
fatigue life (Nf) vs. stress amplitude was also generated. This study
showed that the CF resistance increases with increase in deformation rate
decreases with increasing mean stress. The crack initiation and
propagation shows a transgranular mode in all the tested conditions.
FATIGUE DAMAGE EVALUATION OF RIVETED
JOINTS UNDER TENSION - COMPRESSION
CYCLIC LOADING WITH ACOUSTIC EMISSION
APPROXIMATE ENTROPY APPROACH
S. Kalyana Sundaram*, V.R. Ranganath*, M.R. Bhat**
*Structural Technologies Division, CSIR-National Aerospace
Laboratories, Bengaluru – 560017
**Department of Aerospace Engineering, Indian Institute of Science,
Bengaluru – 560012
kalyan@nal.res.in
Irrespective of passenger or military aircraft, splices in skin structures of
fuselage, wings, stabilizers, control surfaces are uses riveted lap or butt
joints for the interconnection. Formation of cluster of cracks termed as
multi-site damage (MSD) is one of the hazardous damages occurring on
riveted joints due to fatigue. Initial stage, sizes of MSD cracks are sub
millimeter levels and hidden under rivet heads. These cracks grow under
flight loads, coalesce and lead to catastrophic failure. Early detection and
understanding the growth behavior of this multisite damage is extremely
important to maintain structural integrity of the airframe. Results of
research investigation presented here based on approximate entropy
(ApEn) analysis on acoustic emission signals provides the methodology
for early detection and identification of stages of multisite damage on
riveted joints subjected to tension – compression fatigue loads.
Experimental works were done with single strap riveted butt joint
specimens fabricated from aircraft grade aluminum alloy AA 2024 T3.
Specimens were instrumented with acoustic emission sensors, strain
gages and subjected to fatigue loads in long span UTM. Approximate
entropy was determined on acoustic emission signal parameters acquired
27
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

during fatigue load cycles from start to ultimate failure. Determined EFFECT OF ALUMINIDE COATING ON
values of ApEn and trend were correlated to the stages of multisite
damage on riveted joint. Based on ApEn trend, various stages of
ISOTHERMAL AND THERMOMECHANICAL
multisite damages such as single & multiple crack initiation, stable crack FATIGUE
growth, accelerated crack growth, coalescence of cracks etc were BEHAVIOR OF NEAR  TITANIUM ALLOY
discriminated.
E. Hari Krishna*, Kartik Prasad, Chandrakant Parlikar, D. K. Das,
Key Words: Riveted Joint, Fatigue, MSD, Approximate Entropy, Vikas Kumar
Acoustic Emission Defence Metallurgical Research Laboratory, Hyderabad – 500 058, India
harikrishnaede@gmail.com

Isothermal and thermomechanical fatigue (TMF) behavior of titanium

CYCLIC MEAN STRESS RELAXATION aluminide coated near  titanium alloy Titan 29A has been studied in the
BEHAVIOUR OF P91 STEEL: EXPERIMENTS AND present investigation. Isothermal low cycle fatigue tests were carried out
at 300°C and 600°C and in-phase (IP) and out-of-phase (OP) TMF tests
CONSTITUTIVE MODELLING were carried out in the temperature interval of 300°C 600°C. By
observation of cross-sectional microstructure and fracture surfaces of
Bimal Das, Akhilendra Singh
failed specimens, the likely sites of crack initiation and early stages of
Department of Mechanical Engineering, Indian Institute of Technology,
crack propagation have been identified. In TMF loading, the uncoated as
Patna
well as coated alloy exhibit significantly reduced fatigue life under OP-
Email- akhil@iitp.ac.in
TMF loading, although the life remains marginally affected in presence
of the coatings under IP-TMF loading. The detrimental effect of OP-TMF
In the present study effect of mean strain on cyclic deformation
loading is attributed to the development of tensile mean stresses. The
characteristics and fatigue life of P91 steel is experimentally evaluated in
tensile stresses not only accelerate the process of oxidation at the crack
the low cycle regime. P91 steels used in various components in fossil
tips but also increase the local stress concentration at the crack tips
fired and nuclear power plants subjected to cyclic loading with mean
leading to relatively higher rate of crack propagation.
strains/stresses. Symmetrical and asymmetrical strain cycling tests of P91
steel conducted at room temperature revealed cyclic softening nature
during the fatigue process. The influence of mean strain imposed showed
strong dependence on stress relaxation behaviour and fatigue life of P91
steel. Tensile mean stress was found to relax steeply in initial cycles
followed by stabilization during the asymmetric strain cycling. A
reduction in fatigue life is observed with increase in mean strain for
particular strain amplitude. An attempt has also been made to simulate
symmetric and asymmetric strain controlled behaviour of P91 steel
through cyclic plastic modelling in the framework of rate independent
plasticity theory. Ohno-Wang material model is employed to predict the
influence of mean strain on stress relaxation behaviour of the investigated
steel. The simulated results depicted that Ohno-Wang model captures the
cyclic plastic deformation behaviour of P91 steel reasonably well.

 
References
1. Lee CH, Van Do VN, Chang KH. Analysis of uniaxial ratcheting
behavior and cyclic mean stress relaxation of a duplex stainless steel.
International Journal of Plasticity. 2014 Nov 1;62:17-33.
2. Arcari A, De Vita R, Dowling NE. Mean stress relaxation during cyclic
straining of high strength aluminum alloys. International journal of
fatigue. 2009 Nov 1;31(11-12):1742-50.

28

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2A:CompositeMaterialsandStructures–II
Chairman:RejiJohn,AFRL,USA
SessionCoordinator:VivekKChandravanshi,DMRL
11061133 InvitedTalk:Applicationoflaserspallationtechniqueincomposites
RajeshKittey,IndianInstituteofTechnology,Kanpur
11451157 AnalyticalStudyoftheEffectsofDelaminationinGlareFibreMetalLaminateUsing
ModifiedVirtualCrackClosureTechnique(MVCCT)
H.GShashidharNaikandShubhaJavagal
VisvesvarayaTechnologicalUniversity,Karnataka
11571209 BlastresponseofHollowglass(Hglass)fibrereinforcedepoxymatrixcomposites
C.JayaramiReddy,B.Venkataramudu,K.GopinadhaReddy,G.SeshagiriRao,Rajesh
KumarandV.Madhu
DefenceMetallurgicalResearchLaboratory,Hyderabad
12211233 EffectofFillerFunctionalizationontheThermoMechanical7ehaviourof
PolypropyleneNanocomposites
VivekKhare,ShubhamSrivastava,SudhirKamleandG.M.Kamath
IndianInstituteofTechnologyKanpur
12571309 ThermalshockresistanceandstrengthofZrB2SiCcomposite
ManishPatelandVVBhanuPrasad
DefenceMetallurgicalResearchLaboratory,Hyderabad
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
APPLICATION OF LASER SPALLATION
TECHNIQUE IN COMPOSITES
R Kitey
Associate Professor
Department of Aerospace Engineering, IIT Kanpur
kitey@iitk.ac.in
Polymers and polymer composites have several engineering applications,
ranging from in sensors and miniaturized devices to automobile and
aerospace structures. Besides ease of fabrication the layered structure of a
composite provides tremendous scope to tailor and optimize its in-plane
and out-of-plane properties. Themo-mechanical loading during common
operating conditions often subjects the composite to delamination. Even
the reliability of adhesive bonded joints which unendingly feature in
composite structures is governed by the interfacial properties such as the
adhesion strength and the interfacial fracture toughness. While lap shear
and short beam shear tests are generally applied to quantify interface
(shear) strength of bonded joints and composites, a commonly acceptable
technique to measure normal interface strength in multilayer materials
system is yet to evolve due to the small out-of-plane dimension of
composites. Here we propose laser spallation method as a potential
technique to measure normal interlayer strength.
The Laser spallation technique is non-contact method, specially used in
past to measure the adhesion strength of submicron films. The method
employs laser induced stress waves for dynamically loading the specimen
where the stress pulse with sharp temporal rise and fall times subject the
substrate/film interface to a strain rate of the order of 107/sec. The laser
fluence required to instigate the failure at substrate/film interface is
identified through optical microscopy. The interface strength is then
inferred from the combination of free surface displacement history,
recorded (in situ) by Michelson Interferometry, and computational wave
propagation analysis. With appropriate modifications the laser spallation
technique is extended to perform measurements in meso-scale
bimaterials. By quantifying Interface strength in metal/polymer,
metal/composite and composite/composite layers, the application of the
technique for adhesion measurements in large multilayer structures is
demonstrated.
ANALYTICAL STUDY OF THE EFFECTS OF
DELAMINATION IN GLARE FIBRE-METAL
LAMINATE USING MODIFIED VIRTUAL CRACK
CLOSURE TECHNIQUE (MVCCT)
Shashidhar Naik H.G.1*, Shubha Javagal2.
1
Centre of Excellence in Aerospace and Defence, Visvesvaraya
Technological University, Karnataka, Bangalore 560091 (Email:
naikshashidhar@gmail.com)
2
M.Tech (Research), Department of Civil Engineering, National Institute
of Technology Karnataka, Surathkal 575025 (Email:
shubha.javagal@gmail.com)
Progression in the field of materials used in an aircraft has seen
resurgence in a relatively successful Fibre-Metal Laminate called
GLARE which is composed of several layers of very thin metal (often
aluminium) along with layers of uni-directional Glass fibre pre-pregs. All
the layers are bonded to each other with the use matrix such as epoxy-
resin system. The major advantage of this material is that it can be
tailored to fit the stress condition by varying the orientation of the Glass
fibre layers. Further, other advantages include better damage tolerance,
corrosion resistance, fire resistance and low specific weight.
Although GLARE is a composite material, its material properties and
fabrications techniques are considered to be metallic aluminium like. In
this paper we try to approach this material as a composite and determine
the effect of delamination that occurs due to various reasons. To achieve
this, a finite element model of size of 200mm x 200mm plate is generated
and loaded with an initial unit displacement. Various crack sizes at the
centre of the plate along the stacking sequence is modelled and analysed.
The corresponding Strain Energy Release Rates (SERR) are computed
along with various other parameters such as Elemental Stress,


Displacement and contact stresses. Modified Virtual Crack Closure
Technique (MVCCT) is used to obtain the SERR values in all three
modes of failure and their direct effect on the structural integrity of the
model is studied and reported.
BLAST RESPONSE OF HOLLOW GLASS (H-
GLASS) FIBRE REINFORCED EPOXY MATRIX
COMPOSITES
C.Jayarami Reddy, B.Venkataramudu, K.Gopinadha Reddy,
G.Seshagiri Rao, Rajesh Kumar, V.Madhu
Armour design and development Division, Defence Metallurgical
Research Laboratory, Hyderabad, India
Email: cjrreddy78@gmail.com
The studies on response of materials against explosive blast loads have
enormously increased in the recent years due to the increased blast
incidents across the globe. Few studies have been reported on the blast
performance of glass fibre reinforced composites. However, no studies
were reported on the response of the the H- glass fibre reinforced
composites against explosive blast loads.
The present paper focuses on an experimental investigation on the
response of the H- glass/epoxy composite laminates against small scale
explosive air blast loading. The explosive loading on 5mm thick
composite laminates was generated by detonating plastic explosive at
200mm and 300mm stand-off distances. The incident and reflected
pressures on the composite panels were recorded using piezo-electric
pressure sensors. Multiple failure modes exhibited by the composite at
different loading conditions which include matrix cracking, fibre
breakage, delamination are also reported. The blast performance of the H-
glass composite was compared with the performance of the solid glass
fibre composites.
Key words: H-glass, fibre reinforced composites, Air blast, failure
mechanism.
EFFECT OF FILLER FUNCTIONALIZATION ON
THE THERMO-MECHANICAL BEHAVIOR OF
POLYPROPYLENE NANOCOMPOSITES
Vivek Khare*, Shubham Srivastava^, Sudhir Kamle#, G.M. Kamath$
*Ph.D. Scholar, ^M. Tech Student, #Professor, $Associate Professor
Department of Aerospace Engineering, IIT Kanpur
Corresponding author: vivekkh@iitk.ac.in
Polypropylene (PP) is a widely used thermoplastic polymer in most of the
aerospace industries due to their excellent strength, low cost, low weight,
ease of formability and fatigue resistant properties. It’s semi crystalline
state provides both strength and flexibility. Research efforts had been
made to optimize the strength of polypropylene matrix. Nano fillers like
multi walled Carbon nanotubes (MWCNT) has the potential to enhance
thermo-mechanical properties of PP nanocomposites. However, MWCNT
shows an adverse effect at higher MWCNT concentrations in form of
agglomeration which hinders interfacial strength of PP. Present
investigation is an experimental attempt to study the effect of
functionalized carbon nanotubes (MWCNT-COOH) on thermo-
mechanical behavior of PP-MWCNT nanocomposites.
Solution casting method is used for Nanocomposite development using
PP in pellet form and multi walled carbon nanotubes (both pristine and –
COOH functionalized). Xylene was used as solvent. CNT-xylene mixture
was sonicated and mixed with preheated solution of PP-xylene. Both the
solutions were mixed together and subjected to heating in a magnetic
stirrer. The obtained solution was poured in a petri-dish and kept for
curing in a vacuum oven. Nanocomposite films are developed with
varying MWCNT concentrations.
Temperature controlled Quasi static tests were performed in Tinius-olsen
universal testing machine (UTM) while dynamic tests were conducted in
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

dynamic mechanical analyzer (DMA) to obtain storage modulus, loss

modulus and loss factor. Thermal stability was observed using Thermo-
mechanical-analyzer. Prior to the testing, surface morphology of both
MWCNT grade nanocomposites was monitored using Scanning electron
microscopy (SEM). It was found that incorporation of functionalized
nanotubes enhances the thermo-mechanical properties of the PP as
compared to pristine MWCNT.

THERMAL SHOCK RESISTANCE AND

STRENGTH OF ZrB2-SiC COMPOSITE

Manish Patel and V V Bhanu Prasad

Defence Metallurgical Research Laboratory, Hyderabad
Email: patelmet@dmrl.drdo.in

Due to interest in applications for hot structure based thermal protection

system (leading edges and nose cap) of a hypersonic vehicle, vibrant
research has been carried on ZrB2 based ultra high temperature ceramics
in the recent past worldwide [1-2]. However, low fracture toughness and
thermal shock resistance of ZrB2 based materials questions its structural
integrity in the extreme environments [3]. High temperature strength and
thermal shock resistance of ZrB2-SiC composite was studied. It was
found that thermal shock resistance of ZrB2-SiC composite is better than
monolithic ZrB2. The retained strength value with respect to quenching
temperature shows that the thermal shock severity (
Tc) was 275 and
400 0C monolithic ZrB2 and ZrB2 - SiC composite, respectively. It was
also found that monolithic ZrB2 and ZrB2 - SiC composite have no
mechanical strength after thermal shock from 600 and 800 0C,
respectively. On the other hand, it was found that the ZrB2-SiC composite
retained their strength at 1400 0C more than 80% of their room
temperature strength. Due to thermal shock, crack forms on the surface of
samples. Detail investigations have carried out to understand the thermal
shock behaviour of these materials.

References:
M. Patel, et. al., Scripta Mater., 69 (2013) 370–73
M. Patel, et. al., J. Euro. Ceram. Soc., 32 (2012) 4455–67
D. E. Glass, AIAA 2011-2304

30

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2B:StructuralIntegrityII
Chairman:RajDas,RMITUniversity,Australia
SessionCoordinator:AtulKumar,DMRL
11061133 InvitedTalk:MechanicalPropertiesofAdditivelyManufacturedCobaltandNickel
BasedSuperalloysusedinGasTurbineHotGasPathComponents
DheepaSrinivasan,Consultant,AdditiveTechnologiesandAdjunctFaculty,
IndianInstituteofTechnologyRopar
11451157 StructuralIntegritytestingonMALEUAVwingmodule
B.Siddappaji,SaugataTribedi,Rajagopal,V.Sarveswaran,V.Prabhakaranand
V.Ashokrangan
AeronauticalDevelopmentEstablishment,DRDO,Bangalore
11571209 TensiletestingofSingleFibres
RameshBabuAdusumalli,KarthikChethanVenkateshan,ChandrakalaKunchiand
R.Surya,Vadlamani
BITSPilani,Hyderabad
12211233 StructuralDamageAnalysisofExplosivetestingExperimentalBayusingHEXDAM
ModellingSoftware
S.ThalapathiRaj,SLSilanandVKDevgan
TerminalBallisticsResearchLaboratory,DRDO,Chandigarh
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
MECHANICAL PROPERTIES OF ADDITIVELY
MANUFACTURED COBALT AND NICKEL BASED
SUPERALLOYS USED IN GAS TURBINE HOT GAS
PATH COMPONENTS
Dheepa Srinivasan
Consultant, Additive Technologies
Adjunct Faculty, IIT, Ropar
Dheepasrinivasan6@gmail.com
A couple of recent development efforts in the usage of Direct Metal Laser
Deposition (DMLD) and Direct Metal Laser Sintering (DMLS) in gas
turbine hot gas path component repair applications will be showcased. A
few of case studies will highlight the technology development in using
3D printing to restore a severely damaged part on a Cobalt based
superalloy, after service exposure. A novel manner of achieving superior
creep properties in the DMLS part will be discussed. Other efforts to
restore turbine blade tip build up and turbine blade platform (Nickel
based superalloys) fatigue crack repair using laser deposition will be
discussed. Overall, the important role of additive manufacturing as the
next generation advanced technology in niche applications in the
industrial gas turbine technologies will be addressed. The importance of
mechanical properties at elevated temperatures, via laser Additive
manufacturing will be compared with those used in conventional
manufacturing, via relevant examples.
STRUCTURAL INTEGRITY TESTING ON FULL
SCALE MALE UAV WING MODULE
Siddappaji B, Saugata Tribedi, Dr. Rajagopal, Sarveswaran V,
Prabhakaran V, Ashok Rangan V,
Aeronautical Development Establishment, DRDO Bangalore
sidapa@ade.drdo.in
The demand on Unmanned Aerial Vehicles (UAV) has increased
significantly in the recent years. They are preferred over piloted aircrafts
and satellites due to low cost, multi mission capability, ease of
deployment and ability to accomplish dull, dirty and dangerous missions
quickly. Another advantage is that UAVs can follow a pre-programmed
flight path either fully autonomous or semi-autonomous mode.
Low speed Medium Altitude Long Endurance (MALE) UAVs are
currently being used in the military for Surveillance and Target
Acquisition (SATA) missions. Airframe of UAV is predominantly made
out of laminated Fiber reinforced Composite structural materials, such as
Glass Fiber, Carbon Fiber or Hybrid reinforcement with Epoxy matrix
material.
The unique characteristics of composite materials are high specific
strength, high specific modulus, corrosion resistance, wear resistance,
high fatigue life and other improved mechanical properties. The loads
experienced by airframe are taxing, launch/take-off, manoeuvre, gust and
recovery/landing loads. The Wing Structure of MALE UAV consists of
three modules; viz., Wing Centre Section, Outboard Wings port and
Starboard side have a total span of 20 m and an aspect ratio 15.
Full scale wing assembly module was tested for its structural integrity
through experimental setup for 2.5g and 3.0g load cases. Data
acquisition system was used to capture the deformation strains and wing
deflections through strain gauges and LVDT transducers. NDT tests were
conducted after successful completion of integrity testing.
This paper presents the wing strength and stiffness testing methodology
and data capture for qualification of wing for structural loads. The
structural integrity was confirmed by applying various loads as per the
designed requirements and specifications.
Key words: Laminated Composite structures, Unmanned Aerial Vehicle,
structural integrity, strength and Stiffness


TENSILE TESTING OF SINGLE FIBRES
Ramesh Babu Adusumalli 1*, Karthik Chethan Venkateshan 2,
Chandrakala Kunchi 3, Surya R. Vadlamani4
Department of Chemical Engineering,
BITS Pilani-Hyderabad Campus, Jawahar nagar,
Shameerpet (Mandal); Hyderabad, Telangana, 500078, INDIA
*Email of corresponding author: ramesh.babu@hyderabad.bits-
pilani.ac.in
Carbon, glass and aramid fibres are used widely in making composites.
These fibres have diameter between 5- 50 μm and these individual fibres
are converted to yarn/roving to make the woven preforms. Similarly
paper, which is a nonwoven mat is made from individual cellulose fibres.
Natural fibres such as jute, hemp and hair are widely used in textile
products. These fibres are varying in terms of crystallinity, chemical
composition and homogeneity. Most of the fibres are solid in nature, but
few of them have lumen such as linen (flax) or medulla such as hair.
Tensile testing of these short length fibres is crucial for many
applications, but it is tedious due to their low diameters (<100 μm) and
low loads (mN) are required to fracture. The aim of the tensile test is to
measure modulus, strength and toughness. Paper frame technique adopted
to test these single fibres is discussed and corresponding stress-strain
diagrams are compared between carbon, glass, hair and cellulose fibres.
Fractography of these fibres were also carried out using optical
microscopy and SEM. Crack initiation and propagation mechanisms are
not similar despite they have same similar diameter. Nanoindentation was
also performed on single fibre cross-section and modulus is measured
from unloading portion of the curve. Since the fibres chosen have
different packing geometry and crystallinity, modulus measured from
nanoindentation revealed higher value compared to modulus obtained
from tensile test. Tested fibres have strength from 200-3000 MPa and
elongation is ranging from 4-40 %. Weibull statistics was also performed
for tensile strength values.
References:
R.B. Adusumalli, U.Müller, T.Roeder, H.Weber, H.Sixta, W. Gindl.
Tensile Testing of Single Regenerated Cellulose Fibres, Macromolecular
symposia 2006; 244; 83-88.
Shubham Mishra, Chandrakala Kunchi, Karthik Chethan Venkateshan,
Ravi Chandra Gundakaram, Ramesh Babu Adusumalli. Nanoindentaion
and Tensile testing of Human Hair Fibres. Journal of Materials Science
2016, 51(22); 10191-10204.
STRUCTURAL DAMAGE ANALYSIS OF
EXPLOSIVE TESTING EXPERIMENTAL BAY
USING HEXDAM MODELLING SOFTWARE
S.Thalapathi Raj*, SL Silan and Dr VK Devgan #
*Divisional Head (SEED), # Group Director (SEED)
Terminal Ballistics Research Laboratory, Ministry of Defence (DRDO),
Chandigarh.
Email: thalaps@yahoo.com
Modelling of structural damages is a tool for making blast damage
assessments resulting from an explosion on a localized area. This can be
used as a damage/ injury assessment tool to determine the amount of blast
damage/injury done to individual structures/ persons in a certain
geographical area due to the detonation of explosives at ground level or at
a specified height above the ground. This paper deals with prediction the
structural damages of an experimental bay building when subjected to
explosive testing, using HEXDAM (High Explosive Damage Assessment
Modelling) software. The modelling software helps to predict the blast
parameters at various points and the structural damages caused to the
structures with in a facility. The basic outputs of HEXDAM are designed
to provide data such as before/after blast display; damage/injury table;
damage vs distance; pressure contours; damage/injury contours and the
data tables for overpressure, dynamic pressure and damage/injury at each
grid point.
The experimental bay building along with the facility building was
scientifically modelled and the trial set up is also modelled using this
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

software. The structural damages to the experimental bay and the nearby
facilities are analysed in this paper when the building set up is subjected
to the explosive loading at the height of 1m. The over pressure data at
various points from the ground level to the height of 9m have been
generated in this modelling. The Outputs are in the form of Damage vs
injury tables, before and after blast displays, pressure and damage vs
injury contour plots and Damage, injury-versus-distance graphs.
Organizations like DRDO, Ordnance Factories, Armed forces and other
government agencies which are handling the explosives can benefit from
this explosion modeling in many different situations like during an
Explosive storage siting, renovation to explosive buildings, when
changing the quantity of explosive stored on site and recreation of
accidental explosion etc.,

Key words: Structural damage, Modelling, Blast parameters, Damage

and injury levels

32

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2C:MechanicalBehaviourofLightAlloysandStructural
IntegrityIII
Chairman:AmitBhattacharjee,DMRL
SessionCoordinator:SSKalyanKamal,DMRL
11061133 InvitedTalk:MultiscaleModelingofFatigueCrackNucleationinTitaniumAlloys
PritamChakraborty,IndianInstituteofTechnology,Kanpur
11331145 Effectoftemperatureandcoolingratesonthe+morphologyofTi6Al4Valloy
AfrozShaikh,SantoshKumar,AshishDawari,ShreyasKirwai,AtulPatiland
RajkumarSingh
KalyaniCentreforTechnology&Innovation,BharatForgeLtd
11451157 HighStrainRatebehaviourofAluminiumproducedbyPowderMetallurgy
TulsiChouhan,HemantChouhanandManojSoni
IGDTUW,Delhi
12091221 StructuralintegrityofultrafinegrainAl3%Mgalloyunder dynamicloadingconditions


SChidambaram,SGiribaskar,GouthamaandP.Venkitnarayanan
NumaligarhRefineryLimited,India
12211233 TheTestSysteminthe‘InternetofThings’(IOT)
K.Ramesh,A.SomayyaandR.Sunder
BangaloreIntegratedSystemSolutionsPvt.Ltd,Bangalore
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
MULTI-SCALE MODELING OF FATIGUE CRACK
NUCLEATION IN TITANIUM ALLOYS
 TulsiChouhan1, Hemant Chouhan 2, Manoj Soni 1
Dr. Pritam Chakraborty
Assistant Professor
Indian Institute of Technology Kanpur
cpritam@iitk.ac.in
The fatigue life and number of cycles to crack nucleation in Ti-alloys
exhibit considerable variation. The underlying microstructure has been
observed to have significant influence on the scatter and needs
consideration for accurate life prediction of these alloys. Microstructural
scale model such as Crystal Plasticity (CP) in conjunction with Finite
Element Method (FEM) has been fairly successful in capturing
grain/phase scale anisotropic plastic behavior and localization. Thus, an
experimentally validated CPFEM model with homogenized response of
the D+E lath and size effects has been utilized. However, CPFEM based
simulations require very small time steps and thus is computationally
prohibitive for fatigue simulations till crack nucleation involving large
number of cycles. To alleviate this issue, a wavelet based multi-time scale
method has been developed, motivated from the dual-time scale evolution
of the CPFE variables. The transformation of the CPFE variables to the
wavelet space enabled decoupling of the coarse scale monotonic and fine
scale oscillatory response. Thus, integration of the transformed CPFEM
equations in the coarse time can be performed with much larger time
steps in the order of cycles. With the use of this multi-time scale
algorithm, huge computational savings has been obtained with fairly
accurate solutions. Subsequently, a non-local crack nucleation criterion
based on the Stroh model has been utilized to predict the cycles to crack
initiation. The validated model has then been applied to obtain
correlations between the microstructural descriptors, load forms and
cycles to crack nucleation to provide engineering scale predictions of
fatigue life.
EFFECT OF TEMPERATURE AND COOLING
RATES ON THE + MORPHOLOGY OF Ti-6Al-4V
ALLOY
Afroz Shaikh1, Santosh Kumar1, Ashish Dawari1, Shreyas Kirwai1, Atul
Patil1, Dr. Rajkumar Singh1
1
Kalyani Centre for Technology & Innovation, Bharat Forge Ltd, Pune-
411036, Maharashtra, India
Email of corresponding author: Afroz.shaikh@bharatforge.com
Ti-6Al-4V is a dual phase (+) titanium alloy widely used in aerospace
industry. Mechanical properties of a component strongly depend upon its
microstructure and morphology. Desired mechanical properties can be
achieved by the development of appropriate microstructure with the help
of different heat treatments and deformation. In the present work,
different microstructures obtained through different heat treatment
processes is studied and presented. A variety of morphologies of +
microstructures were obtained by heating above and below  transus
temperature and cooling at different rates i.e. Water quench, air cool and
furnace cool. Heating above  transus and cooling with different rates
results into lamellar structure whereas a duplex microstructure was
obtained after heating below  transus and cooling with different rates. A
lamellar structure with blocky acicular  is obtained after heating above 
transus followed by furnace cool upto temperature below  transus and
cooling with different rates thereafter.


HIGH STRAIN RATE BEHAVIOR OF ALUMINIUM
PRODUCED BY POWDER METALLURGY
1
Department of Mechanical & Automation Engineering, Indira Gandhi
Delhi Technical University for Women, Delhi, India
2
Mechanical Engineering Department, Indian Institute of Technology
Delhi, Hauz Khas, New Delhi -110016, India
E-mail: tulsihchouhan@gmail.com
The presented study compares the compressive high strain rate behavior
of Aluminium powder as received with the effect of ball milling and
incorporation of rock salt. Three types of sample specimens having
specimen aspect ratio in the range of 0.5±5% were fabricated by
compacting Aluminium powder followed by sintering in Argon
atmosphere at 600 qC for 3 hours. Sample types comprised of (i)
Aluminium powder as received, (ii) ball-milled Aluminium powder for
30 hours at 40 rpm with 1:30 powder to ball weight ratio and (iii)
Aluminium powder with 33% rock salt ball milled for 10 hours with 1:10
powder to weight ratio. 2% stearic acid was added as a process control
agent to minimize the cold welding of metal powder. The compressive
high strain rate testing was done on 16 mm Titanium bars based Split
Hopkinson Pressure Bar(SHPB). For identical incident energy different
strain rates and strengths were attained by all the materials. Pure
Aluminium specimen attained strain rate in the range of 1920-3000 /s and
the corresponding peak stresses were in the range of 165-210 MPa,
respectively. Ball milling for 30 hours resulted in significant powder size
reduction as depicted by scanning electron microscopy(SEM), which
enhanced the peak stress to 190-240 MPa. However, the damage pattern
shifted from purely ductile in case of non-milled powder to partly brittle
and ductile damage for ball milled Aluminium specimens. Incorporation
of higher rock salt percent was meant to produce relatively low-density
brittle Aluminium. The resulting compressive stresses recorded were
much lower in range of 120-140 MPa and the corresponding strain rate
attained was in the range of 1525-3200 /s, respectively. The entire salt
containing specimen underwent brittle failure. The study reveals the
importance of powder size and damage pattern on the rate dependent
stress-strain behavior of Aluminium.
STRUCTURAL INTEGRITY OF ULTRA-FINE
GRAIN Al-3%Mg ALLOY UNDER DYNAMIC
LOADING CONDITIONS
S Chidambarama, b, S Giribaskara, c, Gouthamad, P Venkitnarayanane
a
Former Graduate, Department of Materials and Metallurgical
Engineering, Indian Institute of Technology, Kanpur
b
Numaligarh Refinery Limited (A Group Company of Bharat Petroleum
Corporation Limited), India
c
Advance Forming Research Centre, University of Strathclyde Glass
glow, United Kingdom
d
Professor, Department of Material and Metallurgical Engineering, Indian
Institute of Technology, Kanpur
e
Professor & Head, Department of Mechanical Engineering, Indian
Institute of Technology, Kanpur
Email of corresponding author: chidambaram.s@nrl.co.in
An increase in utilization of various material for constructing dynamic
components and equipments has increased today. The high speed
deformation mechanics was studied in various scale levels, especially in
micro and nano scales. Understanding the micromechanics using shock
waves had led to development of armour plates in military technology.
One dimensional elastic stress is applied using split Hopkinson pressure
bar for the ultra-fine grain aluminium samples and microstructural
evolution was discussed in detail. The material characterization of equi
channel pressing and its effect on stability of material after shock wave
testing is provided. It is observed that grain size of material steadily
decreases to obtain ultra-fine grain structure and by application of shock
waves, the grain size increases within material. The recovery, re-
crystallization and grain growth has observed in that shock tested samples
due to induced temperature during such shock testing. The existing
dislocation sub structure in pressed samples has been devoid after inertia
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

effects. It is proposed further to understand the interaction between

precipitate particle and dislocations.

Keywords: Ultra-fine grain; Dynamic response; Material behaviour;

Shear band; Deformation

THE TEST SYSTEM IN THE ‘INTERNET OF

THINGS’ (IOT)

Ramesh1, A. Somayya and R. Sunder

BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author, E-mail:
somayya@biss.in, Mob: +91-9880-432-322

Increasing demand on the utilization of mechanical test systems,

particularly in long duration fatigue and creep tests on the one hand and
advances on the other hand in information technology and automation
open up the opportunity to improve the efficiency and productivity of
testing services. This paper describes a five-year R&D effort at BISS that
open up avenues for improved organization and operation of the
mechanical test laboratories.

The effort proceeded in three steps. The first step was to enable ‘Test-by-
wire’ by rendering all the components amenable to programmable
activation. This demanded the replacement of all mechanical switches
and valves by devices that could be controlled and sensed through
electrical signals. The second step was to render the test system as a
‘virtual machine’ (VM), a dedicated area of sharable memory on the host
computer, that could be readily ‘cloned’ on client computer systems. The
third step involved implementing and testing the ‘Test-by-wire’
environment through a tablet serving as operator console on the load
frame, allowing the operator to exercise system control through a
convenient touch screen interface (Test-by-WiFi).

The final step involved implementing an efficient and high speed VM

update on one or more client computers (Test-by-Net). This facilitated
developing dedicated applications that allow an extent of remote access
to laboratory resources that was hitherto impossible. Thus, the Laboratory
Manager can keep track of the utilization of his resources in real-time.
Operators can keep track of tests in progress from ‘anywhere on the
globe’. Tech support personnel can render ‘on-the-spot’ assistance to
users who may require assistance with specific machine or software
related issues. Health monitoring becomes a continuous process as
maintenance engineers can keep track of system status to render ‘on-
condition’ service, rather than the traditional ‘periodic maintenance’. The
development effort involved addressing serious safety and security
concerns that are also described in the paper.

34

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2D:Creepdeformation,damageandfracture
Chairman:AshokKoul,LPTi,Canada
SessionCoordinator:CMOmprakash,DMRL
11061133 InvitedTalk:Studyoffatigue,creepandfracture10ehaviourinanewlydeveloped
advancedausteniticstainlesssteelforstructuralintegrityevaluation
GuocaiChai,LinköpingUniversity,Sweden
11331145 Effectofstraingradientsonpowerlawcreepinbending
SyedIdreesAfzalJalali,PraveenKumarandVikramJayaram
IndianInstituteofScience,Bangalore
11451157 Assessmentofcreepdeformationandrupturebehaviourof304Hcuaustenitic
stainlesssteel
K.C.Sahoo,SunilGoyalandK.Laha
HomiBhabhaNationalInstitute,Mumbai
12091221 MicrostructurebasedcreepmodelforNibasedgammaprimestrengthened
Superalloys
AdarshShukla,RamkumarOruganti,SachinNalawade,SanketSarkarandSanjay
Sondhi
GEIndia,Bangalore
12211233 CreepstudiesofColdWorkedAusteniticStainlessSteel
HariKrishanYadav,A.R.Ballal,M.MThawreandV.D.Vijayanand
VisvesvarayaNationalInstituteofTechnology,Nagpur
12331245 ANumericalStudyofCreepCrackGrowthinanAeroengineTurbineDiscusing
XFEM
M.Kumar,V.B.Pandey,I.V.Singh,B.K.Mishra,S.Ahmad,A.V.RaoandVikas
Kumar
IndianInstituteofTechnologyRoorkee
12451257 Predictingnonsteadystatebendingcreepbehaviourusinguniaxialdata
PriyaGoel,PraveenKumarandVikramJayaram
IndianInstituteofScience,Bangalore
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
STUDY OF FATIGUE, CREEP AND FRACTURE
BEHAVIOR IN A NEWLY DEVELOPED
ADVANCED AUSTENITIC STAINLESS STEEL
FOR STRUCTURAL INTEGRITY EVALUATION
Guocai Chai 1, 2*
1
Research and Innovation, Sandvik Materials Technology, 811 81
Sandviken, Sweden
2
Engneering Materials, Linköping University, 581 83 Linköping, Sweden
guocai.chai@sandvik.com
Future advanced ultra-supercritical power plant will be run at higher
temperature and pressure. New materials need to be developed to meet
the requirements. The structure integrity of these materials should be
evaluated. Sanicro 25 is a newly developed advanced austenitic heat
resistant stainless steel with the aim to be used in next generation 700°C
or 650°C power plants to replace part of Ni based alloys. This paper
provides an overview on study of deformation, damage and fracture
behavior in this material during LCF, TMF, creep and CF. Creep
mechanisms at different temperatures and loading conditions have been
identified. The interactions between dislocations and precipitates are the
main creep mechanism at temperature below 700°C. For LCF,
interaction and impingement between dislocation slip bands and grain or
twin boundaries are the main mechanism with large strain range at high
temperature. The cyclic stress strain response, microstructure evolution
and fatigue life during LCF has been discussed. The influence of strain
condition on the TMF behavior in the virgin and aged materials has been
analyzed. The cyclic plastic deformation, precipitation behavior,
recovery phenomena and local plasticity exhaustion during CF process
have also been investigated. This study provides a deep understanding on
the structure integrity analysis.
Keywords: AUSC Power Plant, Austenitic Heat Resistant Stainless
Steel, Sanicro 25, Low Cycle Fatigue, Thermomechanical Fatigue, Creep
and Creep Fatigue Interaction
). A
EFFECT OF STRAIN GRADIENTS ON POWER
LAW CREEP IN BENDING
Syed Idrees Afzal Jalali*, Praveen Kumar, Vikram Jayaram
Department of Materials Engineering,
Indian Institute of Science, Bangalore, India, 560012.
*email: ali.idrees2@gmail.com
High temperature time dependent deformation may be studied by bending
to minimize the problems ofhandling and gripping faced during uniaxial
tests. Adaptation of instrumented indentation systems forbending further
allows a flexibility in eliminating alignment issue in small scale testing. It
was observedthat for commercially pure aluminum beams of thickness
around 5 mm the steady state strain and strainrates of the outer fiber at
constrained end can be compared to equivalent steady state uniaxial
data.On scaling down a bending sample, however, there is the possibility
of interplay between strain gradients and / or a small ratio of thickness:
grain size on the mechanical properties; such an effect is known from
torsion of small wires which display enhanced strength that has been
attributed to strain gradients. It is therefore important to establish whether
such effects appear during creep since they would influence the ability to
extrapolate from small scale tests to bulk component properties.Beams of
thickness between 7 mm to 0.5 mm were tested in power law and
powerlaw breakdown regimes. It was observed that beams of thickness
3mm and above behave similar to their uniaxial equivalents. Beams
smaller than 3 mm show lower steady state creep rates. Similar trends
were observed in displacement control bend tests of beams which reveal
an increase inthe yield point with decrease in the beam thickness. These
results will be coupled to microstructural observations that shed light on
the possible mechanisms that are responsible for the enhanced strength
and on ways to model such length scale effects.


ASSESSMENT OF CREEP DEFORMATION AND
RUPTURE BEHAVIOUR OF 304HCu AUSTENITIC
STAINLESS STEEL
K. C. Sahoo*1, Sunil Goyal2 and K. Laha3
1
Homi Bhabha National Institute
2
Materials Development and Technology Division,
Indira Gandhi Centre for Atomic Research, Kalpakkam – 603 102, India
3
Mission Directorate, A-USC Project, India
*Corresponding author: Tel.: +91 44 27480500 Extn: 21210; Fax: +91 44
27480075,
E-mail id- kanhu2011.sahoo@gmail.com
Reduction in CO2 gas emission and decrease in fuel consumption can
result increase in efficiency of the thermal power plants. Increase in
efficiency is directly linked steam temperature and pressure which
requires materials having high creep strength. This resulted in
development of Advanced Ultra Super Critical (AUSC) power plant
which aims to increase efficiency to more than 45 % and significant
decrease in CO2 emission. The 304HCu stainless steel is one of the
candidate materials to be used in AUSC power plant. It contains around 3
wt. % of copper, certain amounts of niobium and nitrogen and increased
carbon content for enhancing creep strength. Creep tests are conducted
for 304HCu stainless steel at 923K, 973K and 1023K over a stress range
of 100-240MPa. The creep curve exhibited shorter primary regimes
followed by marginal secondary regimes and extended tertiary regime.
The variation of steady state creep rate with applied stress exhibited
Norton’s power law creep ሺɂሶ ୱ ൌ ɐ୬ ሻ. The value of n (stress exponent)
decreased with increase in temperature but decrease was more
pronounced at 923K. The product of steady state creep rate and rupture
life obeyed Monkman-Grant equation. The contribution of tertiary creep
was found to increase with temperature. Microstructural degradation in
the form of coarsened precipitates, dislocation cell formation and
deformation bands was the primary reason for increase in tertiary regime
of creep curve and increase in the value of damage tolerance factor (
mathematical model based on finite element analysis of continuum
damage mechanics has been used to predict the creep deformation and
rupture life of 304HCu SS. The prediction of creep curve based on this
model was found to be in good agreement with experimental results.
MICROSTRUCTURE BASED CREEP MODEL FOR
Ni-BASED GAMMA PRIME STRENGTHENED
SUPERALLOYS
Adarsh Shukla1, Ramkumar Oruganti1, Sachin Nalawade1, Sanket
Sarkar1,Sanjay Sondhi1,
V K Sivakumar1, T. Vishwanath1,
1
GE Global Research, GE India Technology Center, Bangalore, India
Email of corresponding author: Ramkumar.oruganti@ge.com
A model that enables prediction of creep response from chemical
composition is a desirable goal from the standpoint of new alloy design
and remaining life assessment. In the journey to this overarching goal,
this article presents a new modeling approach that explains the effect of
gamma prime in Ni-base superalloys through its distribution and
thermodynamic volume fraction as determined by the chemical
composition of the alloy. The practical utility of this modified approach is
demonstrated by explaining the creep behaviour of multiple superalloys
with a single equation and parameter set. The only parameters that are
changed from alloy to alloy are related to the gamma prime
characteristics (and grain size in the case of fine-grained alloys), which
can be determined from micrographs. This model also allows prediction
of creep performance as a function of heat-treatment to within a
reasonable degree of accuracy. The ability of the model to provide
guidance for new alloy development for improved creep performance is
also discussed. The model also throws light on some aspects of remaining
creep life assessment of in-service parts.
35
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

CREEPSTUDIES OF COLD WORKED PREDICTING NON-STEADY STATE BENDING

AUSTENITIC STAINLESS STEEL CREEP BEHAVIOUR USING UNIAXIAL DATA

Harikrishanyadav*1, a.r. ballal1, m.m thawre1 , and v.d. vijayanand2
1
Department of Metallurgical & Materials Engineering,
Visvesvaraya National Institute of Technology, Nagpur, India – 440010
2
Metallurgy and Materials Group, Indira Gandhi Centre for Atomic
Research, Kalpakkam, Tamil Nadu, India - 603102
* Corresponding author Email: hkyadav.vnit@gmail.com
Ti modified 14Cr–15Ni austenitic stainless steel (SS) has been developed
for nuclear fuel clad and wrapper material forits superior creep strength
and better void swellingresistance during service. Cold working induces
high dislocation network in the material. These dislocations interact with
point defects,which are generated by neutron irradiation during service
and facilitate recombination to make the material more void swelling
resistant. In present investigation, creep behavior of various cold worked
(up to 40%) samplesalong with mill annealedsampleswas studied.
Initially, the steel was solution treated at 1333 K for 30 minutes followed
by cold rolling at room temperature. Uniaxial creep test was performed at
973 K for various stress levels.The effects of cold work as well as stress
on creep behavior have been studied in this investigation. Cold worked
samples exhibitedbetter creep strength as compared to mill annealed
samples. During creep exposure at 973 K, material showedphenomena of
recovery and recrystallization due to prior cold working. This partial
recovery and recrystallization in material also depend upon the applied
stress and led to variation in creep strength of the material. Formation of
laves phases during creep exposure also affected the creep life of
material. Precipitation of carbides particles was seen to be accelerated at
the grain boundaries and this phenomenon was more prominently
observed in cold worked samples.
Priya Goel, Praveen Kumar, Vikram Jayaram
Indian Institute of Science, Bengaluru-560012
priyagoel@iisc.ac.in
Creep tests of cantilevers under bending offer a way to generate data
from small samples without the need for gripping. The present work
explores the use of phenomenological constitutive models to predict non-
steady state bending creep behaviour from uniaxial data. While stresses in
such a test vary along the length and cross section of the beam, earlier
work has shown that under steady state creep, the stress exponents under
bending match well with uniaxial data, by invoking the assumption that
plane sections remain plane (i.e., strain remains linear across beam
thickness) and that the stress re-distributes in accordance with the power
law dependence between stress and strain rate. Thus, the loading- end
displacements result from a simple addition of the displacements of
sections along the length. Under non-steady state conditions as prevail in
the primary stage, the stress evolves with time. We use phenomenological
models that describe the full uniaxial creep equation to predict
displacements under bending loads. The empirical relation suggested by
Marin and Pao [1] captures transient stage behaviour along with steady
state and considers stress distribution in bending with time. This relation
is used as the constitutive equation to model creep strain rate based on
uniaxial tests. The constitutive equation is used to predict creep behaviour
under bending loads based on the algorithm proposed by Popov [2] which
relies upon the assumption that plane sections remain plane during creep.
It is observed by comparison with experiment that this method is able to
predict the bending behaviour not only in steady state but during the
primary stage as well.

References:
[1] Pao, Y. H. and Marin, J. (1951). Deflection and stresses in beams
A NUMERICAL STUDY OF CREEP CRACK subjected to bending and creep. American Society of Mechanical
Engineers, 52:APM-34
GROWTH IN AN AERO-ENGINE TURBINE DISC [2] Popov, E. P. (1949). Bending of beams with creep. Journal of Applied
USING XFEM Mechanics, 14:A-135.

M. Kumar#, V.B. Pandey#, I.V. Singh#, B.K. Mishra#, S. Ahmad$, A.V.
Rao$, Vikas Kumar$
#
Department of Mechanical and Industrial Engineering,
Indian Institute of Technology Roorkee 247667, Uttarakhand, India
Phone: 91-1332-285888, Fax: 91-1332-285665
$
Defence Metallurgical Research Laboratory, DRDO, Hyderabad, India

In this paper, a turbine disc of an aero-engine having a macro crack under

creep loading is studied to predict the creep crack growth. Extended finite
element method (XFEM) has been used as it does not require conformal
meshing and remeshing due to change in the topology during crack
growth. The elasto-plastic behavior of the material is modelled by
Ramberg-Osgood model and von-Mises yield criterion. The creep
behavior is modelled by coupling of spatial and temporal dimensionsto
capture the effect of stress relaxation and redistribution due to creep
strain. The creep crack growth rate is computed by the C(t)-integral
which includes small-scale creep, transition creep and extensive creep.
The crack growth direction is estimated by the maximum principal stress
criterionwhich is based on the mode-I and mode-II stress intensity
factors(SIFs). The interaction integral approach is implemented for the
evaluation of stress intensity factors of different modes. The history fields
of plasticity and creep are transferred properly from the old configuration
to new configuration after the crack growth which is the main challenge
in this analysis. Thisproposed numerical scheme is then utilized to obtain
the creep crack growth in the componentmade of elasto-plastic-creeping
material. The creep crack growth variation with time is estimatedby the
XFEM to evaluate the life of components under creep conditions.

Keywords: creep; creep crack growth; C(t)-integral; relaxation and

redistribution; XFEM

36

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2E:DamageMechanics,ModellingandSimulation
Chairman:JeanLeopStrudel,France
SessionCoordinator:JalajKumar,DMRL
11061133 InvitedTalk:Themechanicsofevolutionofdamageinstructuralmaterials
SoumitraTarafder,CSIRNationalMetallurgicalLaboratory,Jamshedpur
11331145 AnAsynchronousIntegrationMethodforAcceleratedFiniteElementAnalysis
PratikSarkarandPritamChakraborty
IndianInstituteofTechnologyKanpur
11451157 Failureanalysisofwovencompositesusinghierarchicalapplicationofvariational
asymptoticmethodunitcellhomogenizationtechnique
RajeevG.Nair,TSundararajanandPJGuruprasad
DepartmentofAerospaceEngineering,IndianInstituteofTechnologyBombay
11571209 Analysis,ModelingandSimulationofAmbientCreepFatiguePhenomenoninTi6Al
4VAlloy:ADamageMechanicsApproach
JalajKumar,S.GaneshSundaraRamanandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
12091221 Newinsightsonthestressintensityfactorofedgenotchedclampedbendspecimen
BalilaNagamaniJayaandVikramJayaram
IndianInstituteofTechnologyBombay
12211233 Computationalgenerationoftheyieldsurfaces
MayankChoukseyandSumitBasu
IndianInstituteofTechnologyKanpur
12331245 Implementationofinternalstatevariablebasedmodelintofiniteelementcodeand
itsapplicabilitytostudythetensilebehaviouroftype316L(N)SSwithdifferent
notchradii
C.Praveen,J.Christopher,V.Ganesan,VaniShankarandB.K.Choudhary
IndiraGandhiCentreforAtomicResearch,Kalpakkam
12451257 EffectofAnnealingonStructuralIntegrityofCuFilledThroughSi
DipaliSonawaneandPraveenKumar
DepartmentofMaterialsEngineering,IndianInstituteofScience,Bangalore.
13091321 FiniteElementModelingandSimulationofProjectileImpactonDuctileTarget
SananHKhan,Md.QuaiyumAnsari,PuneetMahajanandShahnawazAhmad
IndianInstituteofTechnologyDelhi
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
THE MECHANICS OF EVOLUTION OF DAMAGE
IN STRUCTURAL MATERIALS
 constant displacement rate. Plastic strain localizes at the narrow area
Soumitra Tarafder
Chief Scientist
CSIR- National Metallurgical Laboratory, Jamshedpur 831 007, INDIA
star@nmlindia.org
It is important that the evolution of damage in engineering structural
materials be understood well so that their destruction is preventable. It is
essential to state that damage results in deterioration of materials and
leads to failure, disintegration or fracture.
Damage in materials subjected to overloads or cyclic loading may be
characterized in terms of fractographic or microstructural features. It may
be comprehended and quantified at an appropriate length scale, usually at
micro- or meso- level. Often however, the progression of damage under
specific types of loading, e.g. under torsional, seismic or high rate of
deformation, is of primary interest. The role of specific microstructural
constituents in promoting or preventing the accumulation of damage is
another aspect that frequently requires elucidation. Some of these
premises are exemplified in this talk to highlight the mechanics behind
the evolution of damage in metallic materials.
In order to understand the process through which damage is incorporated
in a material due to the imposition of mechanical factors, it is instructive
to trace the concatenation of events at the microstructural level that lead
to amalgamation of defects responsible for the appearance of mesoscopic
flaws, which in turn propagate to ultimately result in fracture. The
recognition that the whole chain of events is a continuous process helps
in comprehending why and how correlations exists between various
points in this chain. A number of specific damage processes will be
presented to underscore the existence of such correlations.
An elegant process to visualize, and predict, the development of damage
in materials is through modeling of the deformation behaviour of material
microstructures. Modeling thus becomes a powerful tool to represent the
progression of damage. While scale-hopping realistic models to portray
damage from atomistic to component levels are yet far away, substantial
progress has taken place to enhance multiscalarity of concepts and
conclusions. However the assumptions inherent in such models and
difficulties in experimentally obtaining model parameters, together with
the computational prowess necessary, often make results and predictions
unattainable or inconclusive and unreliable.
There are of course hybrid variants that are able to capture the overall
behaviour of the material without incorporating some of the finer details,
and to a great extent help visualize the evolution of damage in material
microstructures and predict their behaviour at an engineering scale.
Instances of application of such models will be discussed.
The overall domain of material mechanics is vast. The scope and
potential of the mechanics of damage evolution in materials will be
highlighted in the talk.
AN ASYNCHRONOUS INTEGRATION METHOD
FOR ACCELERATED FINITE ELEMENT
ANALYSIS
Pratik Sarkar, Dr. Pritam Chakraborty
Indian Institute of Technology Kanpur, Department of Aerospace
Engineering
pratikj@iitk.ac.in, cpritam@iitk.ac.in
Heterogeneity in geometry, material and loading can lead to localization
of state such as stress, and, plastic flow. Such localization can massively
impact the speed of Finite Element Method (FEM) simulation owing to
the need for very low critical time step to ensure convergence.
Asynchronous integration considering multiple domain with different
time steps and constrained interfaces can alleviate this problem by
considerably reducing the clock time of simulation. However, the
accuracy of the solution is strongly influenced by the interface constraint
condition, sub-domain selection and degree of asynchronicity. In the
present work, a method of asynchronous integration incorporating the
balance of power at the interface between the subdomains is proposed.


The accuracy and efficiency of the method is investigated for both 1d and
2d problems with elastic-viscoplastic material behavior. In the 1d
problem, a tapered bar is deformed by pulling one of the ends with
while the wider region remains nearly elastic. The asynchronous method
when applied to this problem clearly demonstrates its accuracy and time
advantage. In the 2d problem, a power law plastic flow rate with J2 flow
potential is used for a notched plate uniaxially pulled on the top. From a
comparison of the asynchronous integration with standard FEM it can be
seen that at low levels of applied displacements, when the viscoplastic
region is contained with the subdomain, the proposed method gives
significant speed up. However, as the viscoplastic region spreads to the
other domain, a reduction in efficiency happens.
FAILURE ANALYSIS OF WOVEN COMPOSITES
USING HIERARCHICAL APPLICATION OF
VARIATIONAL ASYMPTOTIC METHOD UNIT
CELL HOMOGENIZATION TECHNIQUE
Rajeev G. Naira,b, T. Sundararajanb, P. J. Guruprasada
a
Department of Aerospace Engineering, Indian Institute of Technology
Bombay, India
b
Vikram Sarabhai Space Centre, Indian Space Research Organization,
India
Email of corresponding author: pjguru@aero.iitb.ac.in
When variational asymptotic method (VAM) is used for the
homogenization of a periodic heterogeneous material, it not only
provides the effective properties but also has the capability to relate
macro-fields with micro-fields through recovery relations. Recovery
relations can be used to determine the components of stress on the
constituent phases in a hierarchical framework. In this paper, VAM is
used in two stages/steps to carry out the stress analysis of woven
composite till failure. The analysis is carried out to predict the strength of
woven composites. The first stage is the determination of homogenized
properties for the resin impregnated yarn bundle. This stage also provides
recovery relation between yarn bundle and its constituents - the fibre and
matrix. In the second stage, VAM is used in 3D to homogenize the woven
composite representative unit cell (RUC), where the homogenized
properties for the yarn bundle from the first stage is used. Here again, the
recovery relation is obtained between the woven RUC and its constituents
- yarn bundle and pure matrix. Once the constituent stress is available, a
micro-mechanics based damage model is used to determine the extent of
damage in the constituent phases which is expressed by a damage factor.
This damage factor in the constituent phases are volume averaged to
arrive at the homogenized
damage factor for higher level in
the hierarchy. The analysis is
carried out in multiple load steps
increasing from zero to higher
loads till the complete failure of
RUC occurs. At each load steps
the stiffness of the constituent
phases are factored based on the
damage factor. The analysis
results in a non-linear stress
strain curve indicating the failure
behavior of woven composite. In
this paper stress analysis procedure mentioned above is carried out on
woven composite problems available in literature. The results obtained
from the analysis validates the effectiveness of hierarchical application of
VAM to predict the strength of woven composites. Parametric study on
the composite is carried out to understand the failure behavior of woven
composite.
37

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
ANALYSIS, MODELING AND SIMULATION OF
AMBIENT CREEP-FATIGUE PHENOMENON IN
Ti-6Al-4V ALLOY: A DAMAGE MECHANICS
APPROACH
Jalaj Kumar*, @, S. Ganesh Sundara Raman# and Vikas Kumar*
*Defence Metallurgical Research Laboratory, Hyderabad-500058
#
Metallurgical and Materials Engineering Department, IIT Madras,
Chennai-600036
@
Corresponding author: jalaj@dmrl.drdo.in, k_jalaj@yahoo.com Phone:
+914024586469 Fax: +914024340266
In the present study, Ti-6Al-4V alloy has been characterized for ambient
fatigue, creep and creep-fatigue loading conditions using online IR-
thermography (IRT), EBSD and SEM based analysis. Thermal signatures
during pure fatigue and creep-fatigue loading conditions are captured
using IRT. Thermodynamic modeling has been performed on the
experimentally evaluated IRT data to evaluate total stored energy
consisting of damage energy (due to voids and microcracks) and
deformation energy (due to dislocations). The deformation energy is
estimated through EBSD analysis. Subsequently, the evolving damage
and deformation induced by creep and fatigue loading have been modeled
as functions of applied stress and cumulative plastic strain, separately. By
using the data of experimental creep stress and fatigue strain for each
creep-fatigue cycle, the individual contributions of creep and fatigue
damage energies have been estimated for creep-fatigue interaction.
Fatigue and creep damage parameters have been proposed based on the
damage mechanics concepts. Damage evolution has been simulated at
different length scales – microstructure, specimen and component level.
Overall, the damage mechanics based modeling has been found to be
very effective not only for simulations at various length scales but also in
mapping critical damage locations.
Keywords: Creep-fatigue; damage mechanics; Ti-4Al-4V alloy
NEW INSIGHTS ON THE STRESS INTENSITY
FACTOR OF EDGE NOTCHED CLAMPED BEND
SPECIMEN
Balila Nagamani Jaya1* and Vikram Jayaram2
1
Department of Metallurgical Engineering and Materials Science, Indian
Institute of Technology Bombay, Powai, Mumbai-400072, India
2
Department of Materials Engineering, Indian Institute of Science,
Bangalore-560012, India
*Email: jayabalila@iitb.ac.in
The edge-notched clamped bend (ENCB) specimen was first developed
as a fracture testing geometry primarily for studying micro-scale fracture
behavior in thin films and coatings [1-2] which could not directly adopt
the conventional single edge notch bending (SENB) under 3 point load.
Its extension to macro-scale fracture tests is facilitated by its unusual
stability against catastrophic fracture, even under load control (Fig 1 a-b).
Extended finite element simulations (XFEM) were carried out to
understand this behavior. Compared to a SENB specimen, which shows a
monotonic increase in stress intensity factor (KI) with increasing crack
length (a/W) (Fig 1 c), the ENCB displays a maxima in the KI vs a/W
curve (Fig 1 b, d), indicating a possible range of a/W ratios for which
crack can grow
stably even in materials which exhibit ideal brittle behavior. More
importantly, this stability is a function of the aspect ratio (L/W) of the
beam, with a thicker beam being more stable than a slender one.
Therefore the formulation for KI of ENCB specimen is given by eq 1.
୔୐ ୟ ୐
 ୍ ൌ మ ξƒˆ ቀ ቁ ‰ ቀ ቁ (1)
୆୛ ୛ ୛
Analytical solutions forKI ofENCB geometrywill be presented for a wide
range of useful specimen sizes and loads obtained by fitting the numerical
solutions from FEM calculations. Advantages of different specimen size
ratios will be discussed as guidelines for future users of this geometry. In
the talk, experimental validation of fracture toughness on various material


systems and their application in determination of R-curve behavior,
cyclic loading response, and in pre-cracking will also be shared [3-5].
References
[1] B. N. Jaya, V. Jayaram, and S.K. Biswas, A new method for fracture
toughness determination of graded (Pt,Ni)Al bond coats by
microbeam bend tests, Philos. Mag. 92, 2012, p. 3326.
[2] B.N. Jaya and V. Jayaram, Crack stability in edge notched clamped
beam specimen under bending: modeling and experiments, Int. J.
Fract. 188, 2014, p. 213.
[3] E. Hintsala, D. Kiener, J. Jackson and W. W. Gerberich, In-Situ
Measurements of Free-Standing, Ultra-Thin Film Cracking in
Bending, Exp. Mech. 55, 2015, p. 1681.
[4] Y. Hu, J. Huang and J. Zuo, In situ characterization of fracture
toughness and dynamics of nanocrystalline titanium nitride films,
J.Mater. Res.31, 2016, p. 370.
[5] B. N. Jaya and V. Jayaram, Fracture testing at small length scales:
From plasticity in Si to brittleness in Pt, JOM. 68, 2016, p. 94
COMPUTATIONAL GENERATION OF THE YIELD
SURFACES
Mayank Chouksey, Sumit Basu
Indian institute of technology, Kanpur
mayankc@iitk.ac.in
Ductile fracture in metals proceeds through nucleation, growth and
coalescence of microvoids. Determination of the yield surface of a ductile
porous material is necessary to simulate onset and evolution of ductile
damage in a metal. Since the early work by Gurson [1] where yield
function for concentric spherical void inside a spherical RVE was
considered, several extensions have emerged. It has been shown that the
void shape [2] and anisotropy of the bulk matrix [3] modify the yield
function significantly. All these predictions of yield rely on limit analysis
of the RVE based on the upper bound theorem and Hill-Mandal
homogenization. These models have not accounted for onset of yield
through localization of plastic strain.
Recently [4] has looked at the competition between localization and
uniform yield via the Gurson model. We have extended this work by
performing stress controlled computational homogenization over sub-
spaces of the principal stress space, to probe the yield surface of perfectly
plastic materials with different void shapes. Following [5], a special four-
noded user element is developed in ABAQUS, that, is tied to a RVE with
periodic boundary condition, restrained rigid body rotation and subjected
to either macroscopic deformation gradient or Cauchy stress. The
macroscopic plastic dissipation rate is monitored to detect yield. As a
result, yield due to both uniform plastic deformation and localization are
captured. We have compared the results of our computationally
determined yield surfaces with the theoretical upper bound estimates in
[1-2,4]. We show that over a significant section of the principal stress
sub-space, localization modifies the yield surface. It is shown that the
plane of localization changes with the void shape. Associativity of the
numerically generated yield surfaces are also verified. The yield surface,
even for spherical voids and more so far prolate and oblate ones depends
on the imposed triaxiality and Lode angle.
References
[1] Gurson, Arthur L., “Continuum theory of ductile rupture by void
nucleation and growth: Part I Yield criteria and flow rules for porous
ductile media”, Journal of engineering materials and technology,
99(1):2-15, (1977).
[2] Gologanu, M., Leblond, J.B., Perrin, G. and Devaux, J., “Recent
extensions of Gursons model for porous ductile metals”, Continuum
micromechanics, Springer Vienna, (1997).
[3] Keralavarma, S.M. and Benzerga, A.A., “A constitutive model for
plastically anisotropic solids with non-spherical voids”, Journal of
the Mechanics and Physics of Solids, 58(6):874-901, (2010).
[4] Keralavarma, S.M. and Chockalingam, S. “A criterion for void
coalescence in anisotropic ductile materials”, International Journal of
Plasticity, 82:159-176, (2016).
[5] Schmidt, Ingo, “Numerical homogenization of an elasto-plastic
model-material with large elastic strains: macroscopic yield surfaces
and the Eulerian normality rule”, Computational Mechanics,
48(5):579-590, (2011).
38

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
IMPLEMENTATION OF INTERNAL-STATE-
VARIABLE BASED MODEL INTO FINITE
ELEMENT CODE AND ITS APPLICABILITY TO
STUDY THE TENSILE BEHAVIOUR OF TYPE
316L(N) SS WITH DIFFERENT NOTCH RADII
C. Praveen*, J. Christopher, V. Ganesan, Vani Shankar and B.K.
Choudhary
Materials Development and Technology Division
Indira Gandhi Centre for Atomic Research, HBNI, Kalpakkam – 603 102,
Tamil Nadu, India
(*E-mail: cpraveen@igcar.gov.in)
Tensile work hardening of metals and alloys is associated with the
evolution of dislocation substructure, which in turn is determined by two
competing processes. One involves the hardening results from the storage
of forest dislocations due to the interaction of mobile dislocations with
various obstacles such as sessile dislocations, grain and twin boundaries,
precipitates, and dispersoids. The other is dynamic recovery, which
determines the decrease in dislocation density as a result of thermally
activated rearrangement and annihilation of dislocations. Several models
were proposed to describe the evolution of dislocation density with
plastic strain for the description of tensile deformation behavior of
materials. However, the models must still be tractable for large scale
computations using finite element simulation for structural component
design analysis. In view of above, the two-internal-variable model based
on the evolution of forest dislocation density and mean free path with the
plastic strain has been examined for the description of tensile work
hardening behaviour of type 316L(N) SS. The model accurately predicts
all the three different stages of work hardening behaviour of the steel. In
addition to that, the model has been implemented into finite element code
ABAQUS via user-defined material subroutines (UMAT) using implicit
integration scheme. Applicability of the implemented scheme has been
examined by simulating the tensile behaviour of type 316L(N) with
different U-notch radii as 1.25, 2.5 and 5 mm at 300 K. The predicted
tensile strength and yield strength values increases with increase in notch
radius for the steel. The simulated results showed that Von-Mises
equivalent stress which is responsible for causing plastic deformation
decreases with increasing U-notch radius for a given nominal stress
applied to the specimen. Good agreement between the predicted and
experimental data has been observed.
EFFECT OF ANNEALING ON STRUCTURAL
INTEGRITY OF Cu-FILLED-THROUGH Si
Dipali Sonawane and Praveen Kumar
Department of Materials Engineering
Indian Institute of Science, Bangalore, 560012
Email: dipalis@ iisc.ac.in
Cu-filled through-silicon vias (TSV) of diameter of < 100 Pm are used as
interconnect for stacking multiple dies containing devices in a vertical
column in a 3D microelectronic package. Besides the functional
requirements, these small diameter, high aspect ratio Cu-TSV should also
retain their structural integrity over the life period of the device. These
TSVs are often subjected to thermal excursions, e.g., during post-
fabrication annealing of microelectronic packages, in service due to on-
off period of a device, etc. Due to large difference in thermal expansion
coefficients of Cu and Si, Cu-filled TSVs are subjected to large thermal
stresses during such thermal excursions, which can raise serious thermo-
mechanical reliability issues, such as Cu-extrusion/protrusion/sliding
relative to Si, generation of micro-cracks in Si, interfacial fracture, etc. In
this work, annealing experiments were carried out post electroplating of
Cu at 450 and 650 °C, which are industrially relevant. The annealing
experiments showed the extrusion of Cu, especially near the edges,
relative to Si vias as well as growth of cracks at few locations. The cracks
as well as extrusion were observed to grow substantially during
subsequent annealing cycle. The direction of crack propagation was near
<110>, which is a preferred crack propagation direction for fracture (via
cleavage mechanism) in Si. In addition, extended finite element analysis
(X-FEM) was performed to gain more insights into observed cracking of
Si around the vias and to determine the temperature (during ramping-up
to the annealing temperature) at which the crack would propagate. It can


be inferred from numerical analysis and experimental observations that
the locations of high stress concentration at the interface between Cu and
Si acted as the critical points of crack initiation, which eventually resulted
in cracks propagation and hence failure of the device.
Keywords: Thermal excursions; Cu-Si interface; Fracture; XFEM
FINITE ELEMENT MODELING AND
SIMULATION OF PROJECTILE IMPACT ON
DUCTILE TARGET
Sanan H Khana, Md. Quaiyum Ansaria, Puneet Mahajana and
Shahnawaz Ahmadb
a
Indian Institute of Technology, New Delhi, Delhi, India
b
Defence Metallurgical Research Laboratory, Hyderabad – 500 058,
India
Email of corresponding author: er.sanan@gmail.com
Perforation of plates during projectile impact is a complex process
involving elastic and plastic deformation, strain rate hardening effects,
thermal softening, crack formation, adiabatic shearing, plugging, petaling
and even shattering. Various studies have been published by Backman
and Goldsmith [1], Corbett et al. [2] and Goldsmith [3] which discusses
the phenomenon of material perforation and various parameters involved
in the problem. Gupta and Ansari [4] have studied normal impact on thin
aluminium plates by ogive nosed projectiles at impact velocities greater
than ballistic limit. They have studied the effects of plate thickness and
projectile related parameters on residual velocity and ballistic limit.
Owing to the dynamic nature of the problem, the mechanics of
perforation is so fast that it is quite difficult to analyse it experimentally.
Hence in this study an honest attempt has been made to simulate their
results with further understanding of the various mechanism that are
missed in the experiments.
Ogive nose projectile of calibre radius head 2 is used to impact on
aluminium target of 0.5 mm thickness by using Abaqus/Explicit. A
numerical modeling includes complete failure model for metal that
includes Johnson-Cook plasticity and damage initiation [5] coupled with
Hillerborg’s evolution approach [6] to damage the element following the
smeared cracking. A mesh convergence study was performed to ensure
that sufficiently small elements were chosen so that the results are not
compromised. Fig.1 shows the mesh convergence with the residual
velocity of the projectile. Fig 2 shows the comparison of the post-mortem
results. A failure is accompanied by petaling, dishing and shearing of the
target plate with good reproduction of the experimental behaviour in
simulation study.
References
[1] M. E. Backman and W. Goldsmith, “The mechanics of penetration of
projectiles into targets,” Int. J. Eng. Sci., vol. 16, no. 1, pp. 1–99,
1978.
[2] G. G. Corbett, S. R. Reid, and W. Johnson, “Impact loading of plates
and shells by free-flying projectiles: A review,” Int. J. Impact Eng.,
vol. 18, no. 2, pp. 141–230, 1996.
[3] W. Goldsmith, “Non-ideal projectile impact on targets,” Int. J.
Impact Eng., vol. 22, no. 2, pp. 95–395, 1999.
[4] N. K. Gupta, R. Ansari, and S. K. Gupta, “Normal impact of ogive
nosed projectiles on thin plates,” Int. J. Impact Eng., vol. 25, no. 7,
pp. 641–660, 2001.
[5] G. R. Johnson and W. H. Cook, A constitutive model and data for
metals subjected to large strains, high strain rates and high
temperatures, vol. 547. 1983.
[6] A. Hillerborg, M. Modéer, and P. E. Petersson, “Analysis of crack
formation and crack growth in concrete by means of fracture
mechanics and finite elements,” Cem. Concr. Res., vol. 6, no. 6, pp.
773–781, 1976.
39
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session2F:Ceramics,CompositesandFunctionalMaterials
Chairman:TKNandy,DMRL
SessionCoordinator:GPrabhu,DMRL
11061133 InvitedTalk:StructuralIntegrityofZrB2SiCbasedultrahightemperatureceramic
compositesathightemperaturesandextremeenvironments
RahulMitra,IndianInstituteofTechnology,Kharagpur
11451157 BucklingandvibrationsofFGMcircularplatesinthermalenvironment
RahulSaini,ShivamSaini,RoshanLalandIndraVirSingh
IndianInstituteofTechnologyRoorkee
12091221 StudyontheLowandHighStrainRateBehaviorofFumedNanoSilicaDispersions
NeelanchaliAsija,HemantChouhan,AishaAhmed,KartikeyaandNaresh
Bhatnagar
IndianInstituteofTechnologyDelhi
12331245 FractureBehaviourofpAramidandUltraHighMolecularWeightPolyethylene
BasedHybridComposite
ArunKumarSingh,DharmendraKumarShuklaandNEswaraPrasad
DefenceMaterials&StoresRes&DevEstablishment,Kanpur
 



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

STRUCTURAL INTEGRITY OF ZrB2-SiC BASED STUDY ON THE LOW AND HIGH STRAIN RATE
ULTRAHIGH TEMPERATURE CERAMIC BEHAVIOR OF FUMED NANO SILICA
COMPOSITES AT HIGH TEMPERATURES AND DISPERSIONS
EXTREME ENVIRONMENTS
 Neelanchali Asija, Hemant Chouhan, Aisha Ahmed, Kartikeya, Naresh
Bhatnagar
R Mitra, M Mallik and S Kashyap
Mechanical Engineering Department, Indian Institute of Technology
Professor and Head,
Delhi, Hauz Khas,
Department of Metallurgical and Materials Engineering, IIT Kharagpur
New Delhi -110016, India
rahul@metal.iitkgp.ernet.in
Email: neelanchaliasija@gmail.com
Ultra-high temperature ceramic (UHTC) composites are considered as
Shear Thickening Fluids (STFs) are a special class of field responsive
candidate materials for use in leading edges and nose-cones of re-entry
non-Newtonian fluids which exhibit transition from low viscosity to high
vehicles. Structural integrity of ZrB2-SiC based UHTC composites have
viscosity state when they are subjected to shearing deformation above the
been investigated under creep, oxidation, thermal shock and ablative
critical shear rate (CSR). Due to this unique characteristic of STFs, these
conditions at elevated temperatures. The ZrB2-SiC composites for this
have found application in ballistics, especially in the development of
study have been processed by pressure-less sintering, spark-plasma
special class of body armors called Liquid Body Armors (LBAs) which
sintering or hot-pressing. Creep studies in the temperature range of 1300-
are lighter in weight and more flexible as compared to conventional
1425 oC have shown stress exponent of |1, indicating grain boundary
heavy armours. Fumed silica (FS) is a rheologically significant material
sliding accommodated partially by oxygen diffusion (<1400 oC) or visco-
as it is a well known viscosity modifier owing to its fractal structure, and
plastic flow in the intergranular glassy film as the operating mechanism is generally used in paints, coatings, sealants, printing inks etc. In this
of damage. The creep resistance of these composites is found to scale
study, two different grades of FS (A-130 and A-150) were used for the
with SiC content. The oxidation resistance is found to improve with
synthesis of STFs. The low strain rate studies were conducted on cone
addition of Si3N4 or LaB6 to the ZrB2-SiC composites, but the creep and plate rheometer and high strain rate experiments were accomplished
resistance is adversely affected. The resistance to oxidation in ZrB2-SiC
on split Hopkinson pressure bar (SHPB) set up. The colloidal dispersions
and ZrB2-SiC-Si3N4 composites is ensured by formation of B2O3-SiO2
in PPG-400 (Poly Propylene Glycol 400) were synthesized using
scale. In the ZrB2-SiC-LaB6 composites, formation of refractory layers of ultrasonic homogenization technique. From the experiments it was
La-Zirconate and La-Silicate has been observed. Thermal shock
observed that A-150 fumed silica dispersion exhibited highest severity in
resistance has been examined by subjecting these composites to 800,
shear thickening, in the low strain rate domain, whereas A-130 fumed
1000 or 1200 oC followed by air-cooling, and the damage has been silica dispersion exhibited highest specimen stress and compressional
quantified by examining the decrease in Young’s modulus, hardness and
strain rate under high strain rate dynamic compressive loading. Thus, it
indentation fracture toughness. Ablation tests were carried out by
can be inferred that the same material may exhibit different behaviors in
exposing the composites to neutral oxy-acetylene flame at 2000 oC for the low and high strain rate regimes. Therefore, both the studies play a
durations up to 15 minutes, followed by measurement of above-
vital role to completely characterize the material, especially when the
mentioned properties and mass-changes. For composites with various SiC
material has to be subjected to ballistic applications.
volume fractions, most optimum properties were found for 20 vol.% SiC.
Further, addition of 20 vol.% ZrC is found to enhance thermal shock and
ablation resistance. The mechanisms responsible for aforementioned
behavior will be discussed.

BUCKLING AND VIBRATIONS OF FGM

CIRCULAR PLATES IN THERMAL
ENVIRONMENT
Rahul Sainia, Shivam Sainib, Roshan Lalc, Indra Vir Singhd
a
Research Scholar, Department of Mathematics, IITR, Roorkee 247667,
India
b
Graduate Student, Mechanical Engineering Department, TIET, Patiala
147004, India cProfessor, Department of Mathematics, IITR, Roorkee
247667, India
d
Professor, Department of Mechanical and Industrial Engineering, IITR,
Roorkee 247667, India
E-mail address: rahulsainiiit@gmail.com
An analysis is presented for the study of thermal environment on free
axisymmetric vibration of functionally gradedcircular plates subjected to
uniform in-plane peripheral loading and non-linear temperature
distribution along the thickness direction. It is assumed that the plate
material is graded in thickness direction and mechanical properties are
temperature-dependent. Hamilton’s principle has been used in obtaining
the governing equations for thermo-elastic equilibrium and vibration for
such a plate model on the basis of classical plate theory. Generalized
differential quadrature rule has been used in evaluating the numerical
values for thermal displacements and frequencies in case of clamped and
simply supported plates at the periphery for the first three modes of
vibration. Compressive in-plane loads for which the plate ceases to
vibrate have been reported as critical buckling loads. Effects of various
parameters have been analyzed on the vibration characteristics for all the
modes. For uniform and linear temperature distribution, the benchmark
results have been computed. As a special case, a study with the plate
material having temperature-independent properties has been performed.
Results have been compared with the published work.
Fig. 1:Stress vs Strain response of A-130 FS dispersion Fig. 2:Stress vs
Strain response of A-150 FS dispersion under dynamic compressive
loading on SHPB set-up

FRACTURE BEHAVIOUR OF p-ARAMID AND
ULTRA HIGH MOLECULAR WEIGHT
POLYETHYLENE BASED HYBRID COMPOSITE
Arun Kumar Singha, b, Dharmendra Kumar Shuklab and N Eswara
Prasada
a
Defence Materials & Stores R & D Establishment (DMSRDE), DRDO,
Kanpur-208013 (India)
b
Mechanical Engg. Department, Motilal Nehru National Institute of
Technology, Allahabad-211004 (India)
Damage in the form of delamination and debonding are the most common
failure modes observed in polymeric composites used for high end
structural applications. The principal aim of this work is to investigate the
fracture behaviour of Ultra High Molecular Weight Polyethylene
(UHMWPE) and p-aramid based hybrid composite. In this work, an
optimized processing condition based on highest flexural strength has
been evaluated using Box-Behken design of experiment method to
fabricate the hybrid composite. Based on most optimized processing
conditions process variable such as 14.2 MPa for pressure, 120 oC for
temperature and 12.7 minutes for time, a compression moulded hybrid

40

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

composite are prepared and the same are studied in detail for their
interlaminar fracture toughness. In the present study, a finite notch radius
that varied from 110 – 750 μm is employed. The fracture
toughness/resistance (KQ) of the material has been evaluated and
analyzed by investigating the inuence of varying notch root radii. The
results obtained from the analysis show that the critical notch root radius
of the hybrid composite is around 340 μm. The load displacement data of
three point bend test with varied crack length are used to evaluate plain
strain fracture toughness (K1c). The K1c has been found 1.5 MPam for
the KQ values derived from specimens with a/W of 0.45-0.55. It is
observed that the fracture mechanism which is responsible for fracture
toughness in hybrid composite is fiber pull out due to weak adhesion
between fabric and matrix.

© 2018 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of Peer-review under
responsibility of the SICE 2018 organizers.
Keywords: Fracture toughness; hybrid composite; critical notch root
radius; p-aramid; UHMWPE

41

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3A:StructuralIntegrityIII
Chairman:VMadhu,DMRL
SessionCoordinator:BidyapatiMishra,DMRL
16301657 InvitedTalk:StructuralHealthMonitoringofRocketMotorCasingsbyAcoustic
EmissionTesting
MRMBabu,AdvancedSystemsLaboratory,Hyderabad
16571709 DevelopmentofHighImpactPolycarbonateBasedNanocompositesforBody
Armours&TheirHighStrainRateCharacterisation
AishaAhmed,NeelanchaliAsijaandNareshBhatnagar
IndianInstituteofTechnologyDelhi
17091721 DevelopmentofMountingBracketforCCSelectronicunitofArmouredFighting
Vehicle
N.Venkateswaran,S.SenthurNathanandR.Vinobakrishnan
CombatVehiclesResearchandDevelopmentEstablishment,DRDO,Chennai
17331745 FiniteElementSimulationofArmorSteelusedforBlastProtection
Kartikeya,SanjayPrasadandNareshBhatnagar
IndianInstituteofTechnologyDelhi
17571809 MicroStructuralCharacterizationofCF8CAlloyandItsEffectonTensileProperties
atVariousTemperatures
NeetaPaulose,AnuradhaNayakMajila,D.ChandruFernandoandParthasarathi
Hans
GasTurbineResearchEstablishment,DRDO,Bangalore
18091821 SynthesisandCharacterizationofSubmicronSizedTungstenHeavyAlloycompacts
ProcessedthroughSparkPlasmaSinteringTechnique
S.S.KalyanKamal,J.Vimala,BhaskarMajumdarandL.Durai
DefenceMetallurgicalResearchLaboratory,Hyderabad
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
STRUCTURAL HEALTH MONITORING OF
ROCKET MOTOR CASINGS WITH ACOUSTIC
EMISSION TESTING

M R M Babu
, S.Senthur Nathan1a, R.Vinobakrishnan1b,
Programme Director
AGNI, DRDO
mrmbabu@asl.drdo.in
Solid Rocket motors are one of the major subsystems in missile systems.
The quest for enhancing the capability of range and payload drives us to
minimize the structural massof the solid propellant rocket motors.The
Rocket motor casings realized with ultra-high strength maraging steel and
carbon epoxy filament wound Rocket motor casings with high strength
T700 carbon fibre are the present state of art technology. Structural health
monitoring of these high strength rocket motor casings during fabrication
and subsequent acceptance level pressure testing is of paramount
importance in establishing reliability of the casing for their end use.
Comprehensive quality assurance encompassing the entire manufacturing
cycle i.e the control of raw materials and process control during
manufacturing play important role. Inspection of the casings with various
NDT techniques ensure that the flaws are in permitted level.
However the dynamic growth of acceptable flaws to unacceptable level
during proof pressure testing is also of concern. This issue can be
addressed by introducing Acoustic Emission testing during proof pressure
testing of the casings to study the dynamic growth behaviour of flaws and
however the post-test NDT examination compliments the same.
The development of Acoustic Emission testing technique for high
strength maraging steel rocket motor casings and composite rocket motor
casings has been discussed in this presentation.
DEVELOPMENT OF HIGH IMPACT
POLYCARBONATE BASED NANO-COMPOSITES
FOR BODY ARMOURS & THEIR HIGH STRAIN
RATE CHARACTERISATION
Aisha Ahmed, Neelanchali Asija & Naresh Bhatnagar*
Mechanical Engineering Department, Indian Institute of Technology
Delhi, New Delhi-110016, India.
*nareshb@mech.iitd.ac.in
The present-day sophisticated warfare ammunitions urge the need for
better energy absorbing lightweight solutions for body armours.
Therefore, advanced composite materials are the key materials to cater to
the requirements of body armours. The purpose of this work is to study
the applicability of the Polycarbonate (PC) based blends and
nanocomposites as a backing matrix for ceramics in ballistic applications
depending upon their high strain rate behaviour. PC is an important
engineering thermoplastic polymer and is widely used as a layered
composite in transparent armour. Owing to its complex chemical
structure it has inherently high impact strength. PC, when blended with
Ethylene-methyl acrylate (EMA) copolymer reduces its notch sensitivity
(for its use in body armours) and improves notched impact strength along
with fracture toughness at high strain rates with a minimal decrease in
tensile strength. Further, PC/EMA blend was compounded with multi-
walled carbon nanotubes (MWCNTs) using co-rotating twin screw
extruder. Dynamic mechanical experiments have been performed using
in-house fabricated Split Hopkinson Pressure Bar (SHPB) on all prepared
PC blends and their MWCNTs reinforced composites. The maximum
stress value achieved for the neat PC is 290.71 MPa at the limiting strain
rate of about 8519.61 s-1, which is increased to 154% and 124.5% at
13252.88 s-1 and 11514.66 s-1 strain rates for PC/EMA blends with and
without MWCNT reinforcement, respectively. The blending of EMA
showed a remarkable improvement in fracture toughness at high strain
rates, which is further increased in MWCNTs reinforced nanocomposites.


DEVELOPMENT OF MOUNTING BRACKET FOR
CCS ELECTRONIC UNIT OF ARMOURED
FIGHTING VEHICLE
N. Venkateswaran1
1
Center for Engineering Analysis and Design, Combat Vehicle R & D
Establishment (CVRDE), DRDO,
Avadi, Chennai 600 054, TamilNadu, India,
*email : venkateswaran.n@cvrde.drdo.in
This paper describes the design and development of new mounting
bracket replacing the old one. Commander Control station (CCS) is one
of the accessories for the Gunner’s Main sight and it is fitted on the
mounting bracket in front of Commander’s station at turret roof plate of
the Armoured Fighting vehicle (AFV). It displays the thermal images of
the Gunner’s main sight which is to monitor the Gunner Line of sight
continuously by the Commander.
During the trial, it was noticed that the existing CCS electronics units are
malfunctioned. To know the cause of malfunction, it was planned to
conduct the vibration analysis on the locations of CCS electronics units.
Subsequently the level of vibration on all the locations were recorded and
analyzed for various operating track profiles. The spectrum plot of CCS
location for all these track profiles shows the overall vibration levels in
the frequency band of 20- 2000Hzare well within the qualified limit.
However the CCS electronics units show a resonance at 22.5 Hz in the
lower frequency band where the amplitude is maximum may be of
concern for electronic units mal functionality.
Hence a new CCS unit of light weight compact and durable is planned
to retro fitment with the new modified compact mounting bracket on
AFV. The mounting bracket is designed in such a way that the natural
frequency of the same bracket to be away from 0-100Hz. This is
achieved, by carrying out, Structural, Shock and Response Spectrum
analysis.
FINITE ELEMENT SIMULATION OF ARMOR
STEEL USED FOR BLAST PROTECTION
Kartikeya, Sanjay Prasad, Naresh Bhatnagar
Indian Institute of Technology, Delhi
Email of corresponding author: nareshb@iitd.ac.in
Safety of defense and paramilitary operators in hostile environments can
be ensured by using ballistic materials. Various destructive and non-
destructive techniques are available for characterizing ballistic materials
and performance of respective products but they can be expensive and
protracted. Finite Element method (FEM) is useful in these situation as it
can be used during design phase to determine critical design sections and
material performance in products. This study focuses on FE simulation of
Weldox armor steel used for blast protection in anti-land mine vehicles
using CONWEP method to simulate blast. Plate is modeled as
deformable solid with Johnson-Cook plasticity. Parametric study is
performed to determine appropriate element size. Results of numerical
simulation were validated from results of experiments published earlier
by various researchers. A laminated steel plate of varying thicknesses is
used to assess blast protection as against monolithic armor plate.
Numerical simulation showed that laminated steel plates performed better
than monolithic armor steel plates.

42
 
SeccondInterna
ationalStructturalIntegrittyConferencce&Exhibitio 018) PROCEEDING
on(SICE– 20 GS

MIICRO STRUCTURAL CH HARACTERRIZATION OF

O
CF
F 8C ALLOY
Y AND ITS EF
FFECT ON TENSILE
T
PR
ROPERTIES AT VARIOU US TEMPER
RATURES

Neeeta Paulose#, Annuradha Nayak Majila,

M Chandru Feernando D,
Partthasarathi Hans
Matterials Group, Gaas Turbine Researrch Establishmennt, C V Raman
Naggar, Bangalore-933
# coorresponding authhor: email id: neeeta_paulose@gtree.drdo.in

CF88C alloy is an Iroon-Chromium-Niickel austenitic sttainless steel. It is i a

castt grade of AISI 347
3 stainless steel. CF 8C is Niobbium stabilized allloy
andd is extensively ussed in various commponents of Gas Turbine Engine and a
Turrbo-Charger. It is has good strrength and ducttility up to 5500°C
.Corrosion resistance is better than other
o austenitic stainless steel duee to
the presence of Niobbium. Microstructure of this alloy consists of niobiium
carbbides and delta ()
( ferrite withinn austenitic matriix. The distributiion,
sizee and amount off delta ferrite iss dependent on material processsing
conndition. This papeer is an attempt too understand the effect
e of delta ferrrite
on uniaxial tensionn testing at a coonstant strain ratte over a range of
mperatures. Detailled microstructrall study and elem
tem mental analysis ussing
optiical and SEM has h been carried out to understaand delta () ferrrite
disttribution and fracctographic studiees has been donee to understand the
tenssile deformation.

Keyy word: Austenitiic stainless steel, Gas Turbine enggine, casting, CF 8C,
 feerrite, Tensile testting

SY
YNTHESIS AND
A CHARA
ACTERIZATIION OF
SU
UBMICRON SIZED TUNGSTEN HEA
AVY ALLOY
Y
CO
OMPACTS- PROCESSED
P D THROUGH
H SPARK
PL
LASMA SINT
TERING TEC
CHNIQUE

S Kalyan Kamall*, J. Vimala, Bhhaskar Majumdar and L. Durai

S. S.
Deffence Metallurgiccal Research Labooratory, Kanchannbagh, Hyderabadd-
5000 058, India
* Emmail: kalyanchemm@dmrl.drdo.in

A submicron
s sized tungsten
t heavy alloy
a with a nom
minal compositionn of
W-990 wt%, Ni-7 wt% and Fe-3 wt% % has been syntheesized by coatingg Ni
andd Fe using a moddified polyol proccess on W nanoppowders (NPs). The T
proccess allows us too precisely control the chemical composition andd its
hom mogeneous distribbution. The Ni-F Fe coated W poowders were furtther
usedd to form comppacts in a spark plasma sinteringg equipment, whhich
alloowed us to retaiin the W grain size to submicrron size even after
sinttering. The microstructure revealed that the W-W W interactionn is
resttricted through a matrix interface of Ni-Fe coated on the W particles.
Thee average grain size
s of W particlles is 900 nm ± 50 nm as shownn in
figuure 1. This is a novel
n approach too attain WHA saamples with unifoorm
miccrostructure withoout employing liiquid phase sinteering. The chemiical
commposition and EDS E spectra reevealed a homoogeneous chemiical
commposition. XRD shows
s the presencce of only W andd matrix peaks. Bulk
B
harddness measuremeents revealed a uniform
u hardnesss of 430 ± 20 VH HN
acrooss the sample.

Figuure 1: Scanning electron

e micrograaph of spark plasm
ma sintered tungssten
heavy alloy.

43

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3B:MaterialsDevelopment
Chairman:AKMukhopadhyay,DMRL
SessionCoordinator:RajnishGoyel,DMRL
16301657 InvitedTalk:TowardsSelfrelianceinHighTemperatureMaterialsforIndianSpace
Programme
SharadChandraSharma,VikramSarabhaiSpaceCentre,Trivandrum
16571709 Influenceofniobiummicroalloyingonthemicrostructureandmechanicalproperties
ofhighcarbonnanobainiticsteel
PPonguruSenthil,KSudhakaraRao,HillolKumarNandi,SurajKumar,SSankaran,
KSivaKumarandVemuriMadhu
DefenceMetallurgicalResearchLaboratory,Hyderabad
17091721 HotIsostaticProcessingofHighTemperatureMaterials:Challenges
G.AppaRao,B.SreenuandDVV.Satyanarayana
DefenceMetallurgicalResearchLaboratory,Hyderabad
17211733 EffectofadditionofFlyashandAl2O3particlesonmechanicalandtribological
behaviorofAlMMCatvaryingload,timeandspeed
VikasVerma,P.C.Tewari,RoshanZameerAhamedandSyedTouseefAhmed
LORDSInstituteofEngineeringandTechnology,Hyderabad
17331745 Effectoftemperingtemperatureandtimeonmicrostructureandmechanical
propertiesof26MnB5martensiticsteeltubes
SUshaRaniandMPreethi
TubeInvestmentsofIndiaLtd,Chennai
17451757 MicromechanicalAnalysisofEffectofMorphologyofGraphiteinCastIron
UjjalTewary,AlankarAlankar,GoutamMohapatra,ShyamprasadKaragaddeand
I.Samajdar
JohnDeereIndiaPvt.Ltd.Pune
17571809 ModellingandexperimentalverificationofaCircularDEA
ArpitSrivastavaandSumitBasu
IndianInstituteofTechnologyKanpur
18211833 Effectofhygrothermalagingontheinterlaminarshearstrengthofacarbonfiber
composite
KishoraShetty,ShylajaSrihariandCMManjunatha
CSIRNAL,Bangalore
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
TOWARDS SELF-RELIANCE IN HIGH
TEMPERATURE MATERIALS FOR INDIAN
SPACE PROGRAMME
S C Sharma
Vikram Sarabhai Space Centre
Trivandrum – 695 022
sharma_sc@vssc.gov.in
High temperature materials constitute a very important element of the
current as well as emerging programmes of ISRO which include
Reusable Launch Vehicles (RLVs), Air Breathing Propulsion (ABP)
technology and missions like Two Stage To Orbit (TSTO) and Single
Stage To Orbit (SSTO). Technology development programme for a
variety of high temperature materials addresses to the requirements of
various heat flux regions of these advanced space vehicles. It includes
special ceramics, ceramic matrix based composites, ultra high
temperature ceramics, thermal barrier and high emissivity coatings, high
temperature adhesives and engineering technologies to enable induction
of these materials for intended applications. The present paper brings out
the entire gamut of activities taking place in this important material area
beginning from lab scale developments, scaling-up of the process-
technologies till their qualification for practical use.
INFLUENCE OF NIOBIUM MICROALLOYING ON
THE MICROSTRUCTURE AND MECHANICAL
PROPERTIES OF HIGH CARBON NANO BAINITIC
STEEL
P Ponguru Senthila*, K Sudhakara Raob, Hillol Kumar Nandia, Suraj
Kumara, S Sankaranb, K Siva Kumara, Vemuri Madhua.
a
Defence Metallurgical Research Laboratory Hyderabad, India 500058.
b
Indian Institute of Technology, Madras, Chennai, India 600036.
Email: pgsenthil@dmrl.drdo.in
Carbide free nano bainitic steels have recently become a promising
material for several applications such as rails, armour etc. because of their
impressive combination of mechanical properties. Very high strengths up
to 2500 MPa have been achieved because of the very fine nano-scale
microstructure obtained through transformations at low austempering
temperatures [1]. However, the low ductility and impact toughness are
the limiting factors which prevent their use in several applications. It is
well known that alloying elements such as Nb and V are added in very
small quantity in order to improve strength and ductility of medium to
high carbon steels through Nb, V (C,N) precipitates. Influence of these
microalloying elements on the mechanical properties of nano bainitic
steel is not well understood. In present study, mechanical properties of
two high carbon nano bainitic steels with 0.06 wt% Nb and without Nb
addition have been studied. Both the steels were austenitized at 900oC
followed by austempering at 300oC. The TEM micrograph showing the
plates of bainite and inter-lath films of carbon enriched retained austenite
is shown in figure 1. The mechanical properties of the steels are given in
table 1. Nb addition results in a substantial increase in ductility (total %
elongation) from 16 % to 28 %. Effect of Nb addition on transformation
kinetics and microstructure is also discussed.
Figure 1: TEM micrograph Table 1: Mechanical properties
YS UTS
Material %El %RA
(MPa) (MPa)
B1 1262+40 1633+8 16+4 39+7
B1-0.06Nb 1187+1 1621+2 28+2 28+4
[1] F G Caballero et. al Very strong low temperature bainite, Materials
Science and Technology, 18 (2002) 279-284.


HOT ISOSTATIC PROCESSING OF HIGH
TEMPERATURE MATERIALS: CHALLENGES
G. Appa Rao a, *, B. Sreenu a and DVV. Satyanarayana a
a
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad
500058, India
* E-Mail address: gouduapparao@rediffmail.com
Hot isostatic processing (HIP) is widely used for consolidation of
spherical shape pre-alloyed powder into near-net shape components for
critical applications. In the present study, the inert gas atomized powders
of austenitic stainless steel and nickel base superalloys viz; Inconel 718
and EP741NP were subjected to HIPing under a set of conditions. The as-
HIPed materials have exhibited near theoretical density regardless of
alloy chemistry. However, the microstructure and mechanical properties,
particularly the ductility of the as-HIPed material is greatly influenced by
alloy composition and degree of powder cleanliness. Innovative HIPing
and heat treatment techniques have been adopted to improve the structure
and properties of the HIPed materials to accomplish the desired
combination of properties for specific applications. The details on
processing, structure and properties of HIPed materials shall be discussed
during the presentation.
Key words: Hot isostatic pressing, powder, superalloys
EFFECT OF ADDITION OF FLY ASH AND Al2O3
PARTICLES ON MECHANICAL AND
TRIBOLOGICAL BEHAVIOR OF Al MMC AT
VARYING LOAD, TIME AND SPEED
Vikas Verma1, P. C. Tewari2, Roshan Zameer Ahamed1, Syed Touseef
Ahmed3
1
Department of Mechanical Engineering, LORDS Institute of
Engineering and Technology, Hyderabad, 500091, India
2
Department of Mechanical Engineering, National Institute of
Technology, Kurukshetra 136119, India
3
Department of Civil Engineering, LORDS Institute of Engineering and
Technology, Hyderabad, 500091, India
Email id: vikasverma.iitr@rediffmail.com
The purpose of present research is to identify the effect of addition of
flyash and oxide particles on mechanical and tribological behavior of
Aluminium (Al) base metal matrix composite (MMC). The work involves
processing of Al MMC reinforced with flyash and Al2O3 particulates in
different proportions via stir casting route. Further their wear behavior
were studied at varying load (15 – 25 N), time (3 – 5 minute) and speed
(700 – 900 rpm). Scanning electron micrograph (SEM) of processed
composites revealed uniform dispersion of the coarser particles and
agglomeration due to finer particles. SEM image of pure Al alloy shows
the dispersed, broken alumina oxide layer in Al matrix. The broken oxide
layer particles are irregular in shape distributed in the Al matrix. SEM
image of Al Alloy prepared by reinforcement of flyash and Al2O3
particles revealed homogeneous grains and fine grain boundaries.
Appropriate proportion of flyash increased wettability during process
resulting in effective casting. Results confirmed increase of 48% in
hardness, 63% in strength and 58% in bending strength and considerable
reduction in weight loss measured after wear of processed Al composite
with 5%flyash and 12% Al2O3. Increase in bonding with reduced porosity
between particles were further improved by the applied pressure after the
casting. SEM micrograph of pure Al alloy worn surface revealed
presence of crack and fracture at high load, longer time and at high speed.
Presence of adhered oxide layer is observed in composite with 5%flyash
and 12% Al2O3 which restricted further wear of the composite. Al-
5%flyash-12%Al2O3 composite is preferred among all investigated
compositions.
44

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
EFFECT OF TEMPERING TEMPERATURE AND
TIME ON MICROSTRUCTURE AND
MECHANICAL PROPERTIES
OF 26MnB5 MARTENSITIC STEEL TUBES
S Usha Rani, M Preethi
Corporate Technology Center, Tube Investment of India Ltd, Chennai-
600 054, India
usharani1011@gmail.com
Anti-roll bar, sway or stabilizer bar, is a part of automobile suspension
system. It connects the right and left of the vehicle during turning and
resists swaying of the vehicle in sharp curves or road irregularities. This
tubular component undergoes fatigue failure during service. In the current
paper, the effect of tempering temperature and tempering time on fatigue
properties of 26MnB5 steel is discussed. The electric resistance welded
(ERW) tubes made of 26MnB5 were hardened above Ac3 temperature in
a sealed quench furnace. The tempering is done at 400°C, 450°C, 500°C
for 15, 30 and 60 minutes. The microstructure and the mechanical
properties have been analyzed by means of optical microscopy, hardness
testing and, tensile tests. The tubes were then bent to shape and tested for
fatigue. In this paper, the effect of tempering temperature and tempering
time on microstructure and mechanical properties are discussed and
compared with the fatigue properties of the component.
Key words: 26MnB5; Tempering temperature; electric resistance welded
tube; martensite; anti roll bars; fatigue
MICROMECHANICAL ANALYSIS OF EFFECT OF
MORPHOLOGY OF GRAPHITE IN CAST IRON
Ujjal Tewary1,*, Alankar Alankar2, Goutam Mohapatra1, Shyamprasad
Karagadde2, I Samajdar3
1
Asia Technology Innovation Center, John Deere India Pvt. Ltd., Pune,
India
2
Department of Mechanical Engineering, Indian Institute of Technology
Bombay, Mumbai, India
3
Department of Metallurgical Engineering and Materials Science, Indian
Institute of Technology Bombay, Mumbai, India
*Corresponding author, email: ujjaltewary@gmail.com
Cast iron exhibits its various mechanical properties because of its matrix
and second phase graphite precipitate. The size and morphology of
graphite and its inherent interaction with matrix has profound effect on
itsmechanical response. In the present work, crystal plasticity finite
element (CPFE) modeling technique is used to analyze the effect of
various morphology of graphite and its interaction with matrix
microstructure to predict the mechanical response of cast iron. The
framework is based on the visco-plastic self-consistentpolycrystal
plasticity with a dislocation density-based law used to describe
dislocation hardening. The elastic-plastic deformation of multiphase
aggregate and its mechanical response under uniaxial loading condition
are investigated. Local stress-strain map, texture evolution and
macroscopic stress-strain response because of various morphology of
graphite are analyzed.
MODELLING AND EXPERIMENTAL
VERIFICATION OF A CIRCULAR DEA
Arpit Srivastava and Sumit Basu
Department of Mechanical Engineering
Indian Institute of Technology, Kanpur, India.
E-mail: arpitks@iitk.ac.in, sbasu@iitk.ac.in
Soft dielectric elastomers, with very low stiffness and high permittivity
and electric breakdown strength, hold promise as candidate materials for
a variety of applications including, in energy harvesting, as actuators1 and
biological muscles2. As actuators in particular, a number of applications
have emerged where, utilising coupled electro-hyperelasticity under very


high electric fields in thin, membrane-like structures, large actuation has
been achieved. Moreover, the theoretical framework for electro-
hyperelasticity of these materials has also been established3. But long
time durability of these devices, is still a matter of concern. The concern
arises primarily from the fact that these soft elastomers not only
physically age with time, but are also highly rate dependent. We have
used an equi-biaxially pre-stretched circular dielectric elastomer
membrane attached to a rigid frame with a load hung at the center to
demonstrate the effects of viscoelasticity. The membrane is then loaded
with oscillating voltage and the motion of the center of the membrane is
tracked with a laser displacement sensor, over many time periods.
As the membrane is taken through a large number of cycles, the response
slowly drifts. For a very soft elastomer like VHB, the drift can be
sometimes discerned in as few as 20-30 cycles of operation. To model the
deformation and the drift with time, a coupled electrostatic, visco-
hyperelastic large deformation model for the elastomer has been
incorporated into an explicit Finite Element framework. The response of
the elastomer (VHB in our case) under pure oscillating mechanical loads
(in a dynamic mechanical analyzer MetraviaB DMA+100), as well as
under quasi-static uniaxial loading have been tested and calibrated using
a Prony series and the Ogden model respectively. Further, the variation of
the electric permittivity of the material with equi-biaxial prestretch has
been calibrated using a dielectric spectroscope (Broadband Spectroscopy,
Novacontrol Technologies, Germany). Incorporating the experimental
data into our finite deformation electro-visco-hyperelastic model, we
have been able to reproduce the experimental response of the VHB
membrane fixed to a rigid frame very accurately. In particular, we have
been able to capture the drift in the response with time and identified a
threshold frequency of operation below which this drift is minimal.
Though the modelling has been verified for VHB only, the framework is
general enough to be used to assess the effectiveness of any dielectric
elastomeric material, used as a membrane under any three dimensional
electro-mechanically loaded configuration. We are in the process of
evaluating a number of such materials and configurations.
References
R. Pelrine, R. Kornbluh, Q. Pei, J. Joseph, High-speed electrically
actuated elastomers with strain greater than 100 percent Science 287,
836–839 (2000).
Brochu, P. and Pei, Q. (2010), Advances in Dielectric Elastomers for
Actuators and Artificial Muscles. Macromol. Rapid Commun.,31: 10–36.
doi:10.1002/marc.200900425.
McMeeking RM, Landis CM. Electrostatic forces and stored energy for
deformable dielectric materials. Journal of Applied Mechanics. 2005 Jul
1;72(4):581-90.
Suo Z.,Theory of dielectric elastomers, Acta Mech. Solida Sin., 23
(2010), pp. 549-578.
EFFECT OF HYGROTHERMAL AGING ON THE
INTERLAMINAR SHEAR STRENGTH OF A
CARBON FIBER COMPOSITE
Kishora Shetty1, Shylaja Srihari2, CM Manjunatha3
1
Academy of Scientific and Innovative Research, CSIR-NAL, Bangalore -
560017, India
2
CSMST, 3STTD, CSIR-National Aerospace Laboratoires, Bangalore -
560017, India
Email of corresponding author: kishora_shetty@yahoo.com
Carbon Fibre Reinforced Plastic (CFRP) composites are used many
applications in aerospace structures due to their high specific strength and
stiffness. Composite aircraft structures are usually exposed to a range of
environmental conditions such as hygrothermal, UV radiation, chemical
environments, biological condition etc., in their service life and may
degrade. Moisture absorption at different hygrothermal conditions and its
effects on properties of CFRP composites is a useful parameter to
designers and application engineers.
In this study, UD carbon fiber/epoxy composite laminates were fabricated
(HexPly® M21E/34%/UD/194/IMA) from prepreg using standard
autoclave process. ILSS test specimens were cut and prepared from
theses laminates. Hot-wet specimens were aged at two different
45
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

conditions; 750C/ 85% RH, 550C/ 100% RH until attaining moisture

absorption saturation. Three-point bend tests were conducted as per
ASTM test standard specifications using a 25 KN servo-hydraulic test
machine to determine ILSS properties for aged and unaged material.
Respective hot-wet conditions were maintained even during the
mechanical tests. Tests results show that moisture absorption rate
increases gradually and attains saturation at about 2 wt.% under both
conditions. Inter laminar shear strength reduced significantly by about
30% due to presence of moisture. Microscopic observation of failed
samples is under investigation to study the fracture behavior which will
be reported in the manuscript.

46

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3C:LifeExtensionofAeroengineComponents&Structures
andStructuralIntegrityIV
Chairman:RKSatpathy,DMRL
SessionCoordinator:MPhaniSuryaKiran,DMRL
16301657 InvitedLecture:RemainingLifeAssessmentofAeroEngineComponentsDMRL’s
PerspectivesandExperience
AVenugopalRao,DMRL
17091721 LifeExtensionofUAVs:ACaseStudyofIndianUAVs
ManuJain,SRajashekar,VSubramanian,VMaharajanandVAshokRangan
AeronauticalDevelopmentEstablishment,DRDO,Bangalore
17331745 PhysicalManifestationofa90/95inRemnantLifeRevisionStudiesofAeroengine
Components
VamsiKrishnaRentala,PhaniMylavarapu,J.P.Gautam,Gp.Capt.B.V.N.Shiva,
KGopinathandVikasKumar
UniversityofHyderabad,Hyderabad
17451757 StructuralIntegrityAnalysisandLifeEstimationofTurbineRotorUsingVibration
SignatureasaTool
ShahnawazAhmad,AdityaSuman,NSVyas,BVNShiva,AVenugopalRao,DVV
SatyanarayanaandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
17571809 DynamicLoadCalibrationofaFatigueTestSystem
N.Shivakumar,A.SomayyaandR.Sunder
BangaloreIntegratedSystemSolutionsPvt.Ltd,Bangalore
18091821 Developmentofadirectcurrentpotentialdropsystemformeasurementof
specimencrackgrowthmeasurement
D.Rohit,H.Mahesh,Ramesh,M.MuraliandR.Sunder
BangaloreIntegratedSystemSolutionsPvt.Ltd.,Bangalore
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
REMAINING LIFE ASSESSMENT OF
AEROENGINE COMPONENTS:
DMRL’S PERSPECTIVES AND EXPERIENCE
 
A Venugopal Rao
Scientist ‘G’
DMRL, Hyderabad
venugopal@dmrl.drdo.in

The efficient management of military flying assets is inescapable for
every nation in the world, to ensure their optimal exploitation, in light of
the resource constraints and unavoidable exigencies often encountered in
security forces’ operations. Aeroengine components in the hot section of
gas turbines are critical to the performance, mission reliability, and safety
during the operation of military aircraft, where the service spectra are
highly random and relatively severe in terms of the loading rates. The
increasingly demanding design specifications in terms of higher strength-
to-weight ratios coupled with hostile working environment expose
fracture-critical parts, such as the turbine discs and blades, to complex
thermo-mechanical loading patterns. The Remaining Life Assessment
(RLA) of such components is a complex multidisciplinary task involving
diverse expertise such as Metallurgical and Mechanical characterization
of materials, Fracture Mechanics, Numerical Modeling, and Non
Destructive Evaluation (NDE). DMRL has been active for over a decade
in its efforts for evolution of scientific methods for RLA, based on
extensive laboratory coupon-level material characterization in terms of
fatigue and creep, to be followed by the scale-up of results to actual
components. Finite Element Analysis (FEA) has been an indispensable
engineering tool for evaluation of the mechanical variables that determine
crack initiation and growth (damage tolerance), apart from material
degradation (damage mechanics) prior to physical failure. A major
achievement in these efforts has been the successful application of this
scientific knowledge on RLA to practical use by the armed forces for
upward life revision of the service life for critical equipment, with due
recommendation by the relevant certification agencies. The RLA as a
function of initial condition of components and their service-induced
degradation has been the key factor to be rigorously established under
this task. DMRL’s futuristic perspectives in RLA include, among other
things, development of an integrated scientific approach involving
material & product design - manufacturing process – performance
evaluation of engineering systems relevant to defence forces in specific
and industry in general.
LIFE EXTENSION OF UAVs: A CASE STUDY OF
INDIAN UAVs
Manu Jain, S Rajashekar, V Subramanian, V Maharajan, V Ashok
Rangan
ADE, DRDO, MOD, New Tippasandra, Bangaluru-560075
manujain@ade.drdo.in
UAVs are now integral part of Armed forces. They are being used in dull,
dirty, dangerous and demanding missions. These missions restrict the life
of UAV thus increasing the cost of UAV operations. To keep the
operational cost low it is essential to utilize UAVs to their full potential
and life. The process of aging of UAV which results in structural and
performance deterioration cannot be stopped but its impact can be limited
by using preventive measures, proper maintenance and implementing the
required changes. A well-used UAV can be a befitting candidate for Life
extension. Life extension of UAVs cannot be just on economic factors
but also on reliability and performance in the extended life. This paper
presents the case study of life extension of Indian UAVs which are
designed and developed by Aeronautical Development Establishment,
Bengaluru. These UAVs have been field tested and operationalized by
Armed forces under varying environmental and usage conditions. The
procedure, conditions and lessons learnt during the life extension process
of UAVs are described. Life extension of these UAVs has resulted in
considerable amount of cost and time saving to the users.


PHYSICAL MANIFESTATION OF A90/95 IN
REMNANT LIFE REVISION STUDIES OF AERO-
ENGINE COMPONENTS
Vamsi Krishna Rentala1, Phani Mylavarapu2, J.P.Gautam1,
Gp.Capt.B.V.N.Shiva2, K Gopinath2, Vikas Kumar 2
1
School of Engineering Sciences and Technology, University of
Hyderabad, Hyderabad, India
2
Defence Metallurgical Research Laboratory, Hyderabad, India
Email of corresponding author: vamsikrishnarentala@uohyd.ac.in
Damage Tolerance (DT) lifing methodology for aeroengines requires the
reliability of Non-Destructive Testing (NDT) techniques used.
Probability of Detection (POD) for measuring NDT reliability yields the
a90/95 (flaw detection with 90% probability and 95% confidence) value.
This a90/95 or the largest crack size missed by an NDT technique is in
general incorporated into the DT calculations for estimating the
remaining fatigue cycles the component can withstand before failure.
Hence, it is essential to estimate the a90/95 value to the closest accuracy.
However, the NDT inspection data at a site containing multiple cracks
results in ambiquity of HIT/MISS approaches to be adopted for the
estimation of POD or a90/95 values. Several approaches were attempted by
the researchers but with limited success due to the restrictions in
implementing them. Moreover, to the best of the author’s knowledge, the
physical significance of the a90/95 value and the different HIT/MISS
approaches on the remnant life calculations of aero-engine components
was not available in the literature. Therefore, in the current study,
physical manifestation of a90/95 in remnant life calculations was attempted
along with addressing the effect of maximum flaw size and sum of flaw
sizes approaches for inspection of natural fatigue cracks in a nickel based
superalloy using fluorescent penetrant (FPI) and eddy current inspection
(ECI) techniques. It was observed that ECI technique provides the higher
number of remnant cycles than the FPI technique due to its higher
sensitivity. In addition, it was also observed that regardless of the NDT
techniques used maximum flaw size approach results in higher number of
fatigue cycles. However, the actual number of remnant cycles of the
component can be exactly known when the current NDT techniques are
capable of resolving a group of flaws in a particular location.
STRUCTURAL INTEGRITY ANALYSIS AND LIFE
ESTIMATION OF TURBINE ROTOR USING
VIBRATION SIGNATURE AS A TOOL
Shahnawaz Ahmad1, Aditya Suman, N S Vyas, BVN Shiva1, A
Venugopal Rao1, DVV Satyanarayana1 and Vikas Kumar1
1
Defence Metallurgical Research Laboratory, Hyderabad, India
Email: shahnawaz@dmrl.drdo.in
Turbine rotor is a critical hot end component of an aircraft engine which
is exposed to high thermo-mechanical stresses during service. It is
therefore imperative to closely monitor the design as well as overhaul
schedule of turbine rotor assembly based on severity of loading cycle to
avert any catastrophic failure. The present work aims at quantifying the
relation between rotor vibrations characteristics and fatigue in order to
assess the remaining life of component and to develop a holistic life
prediction methodology. Extensive mechanical testing such as tensile,
fatigue, fracture toughness and fatigue crack growth (FCGR) has been
carried out using ASTM standard to generate relevant material data for
lifing. Also, an attempt has been made to investigate the influence of
crack on vibration parameters of a blade-disc assembly of an aero-engine
gas turbine. Initial investigations are carried out on idealizations
involving cantilever beams with uniform cross-section. The procedures
are then extended to free standing turbine blades with asymmetric
aerofoil cross section and further to the flexible blade-disc assembly of
the gas turbine. Initially, a free vibrations analysis has been carried out
for the healthy system and the next ended to system with cracks in order
to identify the influence of cracks on natural frequencies and mode
shapes. Subsequently, a forced vibration analysis has been performed and
a methodology has been developed using Lazan’s law to extract modal
damping ratios from the strain energies of the system under excitation
pressure fluctuations. The modal damping ratios thus obtained represent
the material damping properties of the components under stress. The
47
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

possibility of employing these modal damping ratios as indicators for the

presence of cracks / defects in the system, where it is difficult to do so
through change in natural frequencies or mode shapes, is outlined.

DYNAMIC LOAD CALIBRATION OF A FATIGUE

TEST SYSTEM

N. Shivakumar, A. Somayya1 and R. Sunder

BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author, E-mail:
somayya@biss.in, Mob: +91-9880-432-322

Accelerated testing of materials and components for endurance demands

movement to higher frequency of cycling. There are several ways in
which test frequency may be restricted. In the case of composites and
certain steels, the tendency of specimen heating limits test frequency to
under 20 Hz. The quality of load control can be adversely affected by test
frequency being in the proximity of resonant frequency. Limitations of
the test system itself by way of servo-valve or pump flow limitations and
frequency response can be a limiting factor. In many practical cases,
particularly involving reasonably stiff test specimens, none of these
factors may apply and increasing test frequency turns into an attractive
prospect, as this can reduce test duration, improve productivity and
reduce the cost of fatigue testing. However, incorrect test results may
result in the event the test system is not verified for dynamic load
calibration.

The proposed paper describes a process to verify a test system for

dynamic calibration. The proposed process permits identification and
correction of errors in load readout accumulating from different sources.
These include inertial loads from the load train, strain bridge response,
signal conditioner filter response and the response of the A-to-D
converter.

DEVELOPMENT OF A DIRECT CURRENT

POTENTIAL DROP SYSTEM FOR
MEASUREMENT OF SPECIMEN CRACK
GROWTH MEASUREMENT

D. Rohit1, H. Mahesh, Ramesh, M. Muraliand R. Sunder
BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author, E-mail: rohit@biss.in,
Mob: +91-9880-432-322

In material testing, measurement of specimen crack growth under

specified loading conditions is crucial in understanding the behavior of
material with defects in it and in estimating the residual life of it. There
are various devices for measurement of crack growth like crack opening
device (COD). However, these devices are limited to room temperature
or short range of high range of high temperatures, say up to 300 0C.
Direct current potential drop (DCPD) is one such system which facilitates
the measurement of crack growth of specimen under high temperature or
any other harsh environmental conditions. The effective functionality of
DCPD requires precise measurement of voltage and stable current source.
The state-of-the-art solutions are limited by the micro voltmeters. The
present paper describes the pulsed DCPD system and measurement
process developed at BISS for precision measurement of crack growth.
The technique does not require electrical isolation of the test specimen.
Further, it is immune to temperature fluctuation leading to distortion of
specimen resistance as readouts are non-dimensionalised.

48

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3D:Corrosion,EnvironmenteffectsonMechanicalBehaviour
andSIV

Chairman:IGurrappa,DMRL
SessionCoordinator:SNSahu,DMRL
16301657 InvitedTalk:Grainsizeandgrainsizedistributioneffectsonthecorrosionbehavior
ofmaterials
SrikantGollapudi,IndianInstituteofTechnology,Bhubaneswar
17091721 Numericalandexperimentalcomparativestudyofaluminiumandhybridmounting
interfacesoflaunchvehicleavionicsforweightreduction
GVamsiKrishna,TarakNathDe,RajeshKumarBurman,BVeeraSekharand
V.GovindaRao
AdvancedSystemsLaboratory,Hyderabad
17331745 ExtractionofOpeningandClosingStatesofCrackedStructureusingAdaptive
VolterraFilterModel
J.PrawinandA.RamaMohanRao
CSIRStructuralEngineeringResearchCentre,Chennai
17451757 StudyforAnalysisofEffectofMachiningParameter&ToPredicttheBehaviorof
PropellantGrainDuringMachiningOperation
RohitKumarMahalle,O.P.Manhar,J.C.Chaudhary,S.S.AhamadandG.K.Naik
SFComplex,DRDO,Jagdalpur
17571809 FatigueCrackGrowthStudiesonPowerPlantPipingMaterialsunderCorrosive
Environment
S.Vishnuvardhan,M.Saravanan,P.GandhiandG.Raghava
CSIRStructuralEngineeringResearchCentre,Chennai
18091821 EffectofMoistureonHighStrainRatePerformanceofUHMWPEfiberbased
Composite
HemantChouhan,NeelanchaliAsija,AishaAhmed,KartikeyaandNaresh
Bhatnagar
IndianInstituteofTechnologyDelhi
 



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

GRAIN SIZE AND GRAIN SIZE DISTRIBUTION

EFFECTS ON CORROSION BEHAVIOUR OF
MATERIALS
Srikant Gollapudi
School of Minerals, Metallurgical and Materials Engineering
IIT Bhubaneswar
srikantg@iitbbs.ac.in

The talk will discuss the work carried out to understand the influence of
grain size and grain size distribution on the corrosion behaviour of
materials. In the first part, the influence of grain size was understood
through corrosion studies on electrodeposited Ni-22Co having a grain
size of 30 nm. Through controlled annealing experiments at 500 and 700
°C, the grain size of this material was varied. Corrosion experiments were
carried out on the as-deposited and annealed Ni-22Co samples in mild
sulphuric acid. A Hall-Petch type of correlation was found between
corrosion current density, a measure of corrosion performance, and the Figure-1: 3D model of mounting interface and launch vehicle avionics
grain size. Additionally in order to understand the influence of grain size
on the efficiency of corrosion inhibition, tryptamine was used as an
inhibitor. It was found that corrosion inhibition was higher in the fine Table-1: Tabulated values of FOS and vibration response of two bracket
grained as-deposited material compared to the relatively coarse grained configurations
annealed samples. The grain size dependence of passivation and Vibration response at critical
breakdown potential was also studied. Bracket Weight location of avionic package (grms)
In the second part, the impact of grain size distribution on corrosion Configuration of Axis of vibration test
behaviour of materials will be discussed. Using analytical equations, bracket
correlations were established between corrosion rate and grain size Long Pitch Yaw
distribution. These equations suggest that for the same average grain size,
a broader grain size distribution leads to increased corrosion resistance in AA 2014 bracket 15 Kg 7.55 7.85 9.96
a non-passivating environment and vice versa in a passivating Hybrid 1.7 Kg 9.81 8.26 11.24
environment. These relationships are also used to describe the corrosion configuration
behaviour of bimodal microstructures.
1 Crictical location of avionic package
10

grms = 7.85(AA 2014 bracket)

grms = 8.26(Hybrid bracket)
NUMERICAL AND EXPERIMENTAL 10
0 (156.25,1.0491)
(151.3672,0.6753)
COMPARATIVE STUDY OF ALUMINIUM AND
Power Spectrl Density (g /Hz)

HYBRID MOUNTING INTERFACES OF LAUNCH

2

-1
10
VEHICLE AVIONICS FOR WEIGHT REDUCTION
-2
10
G Vamsi krishna1,TarakNath De2, Rajesh Kumar Burman3, B Veera
Sekhar4, V. Govinda Rao5
1,2,3,4
Advanced Systems Laboratory, Hyderabad, India-500 058 10
-3

5
Research Center Imarat, Hyderabad, India – 500 069
Email of corresponding author:taraknathde@asl.drdo.in
-4
10
200 400 600 800 1000 1200 1400 1600 1800 2000
Weight is a paramount parameter for launch vehicle application. Avionics Frequency (Hz)

are used for command, control and guidance of launch vehicle. Interface
brackets are used for mounting these avionics to the launch
vehiclechassis. Dynamic loads and vibration responses dominate the
design criteria for these interfaces (brackets). The weight sensitivity on
range is more prominent for the upper stages of the launch vehicle. To
improve the performance of launch vehicle, employment of light weight
hybrid (honeycomb with face sheets at top and bottom) brackets for
mounting launch vehicle avionics is explored in this study. Hybrid
brackets are configured and designed to withstand local buckling loads at
mounting locations due to bolt pre-loads because of bolt torque. For case
under study, honeycomb bracket configured with 25mm aluminium
honey comb structure with 1mm face sheet at top and bottom and all
around the periphery is employed for mounting of two guidance packages
of weight 10.5 kg and 1.5 Kg. Both numerical and experimental
comparative study with Aluminium and hybrid brackets is carried out.
Comparable vibration responsesare obtained along all three axes for the
two bracket configurations with packages mounted. For both the brackets,
numerical FE analysis is carried out and sufficient Factor of Safety (FOS)
for 60g acceleration loads is confirmed. For the case under study, meeting
all the functional requirements weight of hybrid bracket is 1.7 kg
compared to aluminium bracket weight of 15 kg. It is concluded that
tremendous weight saving of mechanical interfaces can be gained without
compromising in factor of safety and amplification of vibration
responses.
Figure-2: Vibration response spectra on avionic package in pitch axis of
two bracket configurations
EXTRACTION OF OPENING AND CLOSING
STATES OF CRACKED STRUCTURE USING
ADAPTIVE VOLTERRA FILTER MODEL
J. Prawin, A. Rama Mohan Rao
CSIR Structural Engineering Research Centre, Chennai
Email of the corresponding author: prawinpsg@gmail.com
Fatigue cracks often exist in structures during the service life of the
structure and need to detect at its earliest stage before it leads to
catastrophic failure. The fatigue breathing crack problem exhibits an
instantaneous change in the stiffness of the structure due to change in the
state of the cracked domain from open to close and vice versa. Therefore
these fatigue cracks exhibit breathing like phenomena, hence widely
referred to as breathing cracks. The present work attempts to separate the
opening and closing of the cracked structure from the global response
using adaptive Volterra Filter Model. Adaptive Volterra Filter model is a
generalization of the linear convolution and the impulse response
function to nonlinear structures in discrete form. The dynamical
properties of the nonlinear system in the Volterra series representation or

49


SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
adaptive Volterra Filter Model are completely characterized by a
sequence of multi-dimensional weighting function called Volterra kernels.
These Volterra kernels are the backbone of adaptive Volterra filter
approach in nonlinear analysis and system identification. A diverse range
of techniques are reported in the literature for Volterra kernel estimation.
Adaptive Volterra series based Least square is used in the present work to
estimate Volterra kernels. The various states of the cracked structure are
then estimated using these Volterra kernels. Numerical simulation studies
are carried out on a simple beam example to demonstrate the capability of
the proposed adaptive Volterra filter in extracting the opening and closing
state response from the global response of the cracked structure.
STUDY FOR ANALYSIS OF EFFECT OF
MACHINING PARAMETER & TO PREDICT THE
BEHAVIOUR OF PROPELLANT GRAIN DURING
MACHINING OPERATION
Rohit Kumar Mahalle*, O.P. Manhar, J.C. Chaudhary,S.S. Ahamad, G.
K. Naik
DRDO, S F Complex, Airport Terminal Building, Jagdalpur-494001(CG)
*
rohitkumar@asl.drdo.in
Solid Propellant Grain machining is one of the critical and hazardous
operations in Solid Propellant Rocket Motor (SRM) processing.
Propellant grain surfaces are casted as per the feasible mandrel shape, but
mostly the final grain surfaces are achieved by propellant machining
operation, that generates various shapes and contours over casted Solid
propellant grain. Some of these machined surfaces are directly exposed to
the ignition and other acts as interface for further processing. These
machined surfaces over propellant grain are generated by using CNC
controlled Vertical Turn Mill Center.
Machining operation depends on three major machining parameters viz.
speed, feed and depth of cut. Being a visco-elastic material machining of
solid propellant surfaceis carried out with Special purpose Hollow
Contouring Cutter with HSS Conical Insert.Solid Propellant in SRM is
the prime mover to propel the payload to a particular range as per the
mission requirement. Machining of extra propellant may lead to deviation
from the target to be achieved. Due to visco-elastic behavior of the
propellant, during machining, propellant surface are compressed and after
machining, partially returns back. Thusthe machined depths are varying
with consecutive depth of cuts.
This paper focuses on study of effect of depth of cuts on propellant grain
surface keeping cutting speed and rotary table feed within a range. Study
is also done to analyze & arrive at a conclusion to predict the machined
depth over propellant grain, resulting in elimination of repetitive check
cuts during propellant machining operation.
FATIGUE CRACK GROWTH STUDIES ON
POWER PLANT PIPING MATERIALS UNDER
CORROSIVE ENVIRONMENT
S. Vishnuvardhan1*, M. Saravanan2, P. Gandhi3, G. Raghava4
1
Senior Scientist, 2 Scientist, 3 Chief Scientist & Head, 4 Forrmerly Chief
Scientist
Fatigue & Fracture Laboratory, CSIR - Structural Engineering Research
Centre
CSIR Campus, Taramani, Chennai - 600 113
* E-mail of corresponding author: svvardhan@serc.res.in
Structures such as offshore structures, bridges, power plant structures and
aircraft which are subjected to repetitive environmental and operational
loads are also exposed to corrosive environment during their service life.
Estimation of corrosion fatigue crack growth (CFCG) rate is of great
importance in life prediction and safety assessment of engineering
structures which are exposed to aggressive environment and subjected to
repeated load applications. In the present studies, fatigue crack growth
(FCG) experiments were carried out on Eccentrically-loaded Single Edge


notch Tension [ESE(T)] specimens made of SA 333 Gr. 6 and SA 516
Gr. 70 steels under demineralized water and 3.5% NaCl aqueous
environments. The corrosion process was accelerated by increasing the
corrosion current, using an external current source and the experiments
were conducted at two different levels of corrosion current by applying
constant Direct Current (DC) of 0.2 A and 0.3 A. The experiments were
carried out under constant amplitude cyclic sinusoidal loading; the stress
ratio was maintained as 0.1 and the test frequency was either 0.25 Hz or
0.50 Hz. Crack growth in the length direction was continuously observed
and the images were recorded at regular intervals of fatigue cycles.
Crack growth rate (da/dN) and stress intensity factor range ('K) values
were evaluated at incremental values of loading cycles and crack length.
Under demineralised water environment, crack growth rate was observed
to be more in SA 516 Gr. 70 steel when compared with that in SA 333
Gr. 6 steel. In the case of SA 333 Gr. 6 steel, crack initiation life
increased by 50% and fatigue life increased by 19% when the applied
external current value decreased from 0.3 A to 0.2 A, under 3.5 % NaCl
aqueous environment. Details of the experiments carried out and results
of the studies are discussed in the paper.
Keywords: Fatigue crack growth, corrosive environment, piping
materials, ESE(T) specimen, fatigue damage
EFFECT OF MOISTURE ON HIGH STRAIN RATE
PERFORMANCE OF UHMWPE FIBER BASED
COMPOSITE
Hemant Chouhan, NeelanchaliAsija, Aisha Ahmed,Kartikeya, Naresh
Bhatnagar
Mechanical Engineering Department, Indian Institute of Technology
Delhi, HauzKhas,
New Delhi -110016, India
E-mail: hemant.chouhan78@gmail.com
The presented study investigates the effect of moisture absorption on the
compressive high strain rate performance of Ultra High Molecular
Weight Polyethylene-Synthetic Rubber(UHMWPE-SR) composite along
the thickness direction. Split Hopkinson Pressure Bar is employed to
investigate the dynamic compressive properties followed by damage
studies. The cylindrical test specimens having aspect ratio of 0.5 ± 5%
were machined from flat composite laminate fabricated by compression
molding at 35 bar and 115 qC. Two types of specimens were used for
high strain rate testing. First set of specimen was oven dried at 65 qC and
second set was dipped in potable water as per NIJ standard 0101.06 for
24 hours. An average increase of 7% was measured in the weight of
composite just after the removal from potable water. For identical
incident energy, the strain rates attained by the dry and wet composite
specimens werein the range of 2100 /s - 4220 /s and 1700 /s -3730 /s,
respectively.The stress growth as a function of rate of compressive
loading was witnessed from 200 MPa to 460 MPa for the dry composite
and from 141 MPa to 210 MPa for the wet composite. The dry composite
attained higher strain at constant peak stress in case of dry composite and
lower total strain with continuously falling stress in case of wet specimen.
The dry composite specimen was recovered intact till the strain rate of
4050 /s. Further higher loading rates resulted in the delamination of dry
composite specimen.The behavior of wet composite under high strain rate
loading was significantly different. Physically intact specimen was
recovered at the lowest loading rate of 1700 /s;further higher loading
rates resulted in macroscopic damage of the wet composite. Significant
property degradation is an indicator of the ill effect of moisture on
UHMWPE-SR composite.

50
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3E:NDEandStructuralIntegrityVI
Chairman:TJayakumar,DMRL
SessionCoordinator:AmretenduMukhopadhyay,DMRL
16301657 InvitedTalk:Aperspectiveonqualityassurance,nondestructiveinspectionand
ageingmanagementofnuclearplantcomponents
BPCRao,IndiraGandhiCentreforAtomicResearch,Kalpakkam
17331745 DevelopmentofInsituInspectionMethodologyforCompositeStructureswith
InfraRedThermalImagingTechnique
S.KshamaandS.KalyanaSundaram
CouncilofScientificandIndustrialResearch,Bangalore
17451757 UseofFullfieldMeasurementsforUnderstandingAcousticEmission(AE)Signals
from15CDV6ESRSteelSpecimens
DigendranathSwain,B.Binu,Yogesh,KKPurushothaman,GSudarsanaRao,Binu
PThomas,ThomasKurianandJebyPhilip
VikramSarabhaiSpaceCentre,ISRO,Trivandrum
17571809 EffectoffibersizeonModeIfracturetoughnessofglassfiberreinforcedepoxy:An
experimentalinvestigation
M.K.SinghandR.Kitey
IndianInstituteofTechnologyKanpur
18091821 StructuralIntegrityAssessmentofFilamentWoundCompositePressureVessel
UsingThroughTransmissionTechnique
SameerkantBehera,SKSahoo,LokeshSrivastavaandA.S.SrinivasaGopal
AdvancedSystemsLaboratory,DRDO,Hyderabad
18211833 AbrasivewearstudiesonspecialcompositeAl2O3ZrO25CaOfortribologicalapplications
Abhinav
AllianceUniversity,Bangalore
18331845 ApplicationofFrugalInnovationinFireSafety
PrateepRoy
GhardaInstituteofTechnology(GIT),Ratnagiri,Maharashtra
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
A PERSPECTIVE ON QUALITY ASSURANCE,
NON-DESTRUCTIVE INSPECTION AND AGEING
MANAGEMENT OF NUCLEAR PLANT
COMPONENTS
B P C Rao
Chief Project Engineer & Associate Director
Fast Reactor Fuel Cycle Facility (FRFCF)
Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, TN-
603102
bpcrao@igcar.gov.in
Stringent quality assurance program and effective periodic non-
destructive evaluation (NDE) hold the key to prolonged life of nuclear
plant components. During manufacturing stages, due emphasis must be
given to design and implementation of effective quality assurance (QA)
plans to minimise unacceptable flaws, distortion and other degradations
that disturb the structural integrity of components. Subsequent to
installation, off-line or on-line inspections and continuous monitoring of
critical regions is essential for early detection of corrosion and
microstructure degradations as part of plant life management. A few
important considerations include accessibility, pre-service inspection data
storage & retrieval, knowledge management, and use of advanced
technologies viz. modular instrumentation, array sensing, rapid imaging,
robotic inspections, and model based POD. The presentation will cover
the advances in NDE and QA through a few case studies including
control of distortion and residual stresses e.g. stainless steel welds in
glove boxes for handling radioactive materials. Finally, it will enlist the
future trends in NDE and QA for structural integrity assessment and life
management of nuclear plant components.
DEVELOPMENT OF IN-SITU INSPECTION
METHODOLOGY FOR COMPOSITE
STRUCTURES WITH INFRARED THERMAL
IMAGING TECHNIQUE
Kshama S., Kalyana Sundaram S.
Scientist, Structural Technologies Division,
CSIR-National Aerospace Laboratories
Bengaluru– 560017
kshama@nal.res.in
Capability of thermal imaging technique on detection and quantification
of various damages and defects on composite structural components are
demonstrated for the purpose of developing in-situ NDE. Components
undertaken for the experimental evaluation are composite panels,
airframe segment and CFRP specimens. Commonly encountered
fabrication defects on composite panels such as inclusion and operational
induced damages like delamination, core crushing, laminate tearing are
focused here for the evaluation with InfraRed Thermography. Difficulties
arising on practical in-situ inspection of composite structures were also
addressed here with selection of inspection methodology and optimized
inspection parameters.
Detection of various sizes of defects and damages occurring on
composite panels at various depths were done with optimizing inspection
parameters such as duration & power of excitation, distance between the
camera and structure etc. It is revealed that the fabrication defects like
inclusions of size greater than the depth of presence and having high /
low thermal conductivity than composites were detected with high
contrast. Determination of probability of detections for various sizes of
defects/damages and depth of presence with respect to inspection
parameters were also presented here. PoD greater than 0.9 were obtained
for the inclusions presented in CFRP laminates with flashmode of
excitation than transient.
Key Words: InfraRed Thermography, Composite Damage, Service
damage, PoD


USE OF FULL-FIELD MEASUREMENTS FOR
UNDERSTANDING ACOUSTIC EMISSION (AE)
SIGNALS FROM 15CDV6 ESR STEEL SPECIMENS
Digendranath Swain#1, Binu B1, Yogesh1, K K Purushothaman1,
G Sudarsana Rao2,Binu P Thomas1, Thomas Kurian3, Jeby Philip1
1
Experimental Mechanics Division, STR Entity, Vikram Sarabhai Space
Centre, ISRO, Trivandrum, India
2
Matrial Characterization Division, MME Entity, Vikram Sarabhai Space
Centre, ISRO, Trivandrum, India
3
Hardware Design & Realization Divn., PRSO Entity, Vikram Sarabhai
Space Centre, ISRO, Trivandrum, India
#
Corresponding author: digendranath@gmail.com
One of the main issues with structural integrity monitoring through
acoustic emission (AE) technique is the lack of correlation of the critical
AE signals with the quantitative mechanical degradation behavior of the
components and structures. In this paper, 3D Digital Image Correlation
(3D-DIC) is used as a complementary quantitative whole-field
displacement and strain mapping technique to assist in characterizing AE
signals obtained from various 15CDV6 electro slag refined (ESR) steel
specimens. Towards this objective, standard surface cracked tensile
(SCT) and plain tensile (PT) specimens were experimented to understand
failure behavior of materials. The surface cracks were generated on welds
whereas the PT specimens were without any welds. Two parameters
namely the crack opening displacement (COD) and the strain fields near
the crack tips generated from SCT specimens were correlated with
various AE parameters to establish various stages of material
degradation. Similarly, in PT specimens AE signals corresponding to
initiation of yielding and growth of an internal defect were identified
correlating with the quantitative parameters from DIC. The full-field
parameters in tandem with AE data helped in understanding the
mechanical nature of the failures and material degradation to a significant
extent. Hence, in future such studies combining qualitative NDT
techniques with quantitative full-field measurements must be carried out
to bring more insight to the failure behavior and structural integrity of
materials and structures.
FILLER SIZE AND VOLUME FRACTION EFFECT
ON THE FRACTURE BEHAVIOUR OF MILLED-
FIBRE COMPOSITES
M. K. Singh1, R. Kitey2
1
Ph.D Student, 2Associate Professor
Department of Aerospace Engineering, IIT Kanpur-208016, India
Email of corresponding author: manojmsk@iitk.ac.in
Filled polymer composites have wide variety of civil and defence
applications. Due to high specific strength and high specific stiffness their
usage in automobile and aviation industries has grown manifold. While
spherical or irregular shaped particles are often used to reinforce
polymers, the slender filler reinforcementis not very common due to the
involved processing complexities,even if theslender filler compositecan
be tailored to achieve the enhanced directional properties. In current
investigation the influence of milled-fibre size and volume fraction on the
fracture behaviour of glass filled epoxy composite is analysed.
The epoxy matrixis preparedby mixingDGEBA(Diglycidyl Ether of
Bisphenol-A) resin and MTHPA (Methyltetrahydrophthalic
Anhydride)hardenerin equal proportion by weight. A small amount
of2,4,5tris[(dimethylamino)methyl]Phenolis usedto accelerate the
polymerization process. Three different sizes of 16 m diameter milled
glass fibre, 1/4”, 1/8” and 1/32” long,are reinforced into the epoxy matrix
up to 4% volume fraction. The fracture tests are conducted by following
ASTM D5045-14 standards. The composites exhibit monotonically
increasing fracture toughness (KIc) with filler volume fraction (Vf) as
well as with the reinforced filler size. While the 1/32”filler composite
shows only a marginal increase in the KIc value at 4% Vf, the1/4”
reinforcement enhances theKIc of matrix by nearly five times. Even the
post crack initiation area under the load vs. deflection curve, indicating
the composites’ resistance to crack propagation, increases with increasing
filler size and volume fraction. The fracture surface micrographs exhibit
51
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

matrix cracking, fibre bridging, fibre/matrix de-bonding andfibre pull out, Keywords: Abrasive wear, Al2O3-ZrO2 ·5CaO, XRD, SEM, specific wear
as the key toughening mechanisms. rate.

STRUCTURAL INTEGRITY ASSESSMENT OF APPLICATION OF FRUGAL INNOVATION IN

FILAMENT WOUND COMPOSITE PRESSURE FIRE SAFETY
VESSEL USING THROUGH TRANSMISSION
TECHNIQUE Dr Prateep Roy
Gharda Institute of Technology (GIT), At & Post: Lavel - 415708, Dist.
Ratnagiri, Maharashtra
Sameerkant Behera1, S K Sahoo2, Lokesh Srivastava3, A. S. Srinivasa
pkroy@git-india.edu.in
Gopal4
1, 2, 3, 4
Advanced System Laboratory, DRDO, HYDERABAD, INDIA.
This paper deals with the application of an open-source software called
+91 7660805932
1 Fire Dynamics Simulator in analyzing the fire hazards, structural integrity
sameerkantbehera@asl.drdo.in
and ensuring the safety of people, property & environment. It can also
optimize the resource utilization in terms of materials, manpower,
Filament wound composite pressure vessel are widely used as rocket construction time, cost and environment in designing and building a
motor case for space applications due to its high performance factor. power plant. In this paper author shares some instances of his experience
Composite materials with their higher specific strength, specific modulus in applying fire modelling & simulation technique in optimizing the
and strength tailorability characteristics which results in reduction of resources towards structural integrity and analyzing the fire hazards based
weight of the structure. However composite structures are more prone to on the results of fire modelling and simulation of a nuclear plant.
damage accumulationdue to matrix cracking, fibre-matrix de-bonding,
fibre buckling, delamination, fiber breakage etc.which are encountered
inentire manufacturing cycle. Timely and accurately detection of above
damage throughout its service life is necessary to have a reliable
structure.As composite manufacturing is process intensive, it is
imperative to have assessment at each critical intermediate stages of
manufacturing where defect likely to occur due to process variation. Also
to accept structure for end use and declare it as flight worthy,it calls for a
reliable testing methodology for assessing overall structural integrity. In
last decade, many open literatures have been available on design,
development and qualification of composite pressure vessel,however no
comprehensive work is available on structural integrity assessment. This
paper discusses an insight of various damage arises during manufacturing
due to process variations and its detection using through transmission
ultrasonic technique.Challenges multifold due to lack of full proof
methodology and standards in open source. Here, a through transmission
ultrasonic testing methodology has been established. A reference sample
has been made simulating defect such as delamination and its ultrasonic
response has been characterized. Ultrasonic response on product level has
been studied with respect to reference sample. Anoverview of overall
plan to assess structural integrity of composite pressure vessel has been
presented. Also a case study has been presented showing various defects
and its ultrasonic responses.

ABRASIVE WEAR STUDIES ON SPECIAL

COMPOSITE -Al2O3-ZrO2 ·5CaO FOR
TRIBOLOGICAL APPLICATIONS.

Abhinav
Alliance University, Alliance College of engineering and design,
Bangalore
abhinavtechno5@gmail.com

An attempt is made to exploit the mechanical and thermal properties of

composite coatings Al2O3-ZrO2 ·5CaO blended in 50:50 by wt.
%.Tribological investigations carried out on atmospheric plasma coated
specimens (100,200 &300μm). An ASTM G132 standard, Pin-on disk
method was adopted to determine the specific wear rates of the
specimens. The test was carried out at the normal load of 5, 10, 15 N and
at variable sliding speeds of 150,200 & 250 rpm. SEM, XRD technique
was used for characterization of the as-sprayed coating. Experimental
results revealed that the top coat primarily subjected to sliding and less
abrasion, the slip has mainly occurred in the plane of <111>,
<200>,<220>,<311>,<222> along with localized abrasion. Irrespective of
the applied normal loads the coefficient of friction doesn’t influence
much in the wear process. The wear mechanism of the above coatings
found primarily dependent on phases and crystallographic structure of the
phases.

52

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session3F:MechanicalBehaviourofHighStrengthSteels
Chairman:RBalamuralikrishnan,DMRL
SessionCoordinator:SharatChandraRachuri,DMRL
16301657 InvitedTalk:OntheFractureMechanicsbasedDevelopmentofCleavageFracture
ResistanceCriteriafortheMaterialsofLargeSizeWeldedStructures
VladimirYuFilin,PROMETEY,Russia
16571709 DamageToleranceBehaviourofWeldJointsofHighStrengthStructuralSteel:
ResistancetoColdCracking,StaticCrackingandDynamicProperties
V.M.Nimbalkar,MMohape,VikasKatkar,SGPandav,TikaramLatalwar,JM
Jangir,SKDakhole,JPanigrahi,NaushadSaikh,ARoyandDSChaudhari
NavalMaterialsResearchLaboratory,DRDO,Ambernath
17091721 FatiguecrackgrowthratebehaviourofHSLAsteelsatvaryingloadamplitudes
SachinBandgar,ChiradeepGupta,GauravRao,PranshuMalik,R.N.Singhand
K.Sridhar
NavalMaterialsResearchLaboratory,DRDO,Ambernath
17211733 CorrosionFatigueBasedResidualLifePredictionofShipBuildingMaterials
DeependraSingh,SatyabrataParida,VivekSrivastavaandVPDeshmukh
NavalMaterialsResearchLaboratory,DRDO,Ambernath
17331745 StressCorrosionCrackingStudiesonHSLAsteel
NChittibabu,DVVSatyanarayanaandVikasKumar
DefenceMetallurgicalResearchLaboratory,Hyderabad
17451757 AninvestigationofperformanceofsprayformedH13toolsteel
SantoshKumar,PravinJadhav,AkshayPatil,ShreyasKirwaiandRajkumarSingh
KalyaniCentreforTechnology&Innovation,BharatForgeLtd,Pune
17571809 Comparisonofmicrostructuresandhardnessofelectronbeamandfrictionstir
weldmentsofreducedactivationferriticmartensiticsteel
VijayaL.Manugula,KoteswararaoV.Rajulapati,G.MadhusudhanReddyand
K.BhanuSankaraRao
MahatmaGandhiInstituteofTechnology,Hyderabad
18091821 Determinationandverificationoftriaxialitydependentcohesivezoneparametersof
SA333Grade6Steel
ViswaTejaVanapalli,B.K.Dutta,J.ChattopadhyayandNevilMartinJose
HomiBhabhaNationalInstitute,Mumbai
 



 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

ON THE FRACTURE MECHANICS BASED

Key words : High strength super structural steel, Indigenous, Weld
DEVELOPMENT OF CLEAVAGE FRACTURE consumables, Sub-marine hull construction, Implant test, CTOD test,
RESISTANCE CRITERIA FOR THE MATERIALS Dynamic bulge test, warships, weldments, fracture toughness
OF LARGE-SIZE WELDED STRUCTURES
V Yu Filin and A V Ilyin
SSA,
NRC Kurchatov Institute – CRISM Prometey
FATIGUE CRACK GROWTH RATE BEHAVIOUR
npk3@crism.ru OF HSLA STEELS AT VARYING LOAD
AMPLITUDES
Critical large-size structures are commonly made of low-alloyed steels
due to their outstanding strength to weight ratio, suitable weldability and Sachin Bandgar*,Chiradeep Gupta#, Gaurav Rao*, Pranshu Malik$ ,
reparability for a reasonable price. Recent development of Russian sea R.N.Singh# and K. Sridhar*
shelf takes place in conditions of low climatic temperatures, ice and *Naval Materials Research Laboratory, DRDO Ambernath, -421 506,
earthquake hazard. The increased operational parameters as loads, #
MMD Division, BARC,Trombay-400 085 $ Western Naval Command,
pressure, pipe diameters and so on combined with longer distance from Indian Navy, Mumbai-400 001
coastal bases highly increase the engineering responsibility. Safe *Corresponding Author Email: svbandgar123@gmail.com
operation of large-size welded structures is a main aim of the developed
test procedures and criteria for fracture toughness and critical ductile-to-
brittle transition temperatures. The same are applied to determine Steels for ship building applications has to possess adequate resistance to
allowable flaw sizes taking into account their probable propagation under propagation of fatigue cracks, as majority of the failures in service are
operational loads. Flaw size is inevitably related to the applicable due to metal fatigue. In this work, the fatigue crack growth rate (FCGR)
procedures, criteria and amount of nondestructive inspection. The behaviour within the Paris regime of two high strength low alloy (HSLA)
presentation will highlight the principles for welded structures structural steels indigenously developed for ships of Indian Navy were studied.. In
integrity assessment, peculiarities of test methods to evaluate the fracture particular the experiments were directed to reveal the effect of R ratio on
toughness and critical temperatures as well as examples of their practical the Paris law constants for the two grades of HSLA steel. Results
application and offer to take part in the development of related standards. indicated that there was increase in Paris slope (m) and decrease in Y
intercept (C) with increase in load ratio for both the steels. Fractography
study was carried out using SEM at locations corresponding to various
values of stress intensity factor in order to reveal possible reasons for
acceleration crack growth with change in R ratio from 0.1 to 0.5. It was
DAMAGE TOLERANCE BEHAVIOUR OF WELD found that secondary cracks were present in significantly larger numbers
JOINTS OF HIGH STRENGTH STRUCTURAL in Steel A at a load ratio of R=0.1 as compared to R=0.5. However for
STEEL: RESISTANT TO COLD CRACKING, Steel B, no great difference in presence of secondary cracks was found at
STATIC CRACKING AND DYNAMIC both the load ratios. This difference in the propensity of secondary
cracking with change in load ratio in the two steels could rationalise the
PROPERTIES fact that the steel B tends to show lower increase in paris slope as R
changes from 0.1 to 0.5. From the plot of crack growth a vs no. of cycles
V. M. Nimbalkar 1a, M Mohape, Vikas Katkar, S G Pandav, Tikaram N, it became evident, the number of cycles for the same range of crack
Latalwar length is lesser for R=0.1 than that for R=0.5 for both steel A and Steel B.
Naval Materials Research Laboratory, Shill - Badlapur Road, Ambernath- It was observed from the plot of a vs Kmax are almost similar for both
421 506 R=0.1 and R=0.5 for Steel A. In the case of steel B, at a given crack
Email : vijayn@nmrl.drdo.in length, higher K max was noted for load ratio of R=0.5 than R=0.1. Paris
J M Jangir2b, S K Dakhole, J Panigrahi, Naushad Saikh, A Roy, D S law parameters of interest, ‘m’ and ’C’ determined from crack growth
Chaudhari rate (da/dN) vs stress intensity range (K) is shown in the following
Mazagon Dock Shipbuilders Limited, Dockyard Road, Mazagon, table.
Mumbai – 400 010

Mater Load Slope Mate Load Slope Int.
Naval high strength structural steel, with an excellent combination of ial ratio (m)
Int.(C)
rial ratio (m) (C)
strength, toughness and weldability has been developed over the last two
decades to replace conventional medium carbon steels. Modern warships Steel R= 8.59E- Steel
require high strength steel in increasing proportions of the underwater 3.136 R=0.1 2.223 1.03E-7
A 0.1 8 B
pressure hull structure for weight reduction, increased payload, and
survivability. So the structural steel and welding materials used in hull Steel R= 5.39E- Steel
4.008 R=0.5 3.363 2.28E-9
fabrication must demonstrate high fracture toughness. Weld joints of a A 0.5 10 B
high strength structural steel must possess requisite impact strength,
tensile strength, fatigue properties, static crack resistance, cold cracking Table1:mandCvaluefordifferentloadratio
resistance and dynamic strength.

The present paper describes tests carried out to study the damage Reference:
tolerance behaviour of a high strength steel weld joint from the point of 1. Kwai S. Chan, Yi-Ming Pan, David Davidson, Fatigue crack
view of its resistance to hydrogen induced cold cracking and static growth mechanisms in HSLA-80 steels, Materials science and
cracking. Resistance to cold cracking was determined by implant testing Engineering A222(1997) 1-8
and resistance to static cracking by determining its CTOD properties. The 2. K. Sadananda, A.K. Vasudevan, Fatigue Crack growth
dynamic behaviour of the weld was also carried out by subjecting the mechanisms in Steels, International Journal of Fatigue 25
welded test plates to explosion bulge test at sub zero temp (-180C). Butt (2003) 899-914
welding experiments were carried out using indigenous weld
consumables. The cold crack test results showed that no cracks have been
formed at the notch under applied load conditioned after 16 hrs and there
is no change in the hardness values in the welded regions after implant
test. CTOD test was performed on weld samples at -100C and 0.10 mm
value was obtained. Dynamic bulge test was carried out as per MIL –
STD 2149 (SH). It showed 16 – 17 %reduction in thickness after five
blasts as desired and no cracks were found in the weld joints and nearby
region.

53


SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
CORROSION FATIGUE BASED RESIDUAL LIFE
PREDICTION OF SHIP BUILDING MATERIALS
Deependra Singh*, Satyabrata Parida, Vivek Srivastava and VP
Deshmukh
Naval Materials Research Laboratory, Defence Research Development
Organisation (DRDO), Ministry of Defence, Additional Ambernath,
Anandnagar P.O; Thane-421 506, INDIA
*Corresponding Author Email: singhdeependra1992@gmail.com
High strength low alloy (HSLA) steel and marine grade aluminium alloys
used in ship building applications are subjected to corrosion fatigue
damage mechanism under corrosive seawater wave loading which may
cause premature failure of marine structures.Therefore, determination of
Corrosion Fatigue Crack Growth Rate (CFCGR) of ship building
materials is of paramount significance for their residual life assessment.
In this paper, CFCGR studies as well as Residual Life Analysis of HSLA
steel (YS = 463 MPa) and 5XXX grade aluminium (YS = 221 MPa)
material has been carried out using damage tolerant fracture mechanics
approach. Mechanical characterization was carried out for both the
material and is reported in Table 1. CFCGR experimentation were
conducted using an electro-mechanical fatigue machine at a load ratio of
0.1 on CT samples in 3.5 wt% NaCl as per ASTM-647 at frequencies
typical to their service condition (0.1 Hz for Steel and 0.128 Hz for
aluminium). Paris constants ‘m’ and ‘C’ as well as critical crack length
were determined from their CFCGR curves as shown in figure 1 and
listed in Table 1. Residual life (in cycles and years/days) was calculated
for both materials for crack growth from minimum NDT detectable size
of 1 mm to critical crack length. The residual life of HSLA steel material
was found to be 10.1E6 cycles or 3.20 years and that of aluminium alloy
material was found to be 8.8 E4 cycles or 8 days.
Figure 1: CFCGR curves of the tested steel and aluminium material
Properties HSLA Steel Aluminium
Alloy
Vicker’s Hardness (VHN) 208 93
0.2% Proof Strength, YS(MPa) 463 221
Fracture toughness (MPa ξ݉ሻ 86 22
Critical crack length (mm) 96 28.56
Paris Constant, ‘m’ 2.32 1.80
Paris Constant,‘C’ (MKS units) 1.07E-10 1.65E-8
Residual life (Cycles) 10.1E6 8.8E4
Table 1: Mechanical property and CFCGR Data of Steel and aluminium
alloy
Reference
1. Upadhyaya, Sridhara, Fatigue Crack Initiation and Propagation Life
Prediction of materials, International Conference on Mechanical,
Electronics and Mechatronics Engineering, 2012
2. S. T. Rolfe, A.E. Henn and K.T. Hays, Ship Structure Committee,
Fracture Mechanics Methodology for Fracture Control in Oil
Tankers, Ship Structures Symposium (1993)1-17


STRESS CORROSION CRACKING STUDIES ON
HSLA STEEL
* N Chittibabu, DVV Satyanarayana, Vikas Kumar
Defence Metallurgical Research Laboratory, Hyderabad – 500 058, India
*dvvsnarayana@dmrl.drdo.in
Evaluation of corrosion behaviour of high strength low alloy steels
(HSLA) is very important particularly when the steels are used in naval
applications. HSLA steels, or micro alloyed steels, which are aimed to
provide better mechanical properties, have better resistance to
atmospheric corrosion than conventional carbon steels. However, the
susceptibility to stress corrosion cracking (SCC) increases with increase
in strength in case of HSLA steels. Therefore, the knowledge of SCC
susceptibility of these steels is very essential when such steels are
considered for naval applications. In this present work, SSC susceptibility
of an indigenously developed High Strength Naval Steel has been studied
by performing slow-strain-rate tests (SSRT) using different strain rates in
air and in 3.5% NaCl solution at ambient temperature. It has been
observed that the steel is more susceptible towards stress corrosion
cracking with decreasing strain rate in the order in the order 10-7> 10-6 >
10-5 s-1.
AN INVESTIGATION OF PERFORMANCE OF
SPRAY FORMED H13 TOOL STEEL
Santosh Kumar1, Pravin Jadhav1, Akshay Patil1, Shreyas Kirwai1, Dr.
Rajkumar Singh1
1
Kalyani Centre for Technology & Innovation, Bharat Forge Ltd, Pune-
411036, Maharashtra, India
Email of corresponding author: Santosh.kumar@bharatforge.com
Spray Forming is a material processing technology in which molten metal
is transformed into near net shape solid by capturing spray of atomized
metal or alloy onto a moving substrate. In the present work, performance
of spray formed tool steel, H13 is investigated in terms of tensile, Charpy
impact and fracture toughness properties and compared with that of
conventional route steel. The analysis was done in two hardness ranges
i.e. 44~46HRc and 48~50HRc. Tensile test results show that YS and UTS
is similar for both route material at both hardness ranges but %El is
higher for conventional route material at higher hardness range but
similar at lower hardness range as compared to that of spray formed
route. Charpy impact strength obtained for conventional route steel is
higher in all three directions as compared to that of spray formed steel.
Fracture toughness results at higher hardness range show that KIC value
obtained for conventional route steel is approximately 24% & 50% higher
than that of spray formed route in LS and TS orientations, respectively.
The same at lower hardness range is approximately 42% and 32% higher
for conventional route steel when compared with that of spray formed
steel in LS and TS orientations, respectively. Metallography and SEM
was done to establish reasons behind the better performance of
conventional route steel.
54
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

COMPARISON OF MICROSTRUCTURES AND plastic finite element analyses were conducted ofthese piping components
to obtain the ‘q’ parameter at the crack tip. Using this ‘q’ parameter, the
HARDNESS OF ELECTRON BEAM AND upper and lower limits of peak stress ‘T’ from the confidence band
FRICTION STIR WELDMENTSOF REDUCED determined above was found out. This range of ‘T’ was then used to carry
ACTIVATION FERRITIC MARTENSITIC STEEL out cohesive zone analyses of these piping components to determine
load-displacement curves. For each piping component, a bunch of load-
Vijaya L.Manugula1*,Koteswararao V.Rajulapati2, G.Madhusudhan displacement curves were determined by assuming a normal variation of
Reddy3, K.BhanuSankara Rao4 parameter ‘T’ over the maximum and minimum limits. The calculated
1
Department of Metallurgical and Materials Engineering, Mahatma load-displacement curves were compared with the experimental results. It
Gandhi Institute of Technology, Hyderabad 500075, India. has been observed that experimental results lie within the computed
2
School of Engineering Sciences and Technology, University of range. It is expected that the generated material data will be useful to
Hyderabad, Hyderabad 500046, India. carry out safety evaluation of piping components with crack made of
3
Defence Metallurgical Research Laboratory, Hyderabad 500058, India. SA333 Grade 6 materials.
4
Ministry of Steel (Govt. of India) Chair, Mahatma Gandhi Institute of
Technology, Hyderabad 500075, India. Keywords: Cohesive zone model, multi-axiality quotient, Transferability
*Corresponding author: vijaya.511@gmail.com of cohesive parameters.

This paper presents the comparative evaluation of microstructural

features and hardness of electron beam welded (fusion welding) and
friction stir welded (solid-state welding) Indian Reduced Activation

Ferritic Martensitic steel joints.The current study is pursued with the aim
of obtaining a comprehensive systematic understanding of the various
zones in the weld joint. Base metal (BM) and various zones in the
weldments were characterised extensively using optical, scanning
electron microscopy-electron back scattered diffraction (SEM- EBSD)
and transmission electron microscopy (TEM) techniques. In BM, the
prior austenite grain boundaries and martensite lath boundaries were
decorated with relatively coarse chromium and tungsten rich M23C6 type
carbides and Ta,V rich MX type of carbides occupied intralath regions.
This tempered martensitic structure has undergone substantial changes
during the weld thermal cycle.As welded condition revealed martensite in
coarse grains devoid of strengthening carbides and small amount of -
ferrite in the fusion zone of electron beam welded joints. On the other
hand the phase transformation to martensite occurred in stir zone of
friction stir weld joint and showed lack of M23C6 type carbides.The
hardness was much higher compared to the BM at both the welding
conditions. The welds were also subjected to post weld heat treatments
(PWHTs) to temper the martensite and to relieve the residual stresses.
Reduction in hardness was observed in the heat affected zone (HAZ) for
12 mm thick friction stir welded sample.PWHT is an effective way to
lower the weld zone hardness to that of BM.

DETERMINATION AND VERIFICATION OF

TRIAXIALITY DEPENDENT COHESIVE ZONE
PARAMETERS OF SA333 GRADE 6 STEEL

ViswaTeja Vanapalli1,2*, B.K. Dutta1**, J. Chattopadhyay1,2 and Nevil

Martin Jose2
1
Homi Bhabha National Institute, Anushaktinagar, Mumbai 400094, India
2
Reactor Safety Division, Bhabha Atomic Research Centre, Trombay,
Mumbai 400085, India
*viswateckie@gmail.com, **bkdutta@barc.gov.in

Cohesive zone models are employed to simulate crack propagation in

fracture process zone. It has been demonstrated in the present study that
the cohesive zone parameters, viz. peak stress ‘T’ and cohesive energy
‘G’depends not only on material, but also on stress triaxiality.To
determine cohesive zone parameters, experimental results of 14 three-
point bend specimens made of SA333 Grade 6 steel were analyzed using
3D finite element model using WARP3D. Cohesiveparameters were
determined by carrying out parametric studies of these specimens by
varying peak stress ‘T’. An exponential traction separation law was used
for this purpose.In addition, elastic plastic finite element analyses are
conducted to determine the multi-axiality quotient ‘q’ at the crack tip. A
confidence interval band between crack tip multi axiality quotient ‘q’ and
peak stress ‘T’is plotted to study the transferability of cohesive
parameters to pipe components.

To test the accuracy of cohesive parameters determined above,

experimental results of six piping components with through-wall
circumferential crack made of SA333 Grade 6 steel tested earlier were
used. The components were tested under four-point bending loads. Elastic

55

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

 

Session4A:StructuralIntegrityVII
Chairman:VedaErukulla,LPTi,Canada
SessionCoordinator:AtulKumar,DMRL
14151442 InvitedTalk:CorrosionandAircraftStructuralIntegrity
GMKamath,IndianInstituteofTechnology,Kanpur
14421454 DesignandanalysisofformedbellowsfornuclearapplicationsCasestudy
S.C.S.P.KumarKrovvidi,SunilGoyalandA.K.Bhaduri
IndiraGandhiCentreforAtomicResearch,Kalpakkam
14541506 Structuralintegrityusingeffectivefieldqualityassurancepracticesforfabricationof
gloveboxes
MVKuppusamy,ShrikrishnaTripathi,BPCRaoandARavisankar
IndiraGandhiCentreforAtomicResearch,Kalpakkam
15061518 Assessmentofdelayedhydridecrackingatvolumetricflawsformedduetobearing
padfretting
RameshKumar,RituJ.Singh,J.MishraandV.Balasubramaniyan
AtomicEnergyRegulatoryBoard,Mumbai
15181530 StudytheEffectofAnisotropyofElasticPlasticPropertiesonResidualStress
DevelopmentinAutofrettageofThickCylinder
RituJSingh,RameshKumar,JMishra,V.BalasubramaniyamandH.S.Kushwaha
AtomicEnergyRegulatoryBoard,Mumbai
15421554 IndentationandhydrideorientationinZr2.5%NbPressureTubematerial
T.NarayanaMurty;SandeepAChandashiveandR.N.Singh
BhabhaAtomicResearchCentre,Mumbai
15541606 IssuesinOptimizingLaserShockPeeningParametersforNickelSuperAlloys
LSaiSandeep;VamsiKrishnaRentala,PhaniMylavarapu,DGovindaRao,Nagaraju
Guthikonda,PPremKiran,Gp.Capt.B.V.N.Shiva,K.GopinathandVikasKumar
VasaviCollegeofEngineering,Hyderabad
16061618 Acellularmechanicsapproachtothemechanicalbehaviorofnanoscale
interpenetratingphasecomposites
K.R.MangipudiandC.A.Volkert
IndianInstituteofTechnologyBhubaneswar
16181630 EffectofEndConstraintsontheBallooningofaLongThinWalledPressurizedTube
ShekharSumanandSivasambuMahesh
IndianInstituteofTechnologyMadras




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
CORROSION AND AIRCRAFT STRUCTURAL
INTEGRITY
G M Kamath
Department of Aerospace Engineering
Indian Institute of Technology, Kanpur
gmkamath@iitk.ac.in
The management of corrosion, and the repair and restoration of
corrosion-affected structures pose a daunting and formidable challenge to
the aerospace community. The approaches to address this issue have been
largely conservative and heuristic. In the current scenario, aircraft
operators, both civilian and military, wish to utilize the life of their assets
to the maximum extent for strategic and economic reasons. It thus
becomes imperative to develop more rigorous science-based metrics and
methodologies for providing accurate and reliable diagnoses and
prognoses on the structural integrity of corrosion-affected structures. This
paper presents some of the challenges, a brief outline of the approaches,
and some preliminary results towards addressing and achieving these
goals.
DESIGN AND ANALYSIS OF FORMED BELLOWS
FOR NUCLEAR APPLICATIONS- CASE STUDY
S.C.S.P.Kumar Krovvidi*, Sunil Goyal, A.K.Bhaduri
Indira Gandhi Centre for Atomic Research, Kalpakkam-603102, India
* krovvidi@igcar.gov.in
Bellows are highly engineered components which find large number of
applications in nuclear industry. Formed bellows are the most commonly
used type of bellows and used when stoke is less than one thirds of
bellows free length. Conventionally, design and manufacturing of the
formed bellows are extensively addressed in standards of Expansion Joint
Manufacturers Association (EJMA). In nuclear applications, design of the
bellows shall comply with standard nuclear design codes such as ASME
section-III, RCC-MR etc, which follow design by analysis. Hence the
design of the bellows for nuclear systems needs detailed Finite Element
Analysis (FEA) and fatigue life estimation as per the design curves given
in the codes. In this work, a case study of design of formed bellows, made
of SS316LN, operating below creep range for nuclear application is
presented. The bellows are preliminarily designed by EJMA and the
geometry arrived based on preliminary design is analyzed using FEA.
The stress/ strain range in the bellows is estimated by both linear elastic
and inelastic FEA. Non-linear isotropic-kinematic hardening constitutive
model is employed for inelastic analysis of the bellows. The fatigue life
of the bellows is estimated as per the guidelines given in RCC-MR. It is
found that the fatigue life estimated by linear elastic analysis is more
conservative. In the design fatigue curves given in the nuclear design
codes, factor of safety (FOS) of 2 on stress range is considered. By
considering similar factor of safety on the equivalent stress given in
EJMA, the cycle life of the bellows is estimated and compared with the
design life obtained by detailed stress analysis. It is found that after
including FOS of 2 on equivalent stress, the life predicted by EJMA
design curve is conservative and in close agreement with that obtained by
detailed stress analysis. Hence, FOS modified EJMA equation can be
used for design of the nuclear bellows when operating temperature is less
than creep range of the bellows material. Use of FOS modified EJMA
design equation is easy and eliminates the need for detailed stress
analysis by the bellows suppliers. However, other aspects such as
manufacturing tolerances, inspection, testing and qualification of the
bellows shall comply with the standard nuclear design codes.


STRUCTURAL INTEGRITY USING EFFECTIVE
FIELD QUALITY ASSURANCE PRACTICES FOR
FABRICATION OF GLOVE BOXES
M V Kuppusamy, Shri Shrikrishna Tripathi, B P C Rao, A Ravisankar
Fast Reactor Fuel Cycle Facility
Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamilnadu-
603102
masikuppu@igcar.gov.in
Glove boxes (GBs) are primary confinement for radiotoxic materials and
they are designed to be leak tight under seismic conditions as well. All
glove box assembly is required to pass a leak-rate not exceeding 0.05
volume % air/h when tested at an initial pressure differential of 1kPa
(102mmWC) for 24 hours. Due to its inherent corrosion resistance and
better fabricability, AISI Type SS 304L of 3-6 mm is used as material of
construction of glove boxes and Gas tungsten arc welding process
(GTAW) is employed.
Precise control over dimensional tolerances is required for glove box
assembly with a lot of temporary fasteners and attachments to meet the
stringent leak rate requirements. High degree of inside and outside
surface finish is also required both on base metal and weld metal surfaces
for ease of decontamination. Due to high coefficient of thermal expansion
and lower thermal conductivity, controlling the distortion of plates during
welding poses major challenge. To meet such stringent structural
integrity needs a comprehensive field quality assurance plan to be
adopted during the fabrication of GBs of different types. GTAW in
pulsed mode is used to have better control on heat input. Lot of mockup
trials have been carried out especially to weld corner cup with respect to
sequence of passes/layers to minimize the distortion. All weld joints has
been flushed both inside and outside, subsequently with buffing to get the
required surface finish. All flushed welds are liquid penetrant examined
for detecting surface flaws. All the weldments have been surface treated
to ensure the passivity after flushing & buffing. As a final check, helium
leak testing has been performed. Influence of temperature on leak testing
rate has been studied and suitable corrections have been incorporated.
This paper give a detailed account of various activities performed as a
part of effective field quality assurance plan during the fabrication of
glove boxes towards meeting the design and functional requirements.
ASSESSMENT OF DELAYED HYDRIDE
CRACKING AT VOLUMETRIC FLAWS FORMED
DUE TO BEARING PAD FRETTING
Ramesh Kumar, Ritu J. Singh, J. Mishra, V. Balasubramaniyan
Atomic Energy Regulatory Board, Mumbai-94, India
Email of corresponding author: kramesh@aerb.gov.in
Pressurized Heavy water reactor is a horizontal channel type reactor
where fuel bundles are inside pressure tubes (PT) and supported at
bearing pad locations. Bearing pad (BP) fretting results in formation of
volumetric flaws at PT inner surface which may lead to delayed hydride
cracking (DHC). In this paper, safety assessment of pressure tube was
carried out against DHC initiation at volumetric flaws using CSA N285.8
procedures. Bounding envelop was developed for threshold bulk Heq and
volumetric flaw depth for DHC initiation. Several flaw root radius (rho)
were assumed to arrive at bounding flaw sizes and threshold bulk Heq in
the PT. Peak stress was calculated considering hydride ratcheting
condition at flaw tip. Four locations, rolled joint inlet/ outlet and PT main
body inlet/outlet were selected to assess DHC initiation for volumetric
flaws. Residual tensile stress was considered for the assessment at rolled
joint location. The bounding envelop of threshold bulk Heq and
respective bounding flaw depth for DHC initiation in the PT main body
was plotted in Fig.1.
56

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
rho = 0.015
rho = 0.05
42
40
rho=0.13
rho= 0.4
38
36
34
Heq (ppm)
32 (0.76, 30.6)
30
28 (0.63, 29.5)
26
(0.54, 27)
24
22
0.5 0.6 0.7 0.8
Fret Depth (mm)
0.9
Figure 1 Threshold bulk Heq for DHC initiation for BPF under normal
operation for pressure tube inlet
The result plotted in Fig.1 shows that flaw depth of 0.54 with bulk Heq
equal to 27ppm will be susceptible for DHC initiation for flaw root radius
0.015mm.
STUDY THE EFFECT OF ANISOTROPY OF
ELASTIC-PLASTIC PROPERTIES ON RESIDUAL
STRESS DEVELOPMENT IN AUTOFRETTAGE OF
THICK CYLINDER
Ritu J Singh, Ramesh Kumar, J Mishra, V. Balasubramaniyam, H.S.
Kushwaha
Atomic Energy Regulatory Board
Mumbai
Email of corresponding author: ritusingh@aerb.gov.in
 stresses. LSP is an advanced technique in inducing high magnitudes of
Thick-walled cylinders subjected to high internal pressure and/or elevated
temperatures are widely used in the aircraft, defense, nuclear and
chemical industries especially for military applications e.g. the gun barrel
in a ballistic event. In the absence of residual stresses, cracks usually
form at the bore where the hoop stress developed by the working pressure
is highest. To prevent such failure and to increase the pressure-carrying
capacity of the pressure vessel, autofrettage process is used. During
autofrettage a plastic region within the thick wall of the pressure vessel is
produced by loading the pressure vessel in the plastic domain. Upon
unloading, a residual compressive hoop stress is established within the
plastic zone. This residual compressive stress counters the tensile hoop
stress introduced due to service loading, thereby reducing the overall
tensile hoop stress at inner surface. Therefore, autofrettage is used to
introduce advantageous favorable compressive residual hoop stress inside
wall of a cylinder and result in an increase in the fatigue lifetime of the
component. Several researchers have studied the Autofrettaged cylinders,
both analytically and FE simulation. In this paper, effect of anisotropy in
the material properties will be studied on the stress field generated in the
Autofrettaged cylinder. Anisotropy in the material properties may result
due to tube manufacturing processes like extrusion or pilgering. Plastic
deformation leads to the development of preferred orientation of grains in
the components due to slip occurring only in preferred slip planes in a
crystal especially in a HCP material like Zr 2.5%Nb. In this paper, a
thick cylinder made from Zr 2.5% Nb is loaded till elasto plastic interface
is achieved and then unloaded to study the development of residual
stresses. Two material models are considered for the analysis i.e.
isotropic and anisotropic plastic behavior. The effect of anisotropy on the
residual stress developed is studied.
INDENTATION AND HYDRIDE ORIENTATION IN
Zr-2.5%Nb PRESSURE TUBE MATERIAL
T. NarayanaMurty, Sandeep A Chandashive, R. N. Singh
Mechanical Metallurgy Division, Bhabha Atomic Research Centre,
Mumbai-400085
Email: rnsingh@barc.gov.in
In this study indentations were made on Zr-2.5Nb pressure tube material
to induce multi-axial stress filed. AI-shaped punch mark was indented on
the Pressure tube material with predefined punch load. Later material was


charged with 50ppm of hydrogen. The samples near the punch mark were
metallographically examined for hydrides orientation. It was observed
that hydrides exhibited preferentially circumferential orientation far away
from the indent to mixed orientation containing both circumferential an
radial hydrides near the indent. This is probably as a result of stress field
(1.05, 30.5) generated by indenting. Extent of radial hydride formation was observed
to be varying with indenting load.
1.0 1.1
 ISSUES IN OPTIMIZING LASER SHOCK PEENING
PARAMETERS FOR NICKEL SUPER ALLOYS
L Sai Sandeep 1, Vamsi Krishna Rentala 2, Phani Mylavarapu 3, D
Govinda Rao 1, Nagaraju Guthikonda 2, P Prem Kiran 2,
Gp.Capt.B.V.N.Shiva 3, K.Gopinath 3 and Vikas Kumar 3
1
Vasavi College of Engineering, Hyderabad, India
2
University of Hyderabad, Hyderabad, India
3
Defence Metallurgical Research Laboratory, Hyderabad, India
Email of corresponding author: sandeeptwees@gmail.com
Aeroengine components are usually subjected to surface enhancement
techniques such as Shot peening (SP), Laser Shock Peening (LSP), and
Low Plasticity Burnishing (LPB) etc. to hinder fatigue. These surface
enhancement techniques will induce differing amount of cold work in the
material. Even though several techniques are available to measure the
extent of cold work, measuring the Full Width at Half Maximum
(FWHM) using X-Ray based residual stress measurement technique is a
common practice. The FWHM signifies the amount of cold work and in
turn the plastic strain induced in the material. In general, minimal amount
of cold work is beneficial in minimizing the thermal relaxation of
residual stresses along with minimal amount of cold work. In the current
study, Nickel based superalloy samples extracted from a service exposed
aeroengine disc are stress relieved (@0.4-0.5 Tm and for 8 h) to reduce
the existing surface stresses from machining. Further, these samples are
subjected to LSP with optimized parameters so as to achieve optimum
compressive stresses approximately in the range of 80% of yield strength.
Even though LSP studies on Nickel super alloys has been a topic of
interest for some time, major challenge is to identify suitable parameters
for each material depending on the equipment and its parameters. This
presentation will discuss the challenges faced by the researchers in
utilizing literature data for LSP studies followed by the steps taken to
optimize them. More importantly, adaptations of LSP parameters for
cases in the absence of water confinement are stressed.
A CELLULAR MECHANICS APPROACH TO THE
MECHANICAL BEHAVIOR OF NANOSCALE
INTERPENETRATING PHASE COMPOSITES
K.R. Mangipudi1, C.A. Volkert2
1)
School of Minerals, Metallurgical and Materials Engineering, Indian
Institute of Technology Bhubaneswar, Arugul, Khurda, Odisha, India
2)
Institute of Materials Physics, University of Goettingen, Friedrich-
Hund-Platz 1, D-37077 Goettingen, Germany
k.r.mangipudi@iitbbs.ac.in
Interpenetrating phase composites (IPCs) are a special class of
composites in which both the matrix and reinforcing phases form a
continuous intertwined three-dimensional network. The continuity of the
reinforcing phase leads to unique thermomechanical properties of IPCs in
contrast to their discontinuously reinforced composites. The majority of
literature on IPCs focuses on elastic response or fracture toughness.
However, the role of reinforcing phase connectivity in determining the
overall mechanical behaviour has not been fully understood. The existing
literature attempts to explain the strength of an IPC in terms of (i) direct
strengthening due to load partitioning as a result of interphase constraints
and (ii) indirect strengthening in the matrix caused by dislocations
interacting with the reinforcing phase and with other dislocations). Using
polymer infiltrated nanoporous gold (np-Au) composites, in which
indirect strengthening is believed to be absent, we show that the open-cell
foam nature of the reinforcing phase in its stand-alone configuration will
57
 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

alter the load partitioning in an IPC when compared to a discontinuously

reinforced composite, leading to a greater direct strengthening.

In this study, we compare micromechanical tests with incremental mean-

field calculations and full-scale finite element simulations on polymer-
infiltrated and uninfiltrated np-Au. Uniaxial compression simulations
have been carried out using both real np-Au structure (reconstructed by
nanotomography) and regular unit cell-based IPCs. In contrast to the
current literature approaches, our analysis suggests that the elastoplastic
response of IPCs is better explained by treating the reinforcing phase as
an open-cell foam in addition to the composite behaviour given by the
classical self-consistent theory.

Figure 2: Visualization of a section of the reconstructed np-Au structure

(500 nm × 500 nm × 750 nm) from nanotomography (top left) and the
corresponding composite (top right) and an array of 4 × 4 × 1 Gibson-
and-Ashby-type unit cells (bottom left) and the corresponding composite.
One unit cell is shown highlighted in the unit cell array.

EFFECT OF END CONSTRAINTS ON THE

BALLOONING OF A LONG THIN WALLED
PRESSURIZED TUBE

Shekhar Suman, Sivasambu Mahesh*

Department of Aerospace Engineering, Indian Institute of Technology
Madras, Chennai 600036, India
*Email of corresponding author: smahesh@iitm.ac.in

Fuel clad tube of a nuclear reactor experiences large plastic deformation,

known as ballooning, during LOCA (Loss of Coolant Accident). In the
present work an attempt is made to understand the effect of heating rate,
and the effect of axial constraint on the ballooning of the clad tube. An
internally pressurized long cylinder experiencing heat flux at inner
surface is analyzed using finite elements. Convection boundary condition
is applied to the outer surface of the cylinder. Rate dependent Johnson-
Cook plasticity model is implemented to capture the plastic deformation
in the cylinder. The top face of the cylinder is constrained in the axial
direction, while the bottom face is connected to a spring whose stiffness
is varied to model the end confinement of the cylinder. A notch is created
at the mid length to the inner surface of the cylinder to introduce the
perturbation in the model. A systematic characterization of balloon
formation as a function of confinement is presented.

58

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session4B:ModellingofMicrostructureandPlasticity
Chairman:AVenugopalRao,DMRL
SessionCoordinator:JalajKumar,DMRL
14151442 InvitedTalk:MultiscaleModelingofComplexPlasticDeformation
AlankarAlankar,IndianInstituteofTechnologyBombay
14421454 CrystalPlasticityModelingofDynamicRecrystallizationinTi
RitamChatterjeeandA.Alankar
IndianInstituteofTechnologyBombay
14541506 ModellingofFatigueCrackInitiationandPropagationinHydrogenCharged
PolycrystallineNickel
RakeshKumar,DeepeshMeenaandDhirajK.Mahajan
IndianInstituteofTechnologyRopar
15181530 CoupledCrystalPlasticityPhaseFieldModellingofmultiphasemetals
RiteshDadhichandAlankarAlankar
IndianInstituteofTechnologyBombay
15421554 RoleofdislocationreactionsontheplasticdeformationofCopperSingleCrystals
AshishMishraandAlankarAlankar
IndianInstituteofTechnologyBombay
15541606 FiniteElementAnalysisforCableandPipeTransitSealforNuclearpowerplant
Applications
VikrantGupta,N.P.SINGHandUjjwalBaruah
ITERIndia,InstituteforPlasmaResearch,Bhat,Gandhinagar,Gujurat
16061618 SmallscaleinsitumechanicaltestingofCuBiandtheeffectofmicrostructureon
failure
AnanyaTripathi,VikramJayaramandPraveenKumar
IndianInstituteofScience,Bangalore
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
MULTISCALE MODELING OF COMPLEX
PLASTIC DEFORMATION
Alankar Alankar
Assistant Professor,
Department of Mechanical Engineering, IIT Bombay, Powai, Mumbai
alankar.alankar@iitb.ac.in
Multiscale models having crystal plasticity at the core have found
applications in design of advanced metals and alloys for better durability
and structural integrity. Recent research work has shown promise for
complex and extreme conditions e.g. LOCA condition in a nuclear
reactor. This presentation will focus on bridging crystal plasticity models
with smaller length and time scale simulation techniques. Applications of
such models are shown for evolution of crystallographic texture and
deformation microstructure for wide ranges of strain rates and
temperatures. Depending upon boundary conditions, a complex set of
mechanisms may operate and continuum mechanics of materials alone
cease to capture realistic mechanical behavior. Cross-slip, dislocation
climb and dynamic recrystallization may take place. Such mechanisms
can be correctly resolved at atomistic scale. Nevertheless, it is critical to
have them correctly modeled within crystal plasticity models.
Three different classes of crystal plasticity models namely
homogenization based polycrystal models, embedded polycrystal models
in finite element framework and dislocation mechanics based single
crystal models are discussed. Depending upon the applications and
required detail, the selection of a crystal plasticity model is made.
CRYSTAL PLASTICITY MODELING OF
DYNAMIC RECRYSTALLIZATION IN Ti
Ritam Chatterjee, Alankar A.
Department of Mechanical Engineering, Indian Institute of Technology
Bombay
Email of corresponding author: ritam.chatterjee@iitb.ac.in
 Figure 3: A periodic RVE of polycrystalline Nickel for fatigue crack
The present work is an attempt at modeling the phenomenon of Dynamic
Recrystallization (DRX) in pure Ti. A dislocation density hardening
based approach accounts for the occurrence of DRX subject to achieving
a critical value of dislocation density for each grain. The numerical
models describing nucleation and grain growth are integrated into a
polycrystal plasticity framework. Only slip deformation modes are
considered in the present work. To incorporate DRX, nucleation rate and
grain growth are modeled explicitly. Critical dislocation density for each
slip mode is evaluated. In the present work, multiple parametric studies
have been carried out highlighting the extent of DRX grains present after
a particular amount of deformation and time. The evolution of grain
shape with time, effect of parameters such as initial grain size, strain rate
and initial texture on critical dislocation density have been evaluated.
There is a need to gauge the variation of flow stress with changes in grain
shape, grain size and number of recrystallized grains in the microstructure
and this has been attempted. A key feature of DRX is the occurrence of
multiple oscillations in flow stress with time and an attempt has been
made to understand the impact of parameters such as initial grain size,
strain rate, temperature etc. on the frequency and amplitude of
oscillations. This can help devise ways to control recrystallization
kinetics so as to improve mechanical properties of engineering alloys for
strategic applications.
Keywords: Crystal plasticity, titanium, dislocation theory, ICME
MODELLING OF FATIGUE CRACK INITIATION
AND PROPAGATION IN HYDROGEN CHARGED
POLYCRYSTALLINE NICKEL
Rakesh Kumar, Deepesh Meena, Dhiraj K. Mahajan*
Ropar Mechanics of Materials Laboratory, Department of Mechanical
Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab,
India, 140001
*dhiraj.mahajan@iitrpr.ac.in


Hydrogen Embrittlement (HE) leads to the deterioration of fracto-
mechanical properties of metals. Based on the vast literature available,
HE is still not clearly understood and demands significant research in the
field of hydrogen-metal interaction. For better understanding of hydrogen
effect on fatigue behaviour of metal, the present work focuses on
developing a finite element simulation framework for fatigue crack
initiation and propagation studies in metals in the presence of hydrogen.
The developed framework, consists of a nonlocal crystal plasticity model
coupled with hydrogen transport model to study fatigue behavior of
hydrogen charged nickel. A polycrystalline representative volume
element (RVE) under periodic boundary conditions is used in this study,
as shown in Fig 1. The nonlocal crystal plasticity model accounts for the
statistically stored dislocations (SSDs) as well as geometrically necessary
dislocations (GNDs) within intragranular and inter-granular regions.
Whereas, the hydrogen transport model accounts for the diffusion and
trapping of hydrogen in metal due to concentration gradient, pressure
gradient, plastic strain-rate effect and dislocations. The total hydrogen
concentration in the system is partitioned into hydrogen present at the
interstitial lattice site and trapped hydrogen in the dislocation core along
the slip systems. Fatigue crack initiation criterion in RVE with grains of
controlled morphology and orientations is established upon considering
the critical value of fatigue indicator parameter (FIP) which is formulated
based on experimental findings. The simulation framework accounts for
both fatigue crack initiation & propagation to understand the effect of
hydrogen on microstructural short cracks.
Ha
initiation and propagation studies.
Keywords: Nonlocal crystal plasticity, hydrogen transport model, fatigue
crack initiation, fatigue indicator parameter
COUPLED CRYSTAL PLASTICITY-PHASE FIELD
MODELLING OF MULTI-PHASE METALS
Ritesh Dadhich, Alankar Alankar
Mechanical Engineering Department, IIT Bombay, Powai, Mumbai,
Maharashtra 400076
Email of corresponding author: ritesh.dadhich@iitb.ac.in
A code has been developed based on image based crystal plasticity
modeling of multiphase metals. This model coupled with equilibrium
equation and compatibility constraint is solved at each material point of
representative volume element (RVE). A phenomenological dislocation
density based constitutive model describes the material behavior. Crystal
kinematics couples the boundary conditions to constitutive behaviour by
integrating evolution equation for elastic deformation gradient obtained
using the multiplicative decomposition of deformation. The code is tested
for linear homogeneous isotropic elastic material with embedded
inclusions. We analyze two types of inclusions namely an elastic
inclusion and a void. These two baseline studies have been compared
against solutions from currently available commercial and open source
packages. In the second example we study the time evolution of residual
stresses due to growing phases. Such models are especially useful for
understanding the role of interactions and co-deformation of multiple
phases on the overall mechanical response of a multiphase metal.
Experimental data set found in the literature is used for calibration of the
constitutive equations.
Keywords: Crystal Plasticity, Micromechanics, Dislocations, ICME
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

ROLE OF DISLOCATION REACTIONS ON THE

PLASTIC DEFORMATION OF COPPER SINGLE
CRYSTALS

Ashish Mishra, Alankar Alankar

Department of Mechanical Engineering, Indian Institute of Technology
Bombay, Powai, Mumbai, Maharashtra 400076
ashish.mishra15@iitb.ac.in

The hardening behavior of a metal single crystal is controlled by

dislocation interactions leading to junction formation when the
dislocations glide on various slip systems during plastic deformation. All
junctions need not necessarily contribute to hardening. In an FCC crystal,
four independent dislocation reactions are possible namely: the Hirth
lock, Lomer-Cottrell lock, collinear junctions and glissile junctions. The
first three reactions restrict further glide of dislocations in the specimen
whereas the fourth one produces new dislocations that are free to glide on
the new slip system.
Crystal plasticity of copper single crystals in monotonic loading is
studied.The crystal was subjected to tensile straining along [1 0 0], [1 1
1], [1 1 2] and [2 1 3] axes for studying the effect of crystallographic
orientations.The interactions occurring between the dislocations,
formation of junctions, occurrence of cross-slip and dislocation density
evolution were analyzed. Also, analysis was carried out to identify the
number of occurrences of different reactions as a function of orientation
mentioned above.
Keywords: Dislocation, crystal plasticity, copper, ICME
FINITE ELEMENT ANALYSIS FOR CABLE AND
PIPE TRANSIT SEAL FOR NUCLEAR POWER
PLANT APPLICATIONS
Vikrant Gupta, N.P.Singh, Ujjwal Baruah
Power Supply Group
Iter-India, Institute For Plasma Research, Bhat, Gandhinagar
Email of corresponding author: vikrant.gupta@iter-india.org
The Cable and pipe transit seal hereafter referred as Epoxy bulk head
allows transition of cables and pipes among radiation zones and outer
environment of nuclear installations. The epoxy bulkhead needs to be
designed for structural load, Thermal load, Pressure gradient load, and
Electric field stress and neutron radiation.
Epoxy bulk acts like an adaptor for hydraulic lines, gas feed lines,
cable/busbars (at high voltage) while providing containment function. It
is envisaged that these components to be embedded under resin cast and
formed as plug to meet the functional requirements of high voltage
withstand at 120kV. Structural integrity of epoxy bulkhead need to be
analyzed for load induced due to pressure difference, structural load as
part of integrated system, assessment of thermal stresses arising from
hydraulic lines.
Large size epoxy casting with several embedment is not common with
industry. Further, Specific procedure to qualify pressure leak test, High
voltage test and Thermal load need to be developed. A full scale
prototype is proposed to be established casting, embedment method and
mold development.
SMALL SCALE IN SITU MECHANICAL TESTING
OF Cu-Bi AND THE EFFECT OF
MICROSTRUCTURE ON FAILURE
AnanyaTripathi*, VikramJayaram, Praveen Kumar
Department of Materials Engineering, Indian Institute of Science,
Bangalore – 560012, India
*E-mail address: ananya.tripathi1993@gmail.com
Research is being performed to develop Cu-Bi as a high temperature
solder alloy that can operate at temperatures greater than 200 ºC. This
work is conducted to evaluate the mechanical integrity of Cu-Bi under
tensile condition. Althoughsolubility of Bi in Cu is negligible, these two
constituents have excellent wettability. However, it is very challenging to
get a homogenous distribution of Cu and Bi through casting. Cu-Bi alloy
was cast using a special technique, involving melting in vacuum followed
by stirring, to achieve various types of microstructures. Effect of three
types of microstructures, with different types of orientation and
distribution of Cu dendrites in the sample, on the room temperature
mechanical behavior and the failure mechanism of Cu-Bi was studied.
Miniaturized samples with optimized geometry were prepared from the
cast rod using electron discharge machining for conducting in
situmechanical testing inside a scanning electron microscope (SEM),
enabling direct observation of onset of failure. The failure was observed
to originate from Bi rich regions and the crack propagated along the Cu-
Bi interface across the gauge section. Digital image correlation (DIC)
technique was used as a non-contact technique for measuring strain and
plot strain field in the sample. Furthermore, microstructure based finite
element analysis (FEA) was performed to determine the stress and strain
distributions along the different phases and interface of Cu and Bi in the
microstructure. The FEA simulation results were compared with the DIC
results, and it was determined that the high strain regionswere confined
along the Cu and Bi interface.
Keywords: Cu-Bi alloy;In situ mechanical testing;Microstructure based
FEM; Digital image correlation


Simulation based on FEA is presented for epoxy bulk head having

thickness of 350mm with a diameter of 1650mm. Arrangement of internal
embedded components in coaxial arrangement is analyzed for structural
load, thermal load, Pressure gradient & Electric field stress. Assessment
of radiation induced conductivity shall be studied subsequently upon
availability of radiation exposure dose.

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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session4C:StructuralIntegrityVIII
Chairman:GAppaRao,DMRL
SessionCoordinator:SSKalyanKamal,DMRL
14151442 InvitedTalk:MechanismsforFatigueStrengthDegradationinCementitious
Materials
JMChandraKishen,IndianInstituteofScience,Bangalore
14421454 AnalysisofStructuresSubjectedtoCrowdLoads
AngithaVijayan,NimmyMariamAbraham,S.DAnithaKumariandM.VDeepthi
MSRamaiahUniversityofAppliedSciences,Bangalore
14541506 EffectofElevatedTemperatureontheMechanicalPropertiesofConcrete
D.AnupamaKrishna,RSPriyadarsiniandS.Narayanan
KeralaTechnologicalUniversity
15301542 RelocationofexistingjacketplatforminwesternoffshoreofIndia
PraveenBhatandS.Karunanithi
OilandNaturalGasCorporationLtd.(ONGC)
15541606 Failureinvestigationofsuperrapidgunmountcartridgecase
RajeshSharma,PTekade,RaviKiran,VijayLaxmi,SatyapalSinghandAKSingh
DefenceMetallurgicalResearchLaboratory,Hyderabad
16181630 Determinationofoptimalcouplingstiffnessusingmodalupdatingtechniquesfor
StiffenedPlates
K.Shrivastava,K.VijayanandV.Arora
IndianInstituteofTechnologyKharagpur
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
MECHANISMS FOR FATIGUE STRENGTH
DEGRADATION IN CEMENTITIOUS MATERIALS
J M Chandra Kishen
Professor, Dept. of Civil Engineering,
Indian Institute of Science, Bangalore
chandrak@iisc.ac.in
Concrete which is one of the most widely used construction material, is
treated as homogeneous from a design perspective. However, on a close
meso level examination it is observed that the internal structure is
heterogeneous, consisting of coarse aggregates embedded in cement
matrix. Further, there exists a region, known as the interfacial transition
zone (ITZ) which occurs between the cement paste and aggregates. The
cement paste and aggregates are bonded at the interface whose strength
depends on its microstructural characteristics. The stiffness of the
interface decreases although the individual components on either side of
the interface possess high stiffness due to the presence of voids and
microcracks. The packing and density of the cement particle around the
aggregates defines the strength of the interfacial zone. Hence, the
macroscopic behavior of concrete is influenced by the properties and the
physical mechanisms occurring at the meso or micro scales. The effect of
microstructure on the overall behavior is more pronounced at the initial
stages of damage which provides scope for preparing engineered
materials for design purposes. In this presentation, the role of different
mesoscopic parameters (such as the aggregate size, volume fraction of the
aggregates, elastic properties of the constituents and the properties of the
aggregate-mortar interface) and the mechanisms responsible for
degradation of stiffness under fatigue loading investigated using the
acoustic emission technique would be highlighted.
ANALYSIS OF STRUCTURES SUBJECTED TO
CROWD LOADS
Angitha Vijayan1, Nimmy Mariam Abraham2*, Anitha Kumari S D3,
Deepthi M V2
1
Post Graduate Student, 2Assistant Professor, 3Associate Professor
1,2,3
Department of Civil Engineering, M S Ramaiah University of Applied
Sciences,
Peenya, Bangalore 560 058
Email: *nimmy555@gmail.com
The movement of people on any structure induces dynamic crowd load.
The enthusiastic potential behaviour of people, from overwhelming
happiness in concert, shows etc. on structures such as stadiums,
auditorium, grandstands, bridges, malls and convention centres causes
synchronised rhythmic movements. Resonance between forcing
frequency and one or more natural frequencies of the structure resulting
from human-structure synchronization leads to strong vibrations. Such
vibrations not only affect structural stability, but also create discomfort
among people. Pedestrian induced lateral vibration of Millennium Bridge,
London is a classic example for the same. Crowd loads impose vertical as
well as horizontal loads on the structure. Vertical loads are attributed to
weight of the crowd whereas horizontal loads are due to crowd
movement. Both these loads induce vibrations in corresponding
directions. Beyond an acceptable limit of vibration level, people may feel
uncomfortable. If there is a mode of low natural frequency, even a
significantly low forcing frequency can lead to strong vibrations, which
in turn may cause panic. The present research focusses on analysis of a
reinforced concrete frame subjected to crowd loads. The load due to
crowd is analytically modelled and dynamic analysis is carried out in a
linear elastic framework. Furthermore, the effect of various parameters
such as crowd size, mass of the structure and damping on the structural
response is studied. This study helps in predicting the comfort level of the
people for any similar structure carrying crowd of given size.


EFFECT OF ELEVATED TEMPERATURE ON THE
MECHANICAL PROPERTIES OF CONCRETE
AnupamaKrishna.D1, Priyadarsini R S2, Narayanan S3
1
Reserach Scholar, Department of Civil Engineering, College of
Engineering, Trivandrum, Kerala
anupamakrishnad@gmail.com
2
Professor, Department of Civil Engineering, College of Engineering,
Trivandrum, Kerala. Trivandrum, Kerala
Priyadarsini_rs@yahoo.com
3
Prof. & Head of Department, Department of Civil Engineering,
Mohandas College of Engineering, Trivandrum,
Kerala.nsambupotty@yahoo.com
Cement concrete is widely used as structural material in building
construction where fire resistance is one of the key considerations in
design.High temperature is well known for seriously damaging concrete
micro- and meso-structure, which brings in a generalised mechanical
decay of the concrete and even detrimental effects at the structural level,
due to concrete spalling and bar exposure to the flames, in case of fire.
Concrete, at elevated temperatures undergoes significant physicochemical
changes. Fire response of concrete structural members is dependent on
the thermal, mechanical, and deformation properties of concrete.Because
of the relevance of concrete behaviour at high temperature and in fire,
many studies have been carried out, even very recently, on cementatious
composites at high temperature, and the most relevant parameters have
been identified and investigated. In this paper, the results on the effect of
elevated temperature on the mechanical properties of concrete are given.
The mechanical properties that are of primary interest in fire resistance
design are compressive strength, tensile strength, elastic modulus, and
stress-strain response in compression.For this cubes and cylinders of
standard size have been casted and subjected to elevated temperature
from 100oC to 1000oC and then tested for different regimes of
temperature. The variation of mechanical properties of concrete with
temperature is not available in the Indian Standards, so an attempt has
been made to study the properties of concrete at elevated temperature, so
that the curves generated can be used for design criteria if possible. The
experimental values thus obtained have been compared with the variation
of values with Eurocode (EN 1991-1-2), ASCE (American Society of
Civil Engineers,) and Published literature.
Keywords: Concrete Spalling, Elevated temperature, Elastic Modulus,
Stress – Strain response
RELOCATION OF EXISTING JACKET
PLATFORM IN WESTERN OFFSHORE OF INDIA
Praveen Bhat, S. Karunanithi
Institute of Engineering & Ocean Technology (IEOT)-ONGC-Panvel,
Mumbai-India
bhat_praveen@ongc.co.in
ONGC started its hunt for “Black Gold” in the Indian western offshore
region in 1976 and is currently operating more than 280 fixed platforms
in water depths ranging between 25-90m. Many of the existing wells on
the platforms have matured over a period of time, resulting in decline of
productivity. Considering the techno-commercial constraints for offshore
development, IEOT-ONGC has taken up a study for re-location of
existing non-producing offshore platform to a newer location. The
structural adequacy of the existing structures at new locations has been
ascertained for 100 year return period extreme storm condition and other
design loads as per API RP 2A (WSD), considering in-situ met-ocean and
soil conditions. The structural integrity assessment procedure using
design level and ultimate strength level analyses explores the need
for strengthening/mitigation measures in case the inherent capacity of the
structure to withstand the incoming loading is not sufficient at the new
site of installation.
For relocation of existing jacket platforms to new locations at different
water depths in western offshore of India, a general philosophy for
foundation design has been developed in the form of:
1. Installation of plinth platform for relocation to field where water
depth is higher than existing one.
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

2. Installation of insert piles and extra clamp-on skirt piles, if required, DETERMINATION OF OPTIMAL COUPLING
where water depth at relocation is similar to existing water depth for the
platform.
STIFFNESS USING MODAL UPDATING
The platform relocation process will include the abandonment and TECHNIQUES FOR STIFFENED PLATES
decommissioning aspects like well plugging and abandonment (P&A),
purging of hydrocarbons from pipelines and equipments followed by K. Shrivastava*1, K. Vijayan1, V. Arora2
1
platform removal. After removal, the platform structure will be Dept. of Ocean Engineering and Naval Architecture, Indian Institute of
refurbished for making it compatible for installation at the new location. Technology Kharagpur
This is a first of its kind project in the Indian sub-continent and would Kharagpur, India - 721302
2
help in realizing early monetization from the new offshore fields. ITI, SDU Mechanical Engg, Campusvej 55, 5230 Odense M, Denmark
Email of corresponding author: krshrivastava@iitkgp.ac.in
Platform to be Water Depth New Water Depth (m)
Stiffened structures are often utilized as structural members for numerous
relocated (m) Location at new location
applications in various fields of engineering like Civil, Automobiles,
A 25 Y 25.1 Naval, Aerospace, etc. Thus analyzing stiffed structure for their structural
A 25 Z 33.84 integrity become pivotal. Simplest instance of a stiffened structure could
B 19 X 22.65 be a plate with a beam acting as a stiffener. The presented study focuses
B 19 Y 25.1 on Modal analysis of a stiffened plate comprising of a base plate and a
B 19 Z 33.84 beam attached to it in the longitudinal direction. Numerical analysis is
C 19 X 22.65 carried out by formulating a FE model for the beam and plate. The plate
C 19 Y 25.1 and beam elements are coupled using discrete spring element. The
C 19 Z 33.84 capability of the model is verified by comparing the natural frequencies
obtained through ANSYS simulation and experimental techniques. A
Table 1: Feasibility Study for Relocation to new fields numerical based model updating was carried out to determine the optimal
spring stiffness using Latin hypercube sampling. The optimal values of
the spring stiffness were determined which reduced the error in the
natural frequencies.

Fig. 1: Platform Relocation Process

FAILURE INVESTIGATION OF SUPER RAPID

GUN MOUNT CARTRIDGE CASE

Rajesh Sharma*, P. Tekade, Ravi Kiran, Vijay Laxmi, Satyapal Singh

and A. K. Singh
Scientist, Defence Metallurgical Research Laboratory, Kanchanbagh
P.O., Hyderabad – 500 058, India.
rajeshsharma2301@gmail.com

Present work describes a failure analysis of super rapid gun mount

cartridge case (CC). It is a light weight, rapid fire naval gun. Few
indigenized cartridge cases were failed during trial. Two broken pieces of
a cartridge case have been received for failure investigation. The failure
of this CC has taken place near the head region. The thorough
investigation was accomplished which involved photography, stereo
microscopy, chemical analysis, fractography, microstructural
characterisation and hardness measurement. The CC is made up of 70/30
cartridge brass alloy which is an equivalent to C26000 alloy. The most of
the fracture surface are rubbed and covered with oxide layers. Pits and
secondary cracks are observed at some places. Microstructure profile
shows equiaxed grains with twins and heavily deformed grains with shear
bands depending upon the location from shoulder to head region of the
case. The same is reflected from the hardness profile. The Vickers
hardness values are from 101 to 190 Hv at neck and head regions,
respectively. The outer surface of CC is coated with Kal Gard Gun Kote.
The pits and branched cracks are observed on the inner surface of CC
which is a typical feature of stress corrosion cracking. These cracks are
seen extending deep into the section causing loss of strength of material.

62

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session4D:FailureAnalysis
Chairman:RKSatpathy,DMRL
SessionCoordinator:ChandanMondal,DMRL
14151442 InvitedTalk:FailureofstrategicalloysduringproductionanduseSomecase
studies
PallabSarkar,VardhamanCollegeofEngineering,Hyderabad
14421454 FailureAnalysisofaCrackedSplicePlateUsedinaPowerTransmissionLineTower
S.K.Dhua,P.P.Sarkar,SantoshKumarandAtulSaxena
R&DCentreforIron&Steel,SteelAuthorityofIndiaLimited,Ranchi
14541506 Failureanalysisofstructuralscrewjointinastartupneutrondetectorhandling
mechanism
SudheerPatri,Hemantkumar,K.KrishnaPrasad,C.Meikandamurthy,B.K.
Sreedhar,R.Vijayashree,V.PrakashandP.Selvaraj
IndiraGandhiCentreforAtomicResearch,Kalpakkam
15181530 Failureanalysisofoilpipelinesofanaeroengine
JivanKumar,V.NSatishKumarandSwatiBiswas
GasTurbineResearchEstablishment,Bangalore
15301542 FailureAnalysisofSpiralBevelGearofEngineAccessoryGearBoxinaFighterclass
Aeroengine
NMoharanaandBenudharSahoo
RegionalCentreforMilitary&Airworthiness(RCMA),DRDO,Sunabeda
15421554 FailureAnalysisofCoolingDuctofTopEngineCowlPanelofFighterAircraft
PremkumarManda,SatyapalSinghandAKSingh
DefenceMetallurgicalResearchLaboratory,Hyderabad
16061618 StructuralFailureofAfterburnerDiffuserofaMilitaryAircraftEngine
PKRao,SASavanur,BenudharSahoo
HindustanAeronauticsLtd,Koraput
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
FAILURE ANALYSIS OF A CRACKED SPLICE
PLATE USED IN A POWER TRANSMISSION LINE
TOWER
S.K. Dhua, P.P. Sarkar, Santosh Kumar & Atul Saxena
Research and Development Centre for Iron & Steel, Steel Authority of
India Limited, Ranchi-834002
E-mail of Corresponding Author: skdhua@sail-rdcis.com
Steel splice plates are used in power transmission line towers (Fig. 1).
During service, some of these plates may fail due the loading stress as
well as stress generated due to inclement weather condition. One such
failed splice plate (Fig. 2), cracked in the heel region of the plate has been
studied in detail to find out genesis of such failure. Metallographic study
of the failed plate material near the crack and away from the crack
indicated presence of white hard martensite layer near the crack (Fig. 3).
Evaluation of mechanical properties of the plate material carried out at
heel and edge regions had also supported the above findings. There was
enhancement of hardness, yield strength, tensile strength of the plate near
heel which had indicated localized hardening of the plate in this region
due to presence of martensite. A substantial deterioration of the Charpy
impact toughness of the material at the heel region could also be observed
particularly at sub-zero testing temperatures due to the same reason. The
material inadequacies and operational stresses must have caused the
initiation and propagation of the cracks in the heel region of the plate
leading to its premature failure.
FAILURE ANALYSIS OF STRUCTURAL SCREW
JOINT IN A START-UP NEUTRON DETECTOR
HANDLING MECHANISM
Sudheer Patri*, Hemant kumar, K. Krishna Prasad, C. Meikandamurthy,
B. K. Sreedhar, R. Vijayashree, V. Prakash, P. Selvaraj
Indira Gandhi Centre for Atomic Research, Kalpakkam
* Corresponding author: patri@igcar.gov.in
This paper deals with the failure analysis of a structural screw joint
located in the load transfer path of a complex mechanism called Start up
Neutron Detector Handling Mechanism (SNDHM). SNDHM is a carrier
mechanism for high temperature neutron detectors, which measure the
neutron flux during initial criticality. The overall length of this long
slender mechanism is 15 m and having maximum diameter of 200 mm.
During performance testing, failure was observed in all the 6 no’s of M5
screws of this structural joint. These screws were as per standard IS 1367-
3 with property class 12.9. Subsequently, these failed screws were
analysed to find out the root cause of failure, so that necessary measures
can be adopted to prevent such failure in future. Fracture surfaces of
failed screws were examined by scanning electron microscopy (SEM),
which revealed fully ductile mode of fracture. Energy dispersive x-ray
spectrocopy (EDS) was also carried out on the fracture surfaces, which
61 HRC. Gear has failed
revealed traces of oxide inclusions. Chemical analysis from EDS
indicated deviation in chemical composition of screw material from the
standard. To confirm the material mismatch, hardness of this screw
material was also measured using vicker’s macro-hardness tester. Results
revealed an average hardness of 229 HV10 against specified value of 356
– 414 HV10. Based on the hardness values, which is nearly 40% lower
than the expected value, it is assumed that the estimated strengh of the


screws would be much lower than the specified values as per standard.
This implies that the joint has failed at load, which is much lower than
the designed value. However, the possibility of over load either due to
errors in assembling or due to operation cannot be ignored. It is
postulated that the un-noticed motor over-travel during final stages of
testing would have resulted in over load. It is proposed to incorporate a
torque limiter in the drive line of the mechanism to prevent over loading
due to erroneous motor operation in future, apart from use of screws
which comply with the standard.
FAILURE ANALYSIS OF OIL-PIPE LINES OF AN
AERO-ENGINE
Jivan Kumar, Satish Kumar VN, Swati Biswas
Materials Group, Gas Turbine Research Establishment, Bengaluru, India
Corresponding author e-mail: swati@gtre.drdo.in
Leakage from the pipeline supplying oil to the aero-engine bearing was
observed during testing. The incident was found to repeat for another set
of same pipeline when subjected to pressure test. In this case the pipelines
were already used in engine testing for about 100 hours. The pipes were
manufactured using austenitic grade stainless steel. The end fittings of the
pipelines were austenitic grade stainless steel adapters which were TIG
(Tungsten Inert Gas) welded to the pipes. Subsequent to the dis-assembly
of the pipelines, the region of leakage was examined under stereo-
binocular microscope. In both the cases, cracks were noticed near the
weld joint. Higher magnification scanning electron microscopy
confirmed presence of multiple cracks in both the components. The crack
was found to be mostly in the heat affected region except for a very small
length where it was very near to the weld region. Fractographic analysis
was carried out after opening the cracks. At higher magnification,
fractured surface revealed faceted structure typically observed in stress
corrosion cracking failure. Presence of corroding elements was also
identified on the fractured surface by energy dispersive spectrum
analysis. Fractographic features and composition analysis results pointed
towards stress corrosion cracking in both the pipes.
Key-words: austenitic stainless steel, TIG welding, SCC

FAILURE ANALYSIS OF SPIRAL BEVEL GEAR
OF ENGINE ACCESSORY GEAR BOX IN A
FIGHTER CLASS AERO-ENGINE
1
N Moharana, 2Benudhar Sahoo#
1
Scientist, 2Regional Director, RCMA (Koraput), CEMILAC,DRDO,
India
E-mail: 1moharana.n@gmail.com 2rdrcma.kpt@cemilac.drdo.in
# Corresponding author
Engine Accessory Gear Box (EAGB) in an aircraft engine is used to drive
the various engine accessories. The high level dependence upon
aggregates (mounted of gearbox) requires an extremely reliable gearbox
drive system which transfers power from HP(high pressure) rotor to the
EAGB through a pair of spiral bevel gears in a twin spool aero-engine.
This case study deals with failure analysis of a failure of spiral bevel gear
of EAGB in a twin engine aircraft leading to single engine landing.
The failed spiral bevel is gear made of low alloy carburized steel of
Russian origin with average chemical constituents of major elements C:
0.15, Cr: 2.7, Ni: 1.3, Mo: 0.5 and W: 1.2. Basic manufacturing route is
forging while generation of tooth profile is by tooth milling & grinding.
Surface hardening of gear tooth is carried out by carburizing to achieve a
case depth of 1.1-1.3mm and case hardness of
approximately at a sector of 60° arc. The mode of failure is fatigue
indicated by distinguished beach marks with the initiation point at the
root radius on a machining mark. Through cracks are observed on the rest
of the failed gear with a magnification of 3X.
Chemical composition analysis could conform to specification, however
the effective case depth is found to be higher than the specification limit.
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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Carburizing not only provides wear resistance at the mating surface of
gear but also introduces residual compressive stress that enhances fatigue
life. Stress concentration effect due to machining marks in combination
with poor core toughness could cause premature failure of gear.
KEYWORDS: Engine Accessory Gear Box (EAGB), Spiral Bevel Gear,
Tooth Milling, Carburizing, Beach marks, Fatigue
FAILURE ANALYSIS OF COOLING DUCT OF TOP
ENGINE COWL PANEL OF FIGHTER AIRCRAFT
Premkumar Manda*, Satyapal Singh and A K Singh
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad –
500 058
*Corresponding author. Tel.: +91-9949663492; fax: +91-40-24340681.
E-mail address: premkumarmanda@gmail.com,
prem_manda@yahoo.co.in
two parts namely, Part-I covers failure analysis of puncturing of diffuser
casing while Part-II deals with optimization of refurbishment schemes by
FEM analysis and experimental evaluation. Metallurgical investigation
could reveal that the puncturing of casing is due to accumulation of hot
gas leading to higher hoop stress in combination with reduced strength at
elevated temperature. Undue stress developed due to thermal expansion
& contraction along with the coarse grain structure at HAZ resulted in
development of cracks causing its replacement during overhaul.
Geometrically flange resembles a T-piece with its major dimensions are
height and length. Flange height is reduced by 3mm from the specified
dimension of 15mm for achieving higher thickness near the transition
area of the step. Length has been increased by 5mm from the drawing
dimension of 28mm to shift the HAZ to a lower stress location.
Structural and thermal stress analysis was carried out on the new flange
and it was observed that the equivalent Von-Mises stress at weld zone
reduced by 6.25% than the original weld zone. Further, dye penetrant
(DP) check was introduced at operating units to reveal such cracks
thereby obviating a major failure.

Present work describes the failure analysis of cooling duct of fighter

aircraft. The broken material pieces of cooling duct of Top Engine Cowl
panel have fallen off during incident. The analyzed chemical composition
of cooling duct indicates that it is manufactured from Al-based alloy (AA
3003 or its equivalent). The microstructure of the cooling duct displays
the presence of two phases, namely, matrix and insoluble particles. These
particles appear to be Fe-Mn-Al ((Fe, Mn)Al6)) and Al-Mn-Si
compounds. The hardness values at different locations within damaged
area of cooling duct reflect nearly same and consistent.
The fracture surfaces of the cooling duct shows the different features such
as micro-cracks, mud cracks, fatigue and featureless features. This also
exhibits transgranular features and cracks with little branching. The
analyzed hydrogen content in cooling duct is significantly higher (a12
ppm) than the specified one (1 ppm). However, the alloy used to
fabricate cooling duct is not susceptible to typical hydrogen
embritlement. Thus, the hydrogen pick up has occurred during service.
The presence of secondary cracks with branching does indicate features
of hydrogen embattlement. In addition, some kind of fatigue features is
also observed. It thus appears that the cooling duct has failed due to pick
up of large amount of hydrogen as well as vibrational fatigue.

Keywords: Cooling duct; Aluminium alloy; Hydrogen embrittlement.

STRUCTURAL FAILURE OF AFTERBURNER

DIFFUSER OF A MILITARY AIRCRAFT ENGINE
1
P K Rao, 2S A Savanur, 3 Benudhar Sahoo
1
Sr. Manager, HAL Koraput, India
2
Addl Director 3Regional Director, RCMA (Koraput), CEMILAC,
DRDO, India

In a military aircraft engine, after burner provides the augmented thrust

requirements during operation. Afterburner diffuser in an aero-engine is
designed to reduce gas flow to have a reliable ignition and combustion
during reheat regime of operation. It is of hollow tapered cylindrical
configuration with reinforcement of the both ends of the cylinder by
flanges with the help of fusion welding as shown in fig.1. The diffuser
casing is made of nickel bases alloy of 1.2mm thickness while the flange
are fabricated from nickel base alloy forgings.

Fig.1 Cross sectional view of Afterburner Diffuser

Puncturing of diffuser casing during operation of an aero-engine causing
abnormal flame led to aborting the mission. This case study comprises

64

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session4E:AdditiveManufacturingandStructuralIntegrityIX
Chairman:KRaviChandar,UniversityofTexas,USA
SessionCoordinator:TSreekanthaReddy,DMRL
14151442 InvitedTalk:Fracturebehaviourof3Dprintedthermoplastics
SivaNadimpalli,NewJerseyInstituteofTechnology,USA
14421454 ResidualStressMeasurementon3DPrintedBlocksofTi6Al4VusingIncremental
HoleDrillingTechnique
DigendranathSwain,SKarthigaiSelvan,BinuPThomas,GovindandJebyPhilip
VikramSarabhaiSpaceCenter,ISRO
14541506 SmallScaleMechanicalTestingforLaserAdditiveManufacturing
SudarshanReddyandDheepaSrinivasan
IntechDMRLPvt.Ltd
15061518 StructuralandMechanicalBehaviorofAdditiveManufacturedIN718Superalloy
GururajTelasan,K.DivyaandG.Padmanabham
InternationalAdvancedResearchCentreforPowderMetallurgyandNewMaterials,
Hyderabad
15181530 MicrostructuralinfluenceondampingforFrictionstirweldedAluminumplates
K.Vijayan,S.Jothi
IndianInstituteofTechnologyKharagpur
15301542 EffectofPoisson’sratioonKI,T11andT33forSENBandCTspecimenAFEstudy
SanjeevM.Kavale,KrishnarajaG.KodanchaandNagarajEkabote
KLETechnologicalUniversity,Hubballi,Karnataka
15421554 DuctileFractureinTubeImpactProblemUsingALodeAngleDependentFailure
Criterion
DipankarBora,SachinS.GautamandManojKumar
IndianInstituteofTechnologyGuwahati
16061618 SystemReliabilityofRandomlyVibratingStructuresunderSupportExcitations:
ComputationalModelingandLaboratoryTesting
A.SomayyaandC.S.Manohar
BangaloreIntegratedSystemSolutionsPvt.Ltd.,Bangalore
16181630 Astudyonimpactforceattenuationcapabilityofclosedcellaluminiumfoams
SNSahu,TSreekanthReddy,PRamasubbaReddy,PSampathKumar,GJReddyand
AAGokhale
DefenceMetallurgicalResearchLaboratory,Hyderabad
 




SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
FRACTURE BEHAVIOR OF 3D PRINTED
THERMOPLASTICS

Siva Nadimpalli
Associate Professor of Mechanical Engineering
New Jersey Institute of Technology, NJ, USA
Siva.p.nadimpalli@njit.edu
Fused deposition modelling (FDM) is a 3D printing technique which has
a thermoplastic polymer filament heated above glass transition
temperature and is extruded through a nozzle to print layer by layer of a
part. While stress and strain based experiments were performed on these
components, fracture toughness data which is an important property of
these thermoplastics is not available. In this work a fracture mechanics
based methodology was developed to characterize the interlayer fracture
of 3D printed polymer. A relationship between the process parameters
and the fracture resistance of 3D printed parts will also be presented.
Double cantilever beam (DCB) specimens were designed and printed
with a pre-crack at the interface of the layers. Bulk elastic properties were
obtained by tensile testing of filaments and 3D printed dog bone. Critical
crack initiation loads from the tests were used in finite element model of
the DCB samples to determine the critical energy release rate. The result
indicated that nozzle temperature and layer heig ht had the most
significant effects on the fracture resistance. The bed temperature and the
layer width appeared to be less significant factors, compare to the nozzle
temperature. The data reported here will provide insight and guidance in
the design of fracture-resistant 3D printed parts for structural and
functional applications.
RESIDUAL STRESS MEASUREMENT ON 3-D
PRINTED BLOCKS OF Ti-6Al-4V
USING INCREMENTAL HOLE DRILLING
TECHNIQUE
Digendranath Swain#1, S Karthigai Selvan1, Binu P Thomas1, Govind2,
Jeby Philip1
1
Experimental Mechanics Division, STR Entity, Vikram Sarabhai Space
Centre, ISRO, Trivandrum, India
2
Foundry Technology Division, MME Entity, Vikram Sarabhai Space
Centre, ISRO, Trivandrum, India

Corresponding author: digendranath@gmail.com
Additive manufacturing (AM) though 3-D printing is envisaged to be a
futuristic alternative for rapid and low-cost production of aerospace
components. One of the primary issues in such fabrication processes are
the emergence of large magnitude of residual stresses. Residual stresses
are detrimental for the structural integrity of any component or structure
if it magnifies the service stresses. Therefore, mitigation plans for
reducing residual stresses developed in the components must be in place.
In this paper, a study involving the measurement of residual stresses on
rectangular blocks of Ti-6Al-4V fabricated through Direct Metal Laser
Sintering (DMLS) process has been carried out. Measurement on two
blocks after annealing was also carried out to compare the residual
stresses in as fabricated condition and after annealing. The results
indicate that large tensile residual stresses inherent in the as fabricated
blocks vanish through annealing. The extension of such mitigation plans
to components or subassemblies must be planned so that the remaining
service life of any structure is enhanced without introducing any
structural deviation and warpage.
SMALL SCALE MECHANICAL TESTING FOR
LASER ADDITIVE MANUFACTURING
Sudarshan Reddy and Dheepa Srinivasan
INTECH DMLS, Pvt. Ltd., Bangalore
Direct metal laser sintering(DMLS) is now gaining a lot of popularity as
an Additive manufacturing technique with parts being built to near net
shape in a simplified manner, leading to direct benefits via, lighter, more
efficient and economically feasible designs (for Additive Manufacturing).
From being a mere prototype generator, the Additive Manufacturing


Technology is now capable of being suitable for full fledged batch
production of parts, to cater to the demands of the Aerospace and
Aviation, Power, Automotive, Healthcare, engineering and other
industries. A series of complex process parameters are required to
produce functional parts via the DMLS process, such as laser power, scan
speed, hatch distance and layer thickness, that are required to enable
dense parts, with superior and consistent mechanical properties.
Mechanical testing during production involves having test specimens in
every build plate and is usually an expensive and time consuming
process. In this study, small scale test specimens have been fabricated for
several additively manufactured alloys, IN718, MM247LC, CoCrMo,
Maraging steel etc., and these have been tested at room temperature,
before and after the required heat treatment, along and perpendicular to
the build direction. Comparisons have been made between the small scale
specimens with standard ASTM specimens and the key differences /
similarities have been elucidated, in a bid to bring in small scale testing
for Additive manufacturing.
STRUCTURAL AND MECHANICAL BEHAVIOR
OF ADDITIVE MANUFACTURED IN 718
SUPERALLOY
Gururaj Telasang, Divya K and G. Padmanabham
International Advanced Research Center for Powder Metallurgy and New
Material
Balapur P.O., RCI Road, Hyderabad – 500 005
Powder bed selective laser melted (SLM) metal additive manufacturing is
a technology of building a virtual 3D CAD model into a functional
component by melting and solidifying metal powder layer upon layer.
Powder bed layered additive manufacturing process involves spreading of
metal/alloy powders of 30 – 50 microns layer thickeness followed by
laser melting of these layers in multiple passes. Further, each of the layers
are subject to rapid solidification and overlap effects between passes
leading to possible defects like porosity, microstructural anisotropy,
residual stresses and surface roughness in the built part. Such inevitable,
process induced structural defects are to be evaluated and addressed for
successful validation of additively manufactured components for a given
application. Aerospace is one of main application sectors for additive
manufacturing, wherein Ni-based superalloys are used extensively.
In the present work, powder bed additive manufacturing of IN 718 a Ni-
based superalloy was carried out and the built parts were analysed for
various defects. Laser assisted metal powder bed SLM 280 HL system is
used to build test coupons in various orientations and combination of
process parameters. Process has been investigated to minimize defects
and sets of test coupons were generated and studied at different stages of
post heat treatment for various metallurgical and mechanical properties at
room temperature. Achieved surface roughness, porosity,
microstructures, phases and residual stress, hardness and tensile behavior
will be discussed in detail. Also, results of a few attempts made on
similar and dissimilar material additive manufacturing using IN 718 alloy
powder on wrought IN 718 pates, stainless steel, copper and titanium will
be covered in terms of microstructures, phases formed and strength
achieved at interface.
Key Words: Selective Laser Melting; Additive Manufacturing; powder
bed technique; superalloy
MICROSTRUCTURAL INFLUENCE ON DAMPING
FOR FRICTION STIR WELDED ALUMINUM
PLATES
K. Vijayan1, S.Jothi2
1
Dept. of Ocean Engineering and Naval Architecture, IIT Kharagpur,
Kharagpur - 721302, India
2
College of Engineering, Swansea University, Bay Campus, Swansea,
SA1 8EN, UK
Email of corresponding author: kiran.vijayan@naval.iitkgp.ac.in
Friction Stir Welding (FSW) is a solid state process. in which a rotating
tool moves along the butted surfaces of rigidly clamped plates to form the
65

SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS
weld. The speed of rotation, the axial load, feed rate and the type of tool
influences the structural properties of the weld. An experimental study
was carried out on Marine grade aluminum plates by varying the carriage
speed, rotor speed and tools. The parametric study was carried out using
three sets of carriage speed, rotor speed and tools. The FSW welded
plates were analyzed for strength using universal testing machine. From
the test results best, intermediate and worst cases were separated out
based on the tensile strength and strain. One of the contributing factors
towards this variability could be the sensitivity of friction coefficient.
This results in improper heating and material distribution across
advancing and retreating side. The microstructure of the welds was
analyzed using microscope and EBSD. EBSD was carried out only for
the sample with good structural strength. The analysis of microstructure
clearly demarcated zones of base metal, heat affected, thermo
mechanically affected and stirred (nugged) zone). Next the influence of
these microstructural grain properties on macroscopic damping behavior
was analyzed by carrying out a modal testing on the welded structure.
Understanding the damping behavior is helpful in characterizing the
vibration of the structure. Sensitivity analyses on the variations in the
damping for different natural frequencies were carried out. The position
of analysis in the case of single sample (best case) was varied. But in the
case of analysis for different samples the position was fixed. The study
clearly indicated a sensitivity of damping on the microstructural
properties the FSW welded plates.
EFFECT OF POISSON’S RATIO ON KI, T11 AND T33
FOR SENB AND CT SPECIMEN-A FE STUDY
Sanjeev M Kavale1 , Krishnaraja G Kodancha2, Nagaraj Ekabote3
1,2,3
School of Mechanical Engineering, KLE Technological University,
Hubballi.
krishnaraja@bvb.edu
The level of constraint at a crack-tip/crack-front plays an important role
in the fracture of the cracked component, and can be revealed by
examining the details of the crack-tip/crack-front stress fields. Significant
research on 2D crack-tip stress fields are available, however the real life
cracks are 3D than 2D. There exists a gap in understanding constraint
effects in different state of stress and 3D cracks. The Tij stress terms,
together with the stress intensity factor (KI), can provide a set of practical
parameters for the characterization of near crack-front fields, nominally
K-Tij. It is observed by many investigators that the effect of Poisson’s
ratio on these parameters is significant. However, a limited amount of
investigation is done on understanding the effect Poisson’s ratio on these
constraint parameters on standard specimens suggested by ASTM. The
main objective of the current research work is to understand the effect of
Poisson’s ratio on Stress Intensity Factor (KI) and Tij-Stresses for SENB
and CT specimens. Using FE analyses for a/W ratio of 0.50 and specimen
thicknesses were studied for different Poisson’s ratio for SENB and CT
Specimen. It is observed from the current work that, in both, SENB and
CT specimens, for same applied stress, the maximum magnitudes of KI
and T11 is observed at the center of the specimen and is increasing with
the increase in Poisson’s ratio of the specimen. However, the magnitude
of T33 is reducing with the increase in Poisson’s ratio in both CT and
SENB specimens. An effort has been put to generate polynomial
formulations which approximately estimate the magnitudes of KI, T11 and
T33. The values of KI obtained through these formulations are validated
with the available experimental results and a maximum error of 9% is
observed between the SIF obtained through the generated formulations
and various materials.

1.6
Normalised KI(max), T11(max), T33(max)
1.2
0.8
0.4
0.0
-0.4
-0.8 a/W=0.50
B/W=0.50
-1.2
0.20 0.25
Poisson's Ratio
Figure 4. Variation of normalized KI(max), T11(max) and T33(max) for different
Poisson's ratio for CT and SENB specimens for same applied stress
=100 MPa


DUCTILE FRACTURE IN TUBE IMPACT
PROBLEM USING A LODE ANGLE DEPENDENT
FAILURE CRITERION
Dipankar Boraa, Sachin S. Gautama, Manoj Kumarb
a
Indian Institute of Technology Guwahati, Guwahati, 781 039
b
National Institute of Technology Jalandhar, Punjab, 144 011
Email of corresponding author: ssg@iitg.ernet.in
Impact problems are an important class of problems usually accompanied
by large deformations and sometime fracture of the impacting bodies. In
many fields such automotive crashworthiness analysis and design, turbine
design, metal forming problems etc. one has to invariably consider the
possibility of fracture and study its effect on the component/structure.
Fracture in these applications is mostly happens after considerable plastic
deformation and is referred to as ductile fracture. A lot of research work
is being carried out in the area of ductile fracture under impact loads [1,
2]. Recently, a new coupled elasto-plastic damage model has been
proposed by Erice and Galvez [3] for ballistic applications incorporating
effect of Lode angle in the Johnson and Cook failure criterion [3] using a
Lode angle dependent function propose by Xue [2]. In the present work,
this model is employed to study the ductile fracture of tubes impacted
against rigid surface using Abaqus Explicit by writing a user input
subroutine VUMAT. The simulation of fracture of thin-walled tubes at
higher impact velocities have already been studied by Gautam and Dixit
[1] without taking the Lode angle effect into account. Figure 1(i) shows
the schematic of the problem and Fig. 1(ii) shows the deformed
configuration.
Figure 1: (i) Schematic of the tube impact problem (ii) deformed
configuration without lode angle effect
References
[1] Gautam S. S., and Dixit P. M., Numerical Simulation of Ductile
Fracture in Cylindrical Tube Impacted Against a Rigid
Surface, International Journal of Damage Mechanics, 21(3): 341-371,
2012
[2] Xue. L. Constitutive modelling of void shearing effect in ductile
fracture of porous materials. Engineering Fracture Mechanics, 75(11):
3343–3366, 2008.
[3] Erice. B., and Galvez F. A coupled elastoplastic-damage constitutive
model with lode angle dependent failure criterion, International Journal
of Solids and Structures, 51: 93-110, 2014.
[4] Johnson G. R., and Cook W. H., Fracture characteristics of three
metals subjected to various strains, strain rates, temperatures and
pressures, Engineering Fracture Mechanics, 21: 31-48, 1985.
Normalised KI(max), SENB
Normalised KI(max), CT
Normalised T11(max), SENB
Normalised T11(max), CT
Normalised T33(max), SENB
Normalised T33(max), CT
0.30 0.35 0.40 0.45

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SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

SYSTEM RELIABILITY OF RANDOMLY

VIBRATING STRUCTURES UNDER SUPPORT
EXCITATIONS: COMPUTATIONAL MODELING
AND LABORATORY TESTING

A. Somayya1 and C.S. Manohar

BiSS (P) Ltd, 497E 14th Cross, 4th Phase, Peenya Industrial Area,
Bangalore 560058, India. 1Corresponding author, E-mail:
somayya@biss.in, Mob: +91-9880-432-322 

The proposed paper addresses the problem of determination of system Fig. 1: a) Variation of DOP and peak force with foam density. At 0.45
reliability of randomly vibrating structures. Similar problems arise in g/cc, DOP and peak force are optimised. b) The tested foam sample of
many application areas of engineering. We discuss in this paper density 0.42 g/cc shows the hole formed due to impact, the ruptured cells
approaches based on Monte Carlo simulations and laboratory testing to and the densified zone at the indenter front.
tackle problems of time variant system reliability estimation. The strategy
we adopt is based on the application of Girsanov's transformation to the
governing stochastic differential equations which enables estimation of

probability of failure with significantly reduced number of samples than
what is needed in a direct simulation study. Notably, we show that the
ideas from Girsanov's transformation based Monte Carlo simulations can
be extended to conduct laboratory testing to assess system reliability of
engineering structures with reduced number of samples and hence with
reduced testing times. Illustrative examples include
laboratory/computational investigations on: (i) road load response of an
automotive system tested on a four-post test rig; (ii) seismic load
response of an asymmetric building model tested on a 3-axis, 6-dof shake
table system.


A STUDY ON IMPACT FORCE ATTENUATION
CAPABILITY OF CLOSED CELL ALUMINIUM
FOAMS

SN Sahu1, T Sreekanth Reddy1, P Ramasubba Reddy1, P Sampath

Kumar1, GJ Reddy1, AA Gokhale2
1
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad
500058, India
2
Indian Institute of Technology Bombay, Powai, Mumbai 400076, India
Email:snsahu2002@gmail.com

Ability of aluminium foam to absorb impact energy and reduce

transmitted force during foreign body impact was assessed using
instrumented INSTRON 9350 drop impact tester. The samples were of 50
mm thickness and 100 mm diameter made from cast foam ingots of
length 200 mm (0.7 g/cc) to 400 mm (0.3 g/cc) and diameter 100 mm.
The drop energy was varied from 3 J to 18 J in these tests. The
transmitted force on the indenter and depth of penetration (DOP) were
measured and analyzed. Mechanism of energy absorption was primarily
by bending, buckling, tearing and rupture of cell walls. The force
attenuation was close to ten times higher than the solid cp aluminium.
Particularly, the low density foams with hexagonal cells collapsed and
ruptured at much lower stress in comparison to the high dense foams with
spherical cells. The results also depicted a medium foam density at which
the peak force and DOP assumed optimal values respectively (see Fig.1).
The foams displayed slight impact sensitivity i.e. the same density
samples transmitted higher force at higher impact speeds (i.e. at higher
drop energy). In general, the results were observed to be reproducible
within 10% variation which indicates good control over cell structure.
Based on the above results, a scaled up impact absorber was designed and
evaluated to absorb 90000J of impact energy at a transmitted stress close
to 67g which satisfactorily fulfilled the user requirement. The tests thus
performed in both laboratory and user levels clearly demonstrate the
excellent ability of aluminium foams as impact energy absorbers for a
variety of applications.

67

 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

Session4F:StructuralIntegrityX
Chairman:GMalakondaiah,FormerCCR&D(HR),DRDO
SessionCoordinator:SrinivasRaoNandam,DMRL
14151442 InvitedTalk:HighTemperatureLowCycleFatigueBehaviourofC263Superalloy
KBhanuSankaraRao,MahatmaGandhiInstituteofTechnology,Hyderabad
14421454 EvaluationofStructuralIntegrityofTacticalMissileCeramicRadomesunder
CombinedThermalandStructuralLoads
S.NarendarandM.Varadanam
DefenceResearchDevelopmentLaboratory,Hyderabad
15061518 InvestigationofProcessParametersontheMechanicalPropertiesofMTVDecoy
FlarePelletsforDefenceApplications
SukamalAdhikary,HimanshuSekharandDGThakur
DefenceInstituteofAdvancedTechnology,Pune
15301542 BirdStrikeDamageandAnalysisofAirframeStructuresofUAV
AkhileshKumarJha,SSathyamoorthyandViswaPrakash
AeronauticalDevelopmentEstablishment,DRDO,Balgalore
16061618 Applicationofstraingaugesformeasurementofpropellertorque
SantanuDeori,UpendraTaywadeandD.Radhakrishna
VehiclesResearch&DevelopmentEstablishment,DRDO,Chennai




 
SecondInternationalStructuralIntegrityConference&Exhibition(SICE– 2018) PROCEEDINGS

EVALUATION OF STRUCTURAL INTEGRITY OF attributed to reduction in porosity of the mixture as well as brittle fracture
of magnesium particles facilitating optimisation of density of green
TACTICAL MISSILE CERAMIC RADOMES compact. This was examined through SEM imaging. However, the effect
UNDER COMBINED THERMAL AND evened out beyond optimum applied load owing to saturation in
STRUCTURAL LOADS accommodating the particles within the available space and also beyond
optimum charge mass owing to higher L/D ratio. A mathematical formula
S. Narendar*, M. Varadanam was finally developed for ascertaining density of pellets by variation of
Defence Research and Development Laboratory, Hyderabad-58, T.S. the process parameters.
*Email of corresponding author:
narendar@drdl.drdo.in/nanduslns07@gmail.com Keywords: Pyrotechnic, Infra-red decoy flares, MTV, density, charge
mass.
Radome is a thermos-structural member used in tactical missiles and
houses the avionic systems like seeker. It is subjected to severe thermal as
well as structural loads during the flight. The material of the radome is
chosen such that it is transparent electromagnetic radiation. The ceramic BIRD STRIKE DAMAGE AND ANALYSIS OF
radome is attached to the metallic bulkhead with high temperature glue. AIRFRAME STRUCTURES OF UAV
The ceramic radome is made of fused silica and bulkhead is made of
Invar steel. In the present manuscript, the experimental evaluation
Akhilesh Kumar Jha1, S Sathyamoorthy2, Viswa Prakash3
methodology implemented for evaluation of the structural integrity of the 1
Scientist E, ADE, DRDO, Bangalore
ceramic radome under combined thermal and structural loads is 2
Scientist D, ADE, DRDO, Bangalore
presented. Initially axial load, to simulate the resultant drag force and a 3
SRF, ADE, DRDO, Bangalore
distributed lateral loads, to simulate the bending moment, are applied via
akhilsdet@yahoo.com, s_sathya_moorthy@yahoo.com,
a pre casted contoured Teflon mock sections, up to proof load and then
viswaprakash2010@gmail.com
time varying temperature is applied. The time-varying temperature profile
is plied via a closed loop control based on PID and the heating
Composite materials are increasingly being used for Aircraft/UAVs
environment is created using short wave infra-red radiation. Exhaustive
structures such as wing components or fuselage panels, etc. A collision to
instrumentation is used in the experiments. After the thermal cycle, the
bird during flight can lead to serious damage to the Aircraft/UAVs
structural loads are increased till the failure of the radome. With the
structures, particularly during takeoff and landing phases. The Federal
developed experimental test setup various radomes are successfully tested
Aviation Regulations (FAR) requires that all forward facing components
and those details are presented in this manuscript under case studies.
need to prove a certain level of bird strike resistance in certification tests
before they are allowed for operational use.This paper focuses on the
numerical modeling and simulationof a two-poundbird impact on
composite structures of the UAV using ABAQUS/Explicit with impact
INVESTIGATION OF PROCESS PARAMETERS ON velocities ranging from 40m/s to 80m/s.The bird is modeled using
THE MECHANICAL PROPERTIES OF MTV Coupled Eulerian Lagrangian (CEL) technique using a material model
DECOY FLARE PELLETS FOR DEFENCE with properties similar to fluid. The internal pressure of the bird model is
linked to the change in volume with an Equation of State (EOS). Based
APPLICATIONS on simulation results, the high probability strike zone has been reinforced
and fifteen successful flightshave been achieved. The experimental tests
Sukamal Adhikary a, Himanshu Sekhar b, D G Thakur a* will be carried out on panel level, taken from various airframes modules
a
Department of Mechanical Engineering, Defence Institute of Advanced of the UAV.
Technology (DU), Ministry of Defence, Pune, Maharashtra - 411025,
India Keywords: Composite, UAV, ABAQUS/Explicit, CEL, EOS.
b
High Energy Material Research Laboratory, DRDO Lab, Pune-411021,
India
a
Sukamal Adhikary, E-mail: sukamal06@gmail.com
a*
Corresponding author: D G Thakur, E-mail:
dineshsingh_thakur@yahoo.com
APPLICATION OF STRAIN GAUGES FOR
Tel: +91 20 24304195; Fax: +91 20 24389318 MEASUREMENT OF PROPELLER TORQUE
b
Himanshu Sekhar E-mail: himanshudrdo@rediffmail.com
Santanu deori Sc ‘C’, Gaurav PanchalSc ‘D’, Upendra Taywade‘E’ and
It has been universally accepted that air power is becoming increasingly Dr. D Radhakrishna Sc ‘G’
challenging. With the advent of the sophisticated Infra-red (IR) guided
missiles, the pilots are at constant threat to accomplish their operational Indigenously developed VRDE (DRDO) 65 hp Rotary engine has been
tasks and safely return back to base. One of the most effective counter coupled with various Propellers having varying diameter and profile
measures against the heat seeking missiles is Infra-red decoy flares. shape. More nos. of Propeller blades attributes good thrust at a particular
These flares have been successfully developed from pyrotechnic rpm but above that rpm, engine couldn’t able to provide the sufficient
composition of Magnesium/Teflon/Viton (MTV) and has been torque to rotate it (propeller) further. Therefore, it is must to measure the
extensively utilised by defence services all over the world. amount of torque being absorbed by propeller at all ranges of Engine
rpm. Hence, a study has been accomplished by applying a non-contacting
However, the supply of MTV flares in the global market are controlled by type strain gauge on propeller flange, to measure the angular
very few foreign manufacturers and the manufacturing philosophy along deflection/strain on flange. This strain on gauges is finally calibrated to
with the performance parameters have been a well-kept secret. As a represent the torque of propeller. This helped us in selection and
result, very limited open source literature is available about the estimation of propeller and its pitch.
mechanical pressing of the MTV composition to form pellets of standard
configurations and the subsequent mechanical performance evaluation of
these pellets. Hence, the present paper is an attempt to study the
mechanical parameters of the pellets by varying two process parameters
viz. the applied load and the charge mass. Pyrotechnic mixture of
magnesium (45-50%) as fuel, Teflon (PTFE) (45-50%) as oxidiser and
Viton (2-8%) as binder was compacted by varying the applied load from
1 ton to 9 tons and subsequently by varying the charge mass from 40 gm
to 160 gm. It was observed that density of pellets increased with increase
in applied load (by 33%) and charge mass up (by 7%) to an optimum
value of both these process parameters. This phenomenon could be

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 Designed & Published by:
Publication & Polygraphy Unit, DMRL