Browsing by Author "Biswal, Romali"
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Item Open Access Comparison of microstructure refinement in wire-arc additively manufactured Ti–6Al–2Sn–4Zr–2Mo–0.1Si and Ti–6Al–4V built with inter-pass deformation(Springer, 2022-09-22) Davis, Alec E.; Caballero Ramos, Armando; Biswal, Romali; Williams, Stewart; Prangnell, Philip B.The titanium alloy Ti–6Al–2Sn–4Zr–2Mo–0.1Si (Ti6242) has been deposited for the first time by a directed energy deposition process using a wire and arc system—i.e., wire-arc additive manufacturing (WAAM)—with and without inter-pass machine hammer peening, and its microstructure investigated and compared to the more commonly used alloy Ti–6Al–4V (Ti64). The application of inter-pass machine hammer peening—where each added layer was deformed before deposition—successfully refined the strongly textured, coarse, columnar β-grain structure that is commonly seen in α + β titanium alloys, producing a finer equiaxed grain structure with a near-random α texture. The average grain diameter and texture strength decreased with the peening pitch. When Ti6242 was deposited under identical conditions to Ti64, by switching the alloy feed wire in-situ, the refined β-grain size decreased across the alloy-to-alloy transition reaching on average 25 pct less in Ti6242 than in Ti64. A similar 25 pct scale reduction was also found in the Ti6242 α-lath transformation microstructure. This comparatively greater microstructure refinement in Ti6242 was attributed to the dissimilar alloying elements present in the two materials; specifically, molybdenum, which has a lower diffusivity than vanadium and led to slower β-grain growth during reheating as well as a finer transformation microstructure.Item Open Access Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy(Elsevier, 2019-01-28) Biswal, Romali; Zhang, Xiang; Syed, Abdul Khadar; Awd, Mustafa; Ding, Jialuo; Walther, Frank; Williams, Stewart W.This study was aimed at investigating the effect of internal porosity on the fatigue strength of wire + arc additive manufactured titanium alloy (WAAM Ti-6Al-4V). Unlike similar titanium alloys built by the powder bed fusion processes, WAAM Ti-6Al-4V seldom contains gas pores. However, feedstock may get contaminated that may cause pores of considerable size in the built materials. Two types of specimens were tested: (1) control group without porosity referred to as reference specimens; (2) designed porosity group using contaminated wires to build the specimen gauge section, referred to as porosity specimens. Test results have shown that static strength of the two groups was comparable, but the elongation in porosity group was reduced by 60% and its fatigue strength was 33% lower than the control group. The stress intensity factor range of the crack initiating pore calculated by Murakami’s approach has provided good correlation with the fatigue life. The kink point on the data fitting curve corresponds well with the threshold value of the stress intensity factor range found in the literature. For predicting the fatigue limit, a modified Kitagawa-Takahashi diagram was proposed consisting of three regions depending on porosity size. Critical pore diameter was found to be about 100 µm.Item Open Access Evaluation of cyclic loading effects on residual stress relaxation in offshore wind welded structures(World Scientific Publishing, 2021-08-14) Statti, Giuseppe; Mehmanparast, Ali; Biswal, Romali; Rizzo, CesareMonopile foundations contain welding residual stresses and are widely used in industry to support offshore wind turbines (OWTs). The monopiles are subjected to hammering loads during installation and cyclic loads during operation, therefore the influence of residual stress redistribution as a result of fatigue cycles must be evaluated in these structures. The existing empirical models to predict the residual stress redistribution in the presence of cyclic loading conditions are strongly dependent on the material, welding process and loading conditions. Hence, there is a need to predict the residual stress redistribution using finite element simulations. In this study numerical analyses have been conducted to predict the initial state of residual stress in a simplified weld geometry and examine the influence of subsequent cyclic loads on the relaxation behavior in residual stress profiles. The results have shown that fatigue cycles have a severe effect on residual stress relaxation with the greatest reduction in residual stress values observed in the first cycle. Moreover, the numerical prediction results have shown that the stress amplitude plays a key role in the extent of residual stress relaxation in welded structures.Item Open Access Experimental investigation of lattice deformation behavior in S355 steel weldments using neutron diffraction technique(Springer, 2021-08-19) Biswal, Romali; Mehmanparast, Ali; Ganguly, Supriyo; Kelleher, JoeThis study aims to investigate the influence of welding process on the elastic lattice deformation and its effects on fatigue and fracture behavior of S355 G10+M steel, which is widely used in fabrication of offshore wind turbine monopile structures. In situ neutron diffraction measurements were taken on cross-weld test samples at room temperature to monitor the evolution of intergranular strains under static and cyclic loading conditions. Both static and cyclic test results have shown that the {200} orientation exhibits the least load carrying capacity while {211} had the maximum stiffness. The hkl-specific response predicted using Reuss and Kröner model were found to agree well with experimental values obtained for the heat-affected zone for all the orientations; however, discrepancies between the experimental and model predictions have been observed for the base metal and weld metal. Moreover, the microstructural differences between the weld metal and heat-affected zone resulted in the maximum elastic–plastic strain mismatch at the interface of the two regions. The results from this experiment would be useful to understand the role of crystal-specific microstrains and lattice deformation on fatigue and fracture behavior of thick-walled monopile weldments.Item Open Access Fatigue damage analysis of offshore wind turbine monopile weldments(Elsevier, 2019-08-25) Biswal, Romali; Mehmanparast, AliOffshore wind turbines (OWT) are subjected to harsh environmental conditions in addition to the variable service loads. The present study is aimed at performing a realistic fatigue life estimation of the monopile structure using operational service loads recorded by online monitoring systems. Fatigue damage analysis has been conducted at the circumferential weld joints using finite element (FE) method by considering geometrical and material property discontinuities. Global-local modelling of the OWT was performed in as-welded condition to capture the local stress range at the weld toe, which acts as the critical site where cracks are most likely to initiate and propagate. The S-N fatigue design approach and maximum stress range at the weld toe have been used to determine the fatigue crack initiation life in monopiles. The results from the proposed approach show that a realistic life assessment can be made on monopile structures by accounting for the geometrical effects at the circumferential weldsItem Open Access High cycle fatigue and fatigue crack growth rate in additive manufactured titanium alloys(Springer, 2019-07-03) Zhang, Xiang; Syed, Abdul Khadar; Biswal, Romali; Martina, Filomeno; Ding, Jialuo; Williams, Stewart W.The Wire + Arc Additive Manufacture (WAAM) process can produce large metal parts in the metre scale, at much higher deposition rate and more efficient material usage compared to the powder bed fusion additive manufacturing (AM) processes. WAAM process also offers lead time reduction and much lower buy-to-fly ratio compared to traditional process methods, e.g. forgings. Research is much needed in the areas of fatigue and fracture performance for qualification and certification of additive manufactured aircraft components. In this study, specimens made of WAAM Ti-6Al-4V alloy were tested and analysed focusing on two key areas of structural integrity and durability: (1) High cycle fatigue and effect of defects: crack initiation at porosity defects was investigated via fatigue and interrupted fatigue-tomography testing performed on specimens with porosity defects purposely embedded in the specimen gauge section. Key findings are as follows. Presence of porosity did not affect the tensile strengths, however both ductility and fatigue strength were significantly reduced. Fatigue life could not be correlated by the applied stress, e.g. in terms of the S-N curves, owing to the different pore sizes. Using the fracture mechanics approach and Murakami’s stress intensity factor equation for pores, good correlation was found between the fatigue life and stress intensity factor range of the crack initiating defects. Predictive methods for fatigue strength reduction were developed taking account of the defect size, location, and distribution. (2) Fatigue crack growth rate: effect of heterogeneous microstructure was investigated via two different material deposition methods and testing two crack orientations. Fatigue crack growth rates were measured for damage tolerance design considerations. Unique microstructure features and their effect on the property anisotropy are discussed.Item Open Access On the composition gradient of steel/Invar functionally graded material manufactured by wire-based direct energy deposition(Elsevier, 2024-09-25) Wang, Jun; Biswal, Romali; Chen, Guangyu; Pardal, Goncalo Rodrigues; Lu, Yao; Ding, Jialuo; Williams, StewartThis study utilized double-wire plasma arc direct energy deposition to produce functionally graded materials (FGMs) with two transition designs, abrupt (AT) and gradual (GT), from Er90s steel to Invar. The study systematically compared the transition in chemical composition, microstructure, phase evolution, thermal stress, and mechanical performance. Both FGM types exhibited a band structure in the Er90s section and coarse columnar grains in the Invar section, with the AT deposit showing a 1 mm thick, defect-free interface and the GT deposit having an 18 mm thick transition region with distinct boundaries. It revealed diverse microstructures across the transition zones, including fine ferrite, martensite with minor retained austenite (RA), coarse columnar austenite with martensite dendrites, and single FCC austenite. The GT sample uniquely featured a microstructure of martensite laths inside prior austenite decorated by RA semicontinuous network, with a crack detected due to dilatational stresses from martensite transformation. Hardness was similar in both FGM types, with higher values at the interfaces, especially in the GT FGM. The GT FGM demonstrated higher strength but lower ductility compared to the AT FGM, with failure occurring in the Invar portion for both. Thermal stress modelling indicated smoother stress transitions in the GT sample but no significant performance differences between Er90s and Invar. This study showcases the effectiveness of double-wire plasma arc DED in producing steel/Invar FGMs with varying composition gradients. It also underscores the importance of selecting the right mixing ratio for Er90s/Invar FGM deposits to avoid cracking and deterioration of properties in the gradient area.Item Open Access On the performance of monopile weldments under service loading conditions and fatigue damage prediction(Wiley, 2021-03-01) Biswal, Romali; Al Mamun, Abdullah; Mehmanparast, AliThick weldments used in offshore structures frequently act as fatigue crack initiation sites due to stress concentration at weld toe as well as weld residual stress fields. This paper investigates the cyclic deformation behavior of S355 G10+M steel, which is predominantly used in offshore wind applications. Owing to the vast size difference of monopile structure and weld cross‐section, a global–local finite element (FE) method was used, and the weld geometry was adopted from circumferential weld joints used in offshore wind turbine monopile foundations. Realistic service loads collected using supervisory control and data acquisition (SCADA) and wave buoy techniques were used in the FE model. A nonlinear isotropic–kinematic hardening model was calibrated using the strain controlled cyclic deformation results obtained from base metal (BM) as well as cross‐weld specimen tests. The tests revealed that the S355 G10+M BM and weld metal (WM) undergo continuous cyclic stress relaxation. Fatigue damage over a period of 20 years of operation was predicted using the local stress at the root of the weldments as the life limiting criterion. This study helps in quantifying the level of conservatism in the current monopile design approaches and has implications towards making wind energy more economic.Item Open Access The role of microstructure and local crystallographic orientation near porosity defects on the high cycle fatigue life of an additive manufactured Ti-6Al-4V(Elsevier, 2020-08-21) Shamir, Muhammad; Syed, Abdul Khadar; Janik, Vit; Biswal, Romali; Zhang, XiangTitanium alloys such as Ti-6Al-4V built by most of the additive manufacturing processes are known to contain process induced defects, non-conventional microstructure and strong crystallographic texture; all of which can affect the fatigue strength. In this study we evaluated the effect of crystallographic orientation of α and α lath width around gas pore defects on the high cycle fatigue life of Wire + Arc Additive Manufactured Ti-6Al-4V by means of Electron Back Scattered Diffraction. Here we show that variations in crystallographic orientation of α lath and its width in the vicinity of the crack initiating defect were the main reasons for the considerable scatter in fatigue life. Pyramidal slip systems with high Schmid factor active around the defects resulted in longer fatigue life compared to pyramidal slip with lower Schmid factor. In the absence of pyramidal slip, cracks initiated from active prismatic slip systems. When considering the influence of the microstructure, a higher number of smaller α laths around the defect resulted in longer fatigue life, and vice versa. Overall, the fatigue crack initiation stage was controlled collectively by the complex interaction of porosity characteristics, α lath width and its crystallographic orientation at the crack initiation locationItem Unknown β-Grain refinement in WAAM Ti-6Al-4 V processed with inter-pass ultrasonic impact peening(Elsevier, 2024-12) Sahu, Vivek K.; Biswal, Romali; Davis, Alec E.; Chen, Xin; Williams, Stewart W.; Prangnell, Philip B.As-deposited Wire-Arc Additive Manufactured (WAAM) Ti-6Al-4V parts typically contain large columnar β-grains on a centimetre scale, with a strong 〈001〉 fibre texture, leading to anisotropic mechanical properties and unacceptable scatter in damage tolerance. Inter-pass deformation, introduced by the application of Ultrasonic Impact Peening (UIP) across each added layer, has been shown to be effective in refining the β-grain structure and achieving a weaker texture. The depth of deformation and the grain refinement mechanism induced by UIP have been investigated by combining advanced electron backscatter diffraction (EBSD) characterization with a ‘stop action’ observation technique. UIP facilitates a similar refinement mechanism and nearly the same depth of deformation as conventional machine hammer peening, with the advantages of a much higher strain rate, lower peak force, and two orders of magnitude lower impact energy, making it a faster and more economical process. β recrystallization is seen within the deformation zone during re-heating through the α → β transition. Although new recrystallized β-grains formed in the UIP surface-deformed layer to a shallower depth than that of remelting, recrystallization initiated ahead of the melt pool and the recrystallized grains grew downwards to a greater depth before remelting. These refined grains were thus able to survive and act as nucleation sites at the fusion boundary for epitaxial regrowth during solidification, greatly refining the grain structure.