A process and investigation into the influence of cast surface condition on fatigue life

dc.contributor.advisor Frank Peters
dc.contributor.author Tscherter, Jeffrey
dc.contributor.department Industrial and Manufacturing Systems Engineering
dc.date 2021-01-16T18:26:09.000
dc.date.accessioned 2021-02-25T21:39:44Z
dc.date.available 2021-02-25T21:39:44Z
dc.date.copyright Tue Dec 01 00:00:00 UTC 2020
dc.date.embargo 2020-10-09
dc.date.issued 2020-01-01
dc.description.abstract <p>The objective of this research is to investigate the impact of varying cast surface conditions on fatigue performance, in the presence of other casting indications such as gas and shrinkage porosity. Additionally, this research aims to draw connections between nondestructive evaluation (NDE) techniques and fatigue results of cast test specimens. A process of specimen manufacturing, processing, and inspection is presented in this research, along with fatigue testing results. It is known that poor surface condition can impact fatigue life, even when comparing surface finishes produced by different manufacturing processes. Cast surface roughness is thought to contribute to reduced fatigue life, which may lead to over-processed or over-designed parts. Little has been done to investigate the impact of different cast surface conditions on fatigue life to justify current industry practices. Fatigue specimen design, inspection techniques, and fatigue testing techniques were developed in this study to compare the impact of cast surface condition on fatigue in the presence of other indications. To investigate this impact, axial load-controlled high-cycle fatigue tests were conducted on large lab-scale specimens cut from cast plates. All specimens underwent radiographic inspection, wet magnetic particle inspection, laser scanning, and visual surface characterization. Cast surfaces were characterized utilizing ASTM A802 comparator plates and through digital methods. Fatigue results showed no difference in mean fatigue lives produced by different surface classifications. Additionally, no correlation was found between digital surface classification and fatigue life. These results indicate that cast surface texture is a not reliable indicator of fatigue life. Post-test measurements of fatigue crack initiation sites provided statistically significant results in a log-log regression with fatigue life. This shows that variation in fatigue performance for a given cast material can be explained by the size of casting indications.</p>
dc.format.mimetype application/pdf
dc.identifier archive/lib.dr.iastate.edu/etd/18414/
dc.identifier.articleid 9421
dc.identifier.contextkey 21104872
dc.identifier.doi https://doi.org/10.31274/etd-20210114-149
dc.identifier.s3bucket isulib-bepress-aws-west
dc.identifier.submissionpath etd/18414
dc.identifier.uri https://dr.lib.iastate.edu/handle/20.500.12876/94566
dc.language.iso en
dc.source.bitstream archive/lib.dr.iastate.edu/etd/18414/Tscherter_iastate_0097M_19101.pdf|||Fri Jan 14 21:41:46 UTC 2022
dc.subject.keywords Casting
dc.subject.keywords Fatigue
dc.subject.keywords NDE
dc.subject.keywords Steel
dc.title A process and investigation into the influence of cast surface condition on fatigue life
dc.type article
dc.type.genre dissertation
dspace.entity.type Publication
relation.isOrgUnitOfPublication 51d8b1a0-5b93-4ee8-990a-a0e04d3501b1
thesis.degree.discipline Industrial Engineering
thesis.degree.level dissertation
thesis.degree.name Master of Science
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