To account for or neglect the defect position, i.e. the fatigue initiating defect location, both radially and axially, is evaluated for hourglass-shaped ultrasonic fatigue specimen. The commonly used analytical equations to calculate the stress is compared against a finite element (FE) based approach, which is able to fully considering the stress state at the defect position. Notably, the effects on several common fatigue analyses are evaluated: the fatigue strength distribution, the stress-life and the stress-defect relationships. Fracture mechanical assessment is also performed, for a comprehensive VHCF characterization of the EN-GJS-500-7 ductile cast iron used in the study. The VHCF properties are characterized up to 3 & sdot; 108 8 cycles, using the Step-Stress fatigue testing method under fully reversed loading. The FE-model and Weibull distribution as the choice of fatigue strength distribution, enables size effect evaluation by Weakest-link effective volume with the highly stressed volume method as benchmark. The work shows that it is imperative to use the local stress state at the defect position, as the distribution of failures can diverge largely from the center of the specimen, and that neglecting this causes systematic error and flawed potentially results.

A general testing and analysis framework for the Step-Stress fatigue testing method is identified, utilizing interval-censored data and maximum likelihood estimation in an effort to improve estimation of fatigue strength distribution parameters has been performed. The Step-Stress methods limitations are characterized, using a simple material model that considers cumulative damage to evaluate load history effects. In this way, the performance including cumulative damage was evaluated and quantified using a probabilistic approach with Monte-Carlo simulations, benchmarked against the Staircase method throughout the work. It was found that the Step-Stress method, even when cumulative damage occurs to a wide extent, outperforms the Staircase method, especially for small sample sizes. Furthermore, positive results reaches further than the increase performance in estimating fatigue strength distribution parameters, where improvements in secondary information, i.e. S-N data gained from failure specimens, are shown to be distributed more closely to the fatigue life region of interest.

When exposed to cyclic quasi-static loading, elastic bodies in contact may develop a favourable condition where slip ceases after a few cycles, an occurrence commonly known as frictional shakedown. If the amplitude of the cyclic load is greater than a so-called shakedown limit, shakedown cannot occur. In this review paper, the validity of shakedown theorems in the context of conforming contacts with a la Coulomb friction is first discussed. Then, an optimisation method for determining the shakedown limit of elastic discrete three-dimensional systems is reviewed. Finally, an incremental Gauss-Seidel algorithm, extended to three-dimensional systems, is here illustrated in details for the first time. The algorithm allows us to describe the transient response of normal-tangential coupled systems under a given cyclic loading scenario, and to determine their possible shakedown depending on the initial conditions. An example concerning a discrete conforming contact problem, where either coupling or uncoupling conditions can be imposed, is illustrated.

High-porosity, three-dimensional wood fiber networks made by foam forming present experimentally accessible instances of hierarchically structured, athermal fiber networks. We investigate the large deformation compression behavior of these networks using fiber-resolved finite element analyses to elucidate the role of microstructures in the mechanical response to compression. Three-dimensional network structures are acquired using micro-computed tomography and subsequent skeletonization into a Euclidean graph representation. By using a fitting procedure to the geometrical graph data, weare able to identify nine independent statistical parameters needed for the regeneration of artificial networks with the observed statistics. The compression response of these artificially generated networks and the physical network is then investigated using implicit finite element analysis. A direct comparison of the simulation results from the reconstructed and artificial network reveals remarkable differences already in the elastic region. These can neither be fully explained by density scaling, the size effect nor the boundary conditions. The only factor which provides the consistent explanation of the observed difference is the density and fiber orientation nonuniformities; these contribute to strain-localization so that the network becomes more compliant than expected for statistically uniform microstructures. We also demonstrate that the experimentally manifested strain-stiffening of such networks is due to development of new inter-fiber contacts during compression.

This document gives an account of some of the work done so far on topology optimization (TO) in the ADDMAN project. As well as the mathematical formulations and implementations details, short discussions are presented on some of the nuances of the different formulations and how they should be used efficiently

Additive manufacturing (AM) is a particularly useful manufacturing method for components designed using topology optimization (TO) since it allows for a greater part complexity than any traditional manufacturing method. However, the AM process potentially leads to anisotropic material properties due to the layer-by-layer buildup of parts and the fast and directional cooling. For Ti6Al4V tensile specimens built using electron beam melting (EBM), it has been observed that flat built specimens show superior strength and elastic moduli compared to top built specimens. Designs with the loading direction parallel to the build layers are therefore expected to show greater reliability.

In this thesis a procedure is developed to optimize the AM build orientation considering anisotropic elastic material properties. A transversely isotropic material model is used to represent the in-plane and out-of-plane characteristics of AM produced parts. Two additional design variables are added to the TO formulation in order to control the orientation of the material using a coordinate transformation. Sensitivity analysis for the material direction variables is conducted for compliance as well as maximum von-Mises stress using a -norm stress aggregation function.

The procedures for the AM build orientation optimization and stress constraints are implemented in the finite element software TRINITAS and evaluated using a number of examples in 2D and 3D. It is found that the procedure works well for compliance as well as stress but that a combination of these may lead to convergence issues due to contradicting optimal material orientations. An evaluation of the -norm stress aggregation function showed that a single global stress measure in combination with a stress correction procedure works well for most problems given that the mesh is refined enough to resolve the stresses accurately.  

Fatigue crack growth rate in Room Temperature and Out-of-Phase Thermo-Mechanical Fatigue notched specimen experiments on the nickel-base alloy IN792 is studied. It is shown that it is possible to explain the observed higher crack growth rate in OP TMF compared to RT testing for the same external load, if plasticity induced crack closure is considered. Modeling utilizes node-release finite element simulations with a temperature dependent yield stress, resulting in different yield stress in tension and compression. It is shown that a simple extension of the analytical Newman crack closure equation can describe the opening level in the performed experiments.

This Licentiate of Engineering thesis concerns modelling and simulation of hydraulic percussion units. These units are often found in equipment for breaking or drilling in rock and concrete, and are also often driven by oil hydraulics, in which complex fluid-structure couplings are essential for their operation.

Current methodologies used today when developing hydraulic percussion units are based on decoupled analyses, which are not correctly capturing the important coupled mechanisms. Hence, an efficient method for coupled simulations is of high importance, since these mechanisms are critical for the function of these units. Therefore, a co-simulation approach between a 1D system simulation model representing the fluid system and a structural 3D FE-model is proposed.

This approach is presented in detail, implemented for two well-known simulation tools and evaluated for a simple but relevant model. The Hopsan simulation tool was used for the fluid system and the FE-simulation software LS-DYNA was used for the structural mechanics simulation. The co-simulation interface was implemented using the Functional Mock-up Interface-standard.

The approach was further developed to also incorporate multiple components for coupled simulations. This was considered necessary when models for the real application are to be developed. The use of two components for co-simulation was successfully evaluated for two models, one using the simple rigid body representation, and a second where linear elastic representations of the structural material were implemented.

An experimental validation of the co-simulation approach applied to an existing hydraulic hammer was performed. Experiments on the hydraulic hammer were performed using an in-house test rig, and responses were registered at four different running conditions. The co-simulation model was developed using the same approach as before. The corresponding running conditions were simulated and the responses were successfully validated against the experiments. A parameter study was also performed involving two design parameters with the objective to evaluate the effects of a parameter change.

This thesis consists of two parts, where Part I gives an introduction to the application, the simulation method and the implementation, while Part II consists of three papers from this project.

In this dissertation, a co-simulation tool is presented that is meant to comprise a more comprehensive environment for modelling and simulation of hydraulic percussion units, which are used in hydraulic hammers and rock drills. These units generates the large impact forces, which are needed to demolish concrete structures in the construction industry or to fragment rock when drilling blast holes in mine drifting. This type of machinery is driven by fluid power and is by that dependent of coupled fluid-structure mechanisms for their operation. This tool consists of a 1D fluid system model, a 3D structural mechanic model and an interface to establish the fluid-structure couplings, which has in this work been applied to a hydraulic hammer. This approach will enable virtual prototyping during product development with an ambition to reduce the need for testing of physical prototypes, but also to facilitate more detailed studies of internal mechanisms. 

The tool has been implemented for two well-known simulation tools, and a co-simulation interface to enable communication between them has been devel-oped. The fluid system is simulated using the Hopsan simulation tool and the structural parts are simulated using the FE-simulation software LS-DYNA. The implementation of the co-simulation interface is based on the Functional Mock-up Interface standard in Hopsan and on the User Defined Feature module in LS-DYNA. The basic functions of the tool were first verified for a simple but relevant model comprising co-simulation of one component, and secondly co-simulation of two components were verified. These models were based on rigid body and linear elastic representation of the structural components. Further, it was experimentally validated using an existing hydraulic hammer product, where the responses from the experiments were compared to the corresponding simulated responses. To investigate the effects from a parameter change, the hammer was operated and simulated at four different running conditions. 

Dynamic simulation of the sealing gap, which is a fundamental mechanism used for controlling the percussive motion, was implemented to further enhance the simulated responses of the percussion unit. This implementation is based on a parametrisation of the deformed FE-model, where the gap height and the eccentric position are estimated from the deformed geometry in the sealing gap region, and then the parameters are sent to the fluid simulation for a more accurate calculation of the leakage flow. 

Wear in percussion units is an undesirable type of damage, which may cause significant reduction in performance or complete break-down, and today there are no methodology available to evaluate such damages on virtual prototypes. A method to study wear was developed using the co-simulation tool to simulate the fundamental behaviour of the percussion unit, and the wear routines in LS-DYNA were utilised for the calculation of wear.  

In this study, a previously developed co-simulation method has been expanded to also simulate the dynamic behaviour of sealing gap regions in hydraulic percussion units. This approach is based on a 1D system model representing the fluid components and a 3D finite element model representing the structural parts of a hydraulic hammer. The sealing gap is a fundamental feature of a percussion unit, where the reciprocating motion of the piston is generated by the valve mechanism of the sealing gap. When the gap is closed it will prevent fluid flow between regions of different pressure levels. However, a small leakage flow through the gap will always occur which size depends on the clearance and the position of the piston. The method proposed here will take the structural motion and deformation into consideration when calculating the leakage flow. The deformed state of the structure is approximated by a cylindrical surface, in a least square manner, and communicated through the co-simulation interface to the fluid simulation module, and then used when calculating the leakage flow. This method aims at a more accurate simulation of the leakage flow that will not only yield a more realistic description of the mechanism on the local level, but also a more accurate estimation of global parameters such as overall performance and efficiency. The results indicate that the simulated leakage flow will decrease when dynamic gaps are used in comparison to static gaps, which is a consequence of the deformed structure that will generate smaller clearances. The leakage flow for the dynamic gaps will even be lower than for the static perfectly concentric case, mainly due to the reduction of clearances. The results also indicate that the dynamic eccentricity does not have a major influence on the leakage flow. The outcome from this study highlights the potentials of the described co-simulation approach for analysing the dynamics of the sealing gaps in a hydraulic percussion unit (i.e. gap heights, eccentricity ratios, etc.) including the evaluation of leakage flows and its impact on the overall performance. © 2021

In this study, a developed co-simulation method, which couples 1D-fluid and 3D-structural models, has been utilised to simulate wear in a hydraulic percussion unit. The effect of wear is generally detrimental on performance and lifetime for such units, but can also cause catastrophic failure and breakdown, requiring a total overhaul and replacement of core components. One experiment of standard straight impact was performed to investigate the tolerance against seizure. The percussion unit was operated at successively increasing operating pressures, and the level of wear was registered at each step, until seizure occurred. The co-simulation model was used to replicate the running conditions from the experiment to simulate the structural response to be used as input for the wear routine to calculate the wear depth. The wear pattern from the simulations corresponds well to the wear pattern from the experiment. Further, the effect of a misaligned impact on wear development was also studied, as this is a loading situation that typically occurs for hydraulic percussion units. The study demonstrates that the simulation method used has a potential for simulating wear and predicting seizure in hydraulic percussion units.

This paper addresses a co-simulation method for fluid power driven machinery equipment, i.e. oil hydraulic machinery. In these types of machinery, the fluid-structure interaction affects the end-product performance to a large extent, hence an efficient co-simulation method is of high importance. The proposed method is based on a 1D system model representing the fluid components of the hydraulic machinery, within which structural 3D Finite Element (FE) models can be incorporated for detailed simulation of specific sub-models or complete structural assemblies. This means that the fluid system simulation will get a more accurate structural response, and that the structural simulation will get more correct fluid loads at every time step, compared to decoupled analysis. Global system parameters such as fluid flow, performance and efficiency can be evaluated from the 1D system model simulation results. From the 3D FE-models, it is possible to evaluate displacements, stresses and strains to be used in stress analysis, fatigue evaluation, acoustic analysis, etc. The method has been implemented using two well-known simulation tools for fluid power system simulations and FE-simulations, respectively, where the interface between the tools is realised by use of the Functional Mock-up Interface standard. A simple but relevant model is used to validate the method.

In this study, a previously developed co-simulation approach has been adopted to simulate the responses of an existing hydraulic hammer product. This approach is based on a 1D system model representing the fluid components and a 3D finite element model representing the structural parts of the hydraulic hammer. The simulation model was validated against four experiments with different running conditions. The corresponding set-ups were analysed using the co-simulation method in order to evaluate the overall responses. A parameter study was also performed involving the working pressure and the restrictor diameter, with the objective to validate that a parameter change in the simulation model will affect the input and output power in the same direction as in the experiments. The experimental responses used in the validation were time history data of fluid pressure, component position and acceleration, and structural stresses. The experiments result in high frequency and high amplitude excitations of the hydraulic hammer and thus require a model with a high resolution of the model dynamics. The conclusion of the validation is that the simulation model is able to replicate the experimental responses with high accuracy including the high frequency dynamics. The favourable outcome of the validation makes the described co-simulation approach promising as an efficient tool for a wide range of other applications where short time duration mechanisms need to be studied.

In this study a previously developed co-simulation method that is based on a 1D system model representing the fluid components of a hydraulic machinery, within which structural 3D Finite Element (FE) models can be incorporated for detailed simulation of specific sub-models or complete structural assemblies, is further developed. The fluid system model consists of ordinary differential equation sub-models that are computationally very inexpensive, but still represents the fluid dynamics very well. The co-simulation method has been shown to work very well for a simple model representing a hydraulic driven machinery. A more complex model was set up in this work, in which two cylinders in the hydraulic circuit were evaluated. Such type of models, including both the main piston and control valves, are necessary as they represent the real application to a further extent than the simple model, of only one cylinder. Two models have been developed and evaluated, from the simple rigid body representation of the structural mechanics model, to the more complex model using linear elastic representation. The 3D FE-model facilitates evaluation of displacements, stresses, and strains on a local level of the model. The results can be utilised for fatigue assessment, wear analysis and for predictions of noise radiation.

We investigate the motion of inertial, rod-like fibres in the decelerating flow of a wedge-shaped channel with non-creeping fibre-flow interactions. We consider the trajectories of isolated fibres to identify the conditions for which these trajectories deflect from the streamlines of the flow as well as a rectilinear path. We carry out analytical and numerical studies under the assumption of an infinite fibre hydrodynamic resistance to transverse flow, and we expand the numerical study by taking into account a finite transverse hydrodynamic resistance. The analytical analysis identifies a longitudinal ballistic number Be and a transverse ballistic number B-t as two dimensionless parameters that govern the fibre dynamics. It is found that Be is the product of the Stokes number Ste(l) in the longitudinal direction of the fibre and the channel opening angle beta. As anticipated, a fibre moves along the streamlines in the viscosity-dominated regime (B-l amp;lt;amp;lt; 1, B-t amp;lt;amp;lt; 1), while it moves in a straight line without being rotated in the inertia-dominated regime (Bt amp;gt;amp;gt; 1). The focus of the present study is on the intermediate regime (B-l amp;gt;amp;gt; 1, B-t amp;lt; 1), in which we identify and analyse a fibre trajectory that significantly deviates from the streamlines of the flow. This behaviour is observed for both infinite and finite resistances to transverse flow, and it is referred to as ballistic deflection. We argue that ballistic deflection may increase the rate of collisions between suspended fibres, and thus potentially affects the rate of fibre aggregation in flowing suspensions. An order of magnitude estimate of the ballistic numbers identifies dry-forming of pulp mats, which includes an air-wood fibre flowing suspension, to operate in the regime of ballistic deflection. (C) 2016 Elsevier Ltd. All rights reserved.

A particle-level rigid fiber model is used to study flocculation in an asymmetric planar diffuser with a turbulent Newtonian fluid flow, resembling one stage in dry-forming process of pulp mats. The fibers are modeled as chains of rigid cylindrical segments. The equations of motion incorporate hydrodynamic forces and torques from the interaction with the fluid, and the fiber inertia is taken into account. The flow is governed by the Reynolds-averaged Navier-Stokes equations with the standard k - omega turbulence model. A one-way coupling between the fibers and the flow is considered. A stochastic model is employed for the flow fluctuations to capture the fiber dispersion. The fibers are assumed to interact through short-range attractive forces, causing them to interlock as the fiber-fiber contacts occur during the flow. It is found that the formation of fiber flocs is driven by both the turbulence-induced dispersion and the gradient of the averaged flow field.

We investigate flocculation in dilute suspensions of rigid, straight fibers in a decelerating flow field of a diffuser. We carry out numerical studies using a particle-level simulation technique that takes into account the fiber inertia and the non-creeping fiber-flow interactions. The fluid flow is governed by the Reynolds averaged Navier-Stokes equations with the standard k-omega eddy-viscosity turbulence model. A one-way coupling between the fibers and the flow is considered with a stochastic model for the fiber dispersion due to turbulence. The fibers interact through short-range attractive forces that cause them to aggregate into flocs when fiber-fiber collisions occur. We show that ballistic deflection of fibers greatly increases the flocculation in the diffilser. The inlet fiber kinematics and the fiber inertia are the main parameters that affect fiber flocculation in the predffuser region.

In the pool of women over the age of 50, the likeliness of an atypical fracture increase drastically, partly due to osteoporosis. With a pre-existing implant in the femur bone, inserted due to a prior atypical fracture, treating a later femoral neck fracture is complex and risky. Currently, a fractured femoral diaphysis is treated using an intermedullary nail which is fixed to the femur bone either through the femoral neck (Recon locking method)or through the lesser trochanter (Antegrade locking method). In a study conducted by Bögl et.al. JBJS102.17 (2020), pp. 1486-1494, it is found that the fixation of the intermedullary nail through the femoral neck reduces the risk of future femoral neck fractures. The study also states that more than 50% of the patients with atypical femoral fractures related to bisphosphonate treatment for osteoporosis (within the study sub population) were treated with the Antegrade locking implant. There does not exist much literature that reasons as to how one locking method is showing lesser risk of re-operation as compared to the other. The purpose of this study is to look into the effects these two implants have on the femur bone using the Finite Element Analysis (FEA). The study presented is aimed at comparing the results of the finite element analysis for the Recon implant model (Recon model) and Antegrade implant model (Antegrade model). The femur model without the implants (native bone model) is used to verify material behavior, while the other two are used for the comparison to study the stress-strain distribution, primarily in the neck region. This is a patient specific study, hence the femur bone model is generated using patient Computed Tomography (CT) scans. The bone model was assigned a heterogeneous isotropic material property derived from patient CT data. The finite element (FE) model of the bone was meshed using Hypermesh. The peak loading condition including the muscle forces were applied on the native bone model along with the Recon and the Antegrademodel. While the loading conditions during normal walking cycle were only applied to theRecon and the Antegrade model to compare the impacts of the two implant types. Both loading conditions were simulated by fixing the distal condyle region of the bone. The analysis results show that the Antegrade implant experiences much higher stresses and strains in the neck region as compared to Recon implant. Also, the presence of the intermedullary nail through the femur diaphysis helps to distribute the stresses and strains in the anterior distal diaphysis region of the bone. For the case of no implants, the model showed strains and stresses in the lateral distal region of femoral diaphysis.

In the transition from conventional to green energy production resources, steam turbines are used to satisfy the lack of energy during peaks in the demand times and the limited access of renewable resources. This type of usage for steam turbines makes them operate on a flexible schedule, which leads to unpredictable issues related to shorter component life and faster crack propagation. Thus, the steam turbine components must be examined to determine their specific life period. This will help set proper maintenance intervals and prevent unexpected failures. For that, thermo-mechanical fatigue (TMF) testing is used, where a specimen made of the same material as the turbine component is subjected to both temperature and load variation. The specimen is pre-cracked to investigate the crack propagation behavior, which is the focus of this study.

This thesis work concentrates on simulating the TMF cycle for the steam turbine casing component. The material is 9%-10%Cr ferritic steel. The aim is to understand the material behavior during crack propagation and to predict a useful testing parameter. The method provided in this work discusses two cases, both are out-of-phase (OP) TMF tests with strain control. The maximum and minimum temperatures for the cycle are 600 ˚C and 400 ˚C respectively, while the maximum and minimum strain levels are 0 and  respectively. The study will investigate different , which is the maximum compressive strain level. Case 1 has a dwell time at the maximum temperature only, while case 2 has dwell times at both maximum and minimum temperatures. The method utilizes the stress intensity factor (SIF) to characterize the crack tip conditions. Also, it uses Paris' law to estimate the duration of the tests. For simplification, only the elastic behavior of the material is considered.

The results obtained show no effect of using different pre-crack lengths due to the strain control condition. Minor effects can be observed by using different dwell times, however very short dwell times must be avoided to produce reliable results. A recommended dwell time of 5 minutes could be used, since longer dwell times will make the test prohibitively time-consuming. The compressive strain levels used in the work shows large effects on the results. Using low compressive strain values will produce a very long time for the tests, while very high compressive strains produce large plasticity. Thus, high compressive strains must be avoided since the SIF describes cracks for only elastic or near elastic cases. Also, small compressive strain levels in case 2 should not be used since it will lead to results like case 1. This is due to the small creep effect at the minimum temperature. Finally, compressive strain levels of 0.6 %, 0.5 % and 0.4 % are recommended for case 1, while only 0.6 % compressive strain level is recommended for case 2.

This thesis contributes to the fields of solid mechanics, fracture mechanics and the use of TMF testing, where a recommended set of testing parameters are provided.

Materials used for high-temperature steam turbine sections are generally subjected to harsh environments with temperatures up to 625 °C. The superior creep resistance of 9–12 % Cr ferritic-martensitic steels makes them desirable for those critical steam turbine components. Additionally, the demand for fast and frequent steam turbine start-ups, i.e. flexible operations, causes accelerated fatigue damage in critical locations, such as grooves and notches, at the high-temperature inner steam turbine casing. A durability assessment is necessary to understand the material behaviour under such high temperatures and repeated loading, and it is essential for life prediction. An accurate and less conservative fatigue life prediction approach is achieved by going past the crack initiation stage and allowing controlled growth of cracks within safe limits. Besides, beneficial load-temperature history effects, i.e. warm pre-stressing, must be utilised to enhance the fracture resistance to cracks. This dissertation presents the high-temperature durability assessment of FB2 steel, a 9-12 % Cr ferritic-martensitic steam turbine steel.

Initially, isothermal low-cycle fatigue testing was performed on FB2 steel samples. A fatigue life model based on finite element strain range partitioning was utilised to predict fatigue life within the crack initiation phase. Two fatigue damage regimes were identified, i.e. plastic- and creep-dominated damage, and the transition between them depended on temperature and applied total strain. Cyclic deformation and stress relaxation behaviour were investigated to produce an elastic-plastic and creep material model that predicts the initial and mid-life cyclic behaviour of the FB2 steel.

Furthermore, the thermomechanical fatigue crack growth behaviour of FB2 steel was studied. Crack closure behaviour was observed and accounted for numerically and experimentally, where crack growth rate curves collapsed into a single curve. Interestingly, the collapsed crack growth curves coincided with isothermal crack growth tests performed at the minimum temperature of the thermomechanical crack growth tests. In addition, hold times and changes in the minimum temperature of the thermomechanical fatigue cycle did not influence crack closure behaviour.

Finally, warm pre-stressing effects were explored for FB2 steel. A numerical prediction model was produced to predict the increase in the apparent fracture toughness. Warm pre-stressing effects can benefit the turbine life by enhancing fracture resistance and allowing longer fatigue cracks to grow within safe limits.

Existing conventional thermal power plants are retrofitted for flexible operations to assist the transition toward more renewable energies. The deployment of many renewable energy power plants is necessary to achieve a clean environment with less pollution. However, the intermittent nature of renewable energies, due to weather changes, and the lack of efficient large energy storage systems put renewables at a disadvantage. Flexible operations of power plants imply fast and frequent start-ups. Thus, retrofitted power production plants can be utilised as an energy backup to satisfy the immediate demand during peak energy times or when renewable energies are suddenly limited. 

Large thermal power plants generally employ steam turbines with high inlet temperature and pressure steam conditions. Materials used for components at the high-temperature turbine sections are expected to withstand harsh environments. The use of 9-12 % Cr martensitic steels is desirable due to, among other things, their superior resistance to creep for temperatures up to 625 °C. Retrofitting for flexible operations put steam turbine components under high-temperature fatigue loading conditions different from how they were designed before. The flexible operations could lead to fatigue cracking at critical locations, such as grooves and notches at the inner steam turbine casing. Thus, fatigue behaviour understanding of steam turbine materials under such loading conditions is essential for components life prediction. Accurate and less conservative fatigue life prediction approach is necessary to extend the turbine components life, which reduces waste and provides economic benefits. This can be done by extending operations past crack initiation phase and allowing controlled propagation of cracks in the components. 

Within the 9-12 % Cr steel class, the martensitic steam turbine steel called FB2 is studied under high-temperature fatigue. This includes investigating high-temperature fatigue life behaviour, cyclic deformation behaviour, stress relaxation behaviour, and crack propagation behaviour along with crack closure behaviour. This was achieved by experimentally testing samples made from FB2 steel under isothermal low cycle fatigue, isothermal fatigue crack propagation, and thermomechanical fatigue crack propagation. 

The increased use of renewable energy pushes steam turbines toward a more frequent operation schedule. Consequently, components must endure more severe fatigue loads which, in turn, requires an understanding of the deformation and damage mechanisms under high-temperature cyclic loading. Based on this, low cycle fatigue tests were performed on a creep resistant steel, FB2, used in ultra-supercritical steam turbines. The fatigue tests were performed in strain control with 0.8-1.2 % strain range and at temperatures of 400 °C and 600 °C. The tests at 600 °C were run with and without dwell time. The deformation mechanisms at different temperatures and strain ranges were characterised by scanning electron microscopy and by quantifying the amount of low angle grain boundaries. The quantification of low angle grain boundaries was done by electron backscatter diffraction. Microscopy revealed that specimens subjected to 600 °C showed signs of creep damage, in the form of voids close to fracture surface, regardless of whether the specimen had been exposed to dwell time or been purely cycled. In addition, the amount of low angle grain boundaries was lower at 600 °C than at 400 °C. The study indicates that a significant amount of the inelastic strain comes from creep strain as opposed to being all plastic strain.

Materials in steam turbine rotors are subjected to cyclic loads at high temperature, causing cracks to initiate and grow. To allow for more flexible operation, accurate fatigue models for life prediction must not be overly conservative. In this study, fully reversed low cycle fatigue tests were performed on a turbine rotor steel called FB2. The tests were done isothermally, within temperature range of room temperature to 600 °C, under strain control with 0.8-1.2 % total strain range. Some tests included hold time to calibrate the short-time creep behaviour of the material. Different fatigue life models were constructed. The life curve in terms of stress amplitude was found unusable at 600 °C, while the life curve in terms of total strain or inelastic strain amplitudes displayed inconsistent behaviour at 500 °C. To construct better life model, the inelastic strain amplitudes were separated into plastic and creep components by modelling the deformation behaviour of the material, including creep. Based on strain range partitioning approach, the fatigue life depends on different damage mechanisms at different strain ranges. This allowed the formulation of life curves based on plasticity or creep domination, which showed creep domination at 600 °C, while at 500 °C, creep only dominates for higher strain range.

Materials made for modern steam power plants are required to withstand high temperatures and flexible operational schedule. Mainly to achieve high efficiency and longer components life. Nevertheless, materials under such conditions experience crack initiations and propagations. Thus, life prediction must be made using accurate fatigue models to allow flexible operation. In this study, fully reversed isothermal low cycle fatigue tests were performed on a turbine rotor steel called FB2. The tests were done under strain control with different total strain ranges and temperatures (20 °C to 625 °C). Some tests included dwell time to calibrate the short-time creep behaviour of the material. Different fatigue life models were evaluated based on total life approach. The stress-based fatigue life model was found unusable at 600 °C, while the strain-based models in terms of total strain or inelastic strain amplitudes displayed inconsistent behaviour at 500 °C. To construct better life prediction, the inelastic strain amplitudes were separated into plastic and creep components by modelling the deformation behaviour of the material, including creep. Based on strain range partitioning approach, the fatigue life depends on different damage mechanisms at different strain ranges at 500 °C. This allows for the formulation of life curves based on either plasticity-dominated damage or creep-dominated damage. At 600 °C, creep dominated while at 500 °C creep only dominates for higher strain ranges. The deformation mechanisms at different temperatures and total strain ranges were characterised by scanning electron microscopy and by quantifying the amount of low angle grain boundaries. The quantification of low angle grain boundaries was done by electron backscatter diffraction. Microscopy revealed that specimens subjected to 600 °C showed signs of creep damage in the form of voids close to the fracture surface. In addition, the amount of low angle grain boundaries seems to decrease with the increase in temperature even though the inelastic strain amplitude was increased. The study indicates that a significant amount of the inelastic strain comes from creep strain as opposed of being all plastic strain, which need to be taken into consideration when constructing a life prediction model.

Exploring crack growth behaviour is needed to establish accurate fatigue life predictions. Cracked specimens were tested under strain-controlled out-of-phase thermomechanical fatigue conditions. The tests included dwell times and three different minimum temperatures. Higher minimum temperature gave faster crack growth rates while the additions of dwell times showed no effects. Crack closure was observed in all the tests where the addition of dwell times and change in minimum temperature displayed little to no effect on crack closure stresses. Finite element models with a sharp stationary crack and material parameters switching provided acceptable predictions for the maximum, minimum, and crack closure stresses.

Using the stress intensity factor to describe the stress field around a crack has become widely adopted due to its simplicity. The stress intensity factor depends on the applied nominal stress, the crack length, and a geometrical factor. Geometrical factors can be obtained from handbook solutions or, for complicated cases, through finite element simulations. Carefully defining the geometrical factor with realistic boundary conditions is vital to obtain accurate values for the stress intensity factor. For fatigue life predictions, even a small error in the stress intensity factor may get amplified as the total fatigue life is computed through integration over thousands of crack growth increments. A commonly used specimen geometry for fatigue crack growth testing is the single-edge cracked specimen. For such a specimen, the crack on one side of the geometry introduces bending, which, to some degree, is constrained by the grips that hold the specimen in the testing rig. The effect of bending on the geometrical factor, and consequently on the stress intensity factor, is generally overlooked due to the assumption that the test rig grips are infinitely stiff. Not considering the bending effects could lead to an inaccurate evaluation of the stress intensity factor, especially for long crack lengths. This work investigated the effect of bending on the stress intensity factor for a single-edge cracked specimen. Different grip dimensions were studied to understand the degree of bending and its impact on the stress intensity factor. The work resulted in recommendations for accurately evaluating the stress intensity factor for single-edge cracked specimens.

In warm pre-stressing (WPS), the fracture resistance of cracked steel components is raised when subjected to certain temperature-load histories. WPS’s beneficial effects enhance safety margins and potentially prolong fatigue life. However, understanding and predicting the WPS effects is crucial for employing such benefits. This study utilised pre-cracked compact tension specimens made from steam turbine steel for WPS and baseline fracture toughness testing. Two typical WPS cycles were investigated (L-C-F and L-U-C-F), and an increase in fracture resistance was observed for both cycles. The WPS tests were simulated using finite element analysis to understand its effects and predict the increase in fracture resistance. A local approach was followed based on accumulative plastic strain magnitude ahead of the crack tip. Since cleavage fracture is triggered by active plasticity, the WPS fracture is assumed when accumulated plasticity exceeds the residual plastic zone formed at the crack tip due to the initial pre-load.

Understanding of crack growth behaviour is necessary to predict accurate fatigue lives. Out-of-phase thermomechanical fatigue crack propagation tests were performed on FB2 steel used in high-temperature steam turbine sections. Testing results showed crack closure where the compressive part of the fatigue cycle affected crack growth rate. Crack closing stress was observed to be different, and had more influence on the growth rate, than crack opening stress. Crack growth rate was largely controlled by the minimum temperature of the cycle, which agreed with an isothermal crack propagation test. Finite element models with stationary sharp cracks captured the crack closure behaviour.

Additive Manufacturing (AM), also known as 3D printing, has transformed traditional manufacturing by enabling the fabrication of intricate and customized parts with unprecedented design freedom. However, comprehending the underlying additive manufacturing processes, including thermal behavior, material interactions, and residual stresses, is quite challenging due to their inherent complexity. This thesis work focuses on using finite element (FE) simulations with Abaqus to enhance AM processes involving polymers. The aim is to develop accurate FE modeling and process simulation to predict and optimize thermal and mechanical phenomena during AM, which directly impacts product quality and waste generation. 

A detailed FE model for Nylon PA6 has been developed, incorporating its temperature-dependent thermal and mechanical properties. A sequentially coupled thermo-mechanical approach has been utilized to simulate the heat transfer, thermal distortion, and residual stress accumulation process in AM. The simulated results are compared with experimental results to analyze temperature distribution and its correlation with mechanical deformation. Realistic boundary conditions, such as preheating the build plate and controlled thermal environments, have been incorporated into the simulations to enhance accuracy. 

The simulation accurately predicted the thermal and mechanical analyses, aligning with the experimental trend data and mechanical deformation. However, there were notable discrepancies in more complex thermal interactions. By refining boundary conditions, introducing flexible constraints, and adjusting coefficients of thermal expansion (CTE), the model was able to more accurately capture the real distortion patterns observed in printed parts. This underscores the effectiveness of FE simulations as a tool to enhance the accuracy and reliability of AM processes. Additionally, these simulations provide valuable insights into optimal conditions for manufacturing, cost-cutting, and improvements in the quality and uniformity of the final product. 

This research contributes to a better understanding of the optimization of AM processes and provides important tools for both academic research and industry applications. It promotes the direct adoption of AM technologies and fosters more efficient and sustainable manufacturing practices. 

Cellulose nanofibrils (CNFs) assemble into water‐resilient materials in the presence of multivalent counter‐ions. The essential mechanisms behind these assemblies are ion–ion correlation and specific ion effects. A network model shows that the interfibril attraction indirectly influences the wet modulus by a fourth power relationship to the solidity of the network (E_w ∝ φ⁴). Ions that induce both ion–ion correlation and specific ion effects significantly reduce the swelling of the films, and due to the nonlinear relationship dramatically increase the wet modulus. Herein, this network model is used to explain the elastoplastic behavior of wet films of 2,2,6,6‐tetramethylpiperidine‐1‐oxyl radical (TEMPO)‐oxidized, carboxymethylated, and phosphorylated CNFs in the presence of different counter‐ions. The main findings are that the aspect ratio of the CNFs influences the ductility of the assemblies, that the bivalency of phosphorylate ligands probably limits the formation of interfibril complexes with divalent ions, and that a higher charge density increases the friction between fibrils by increasing the short‐range attraction from ion–ion correlation and specific ion effects. These findings can be used to rationally design CNF materials for a variety of applications where wet strength, ductility, and transparency are important, such as biomaterials or substrates for bioelectronics.

The unique properties of hydrogels enable the design of life-like soft intelligent systems. However, stimuli-responsive hydrogels still suffer from limited actuation control. Direct electronic control of electronically conductive hydrogels can solve this challenge and allow direct integration with modern electronic systems. An electrochemically controlled nanowire composite hydrogel with high in-plane conductivity that stimulates a uniaxial electrochemical osmotic expansion is demonstrated. This materials system allows precisely controlled shape-morphing at only -1 V, where capacitive charging of the hydrogel bulk leads to a large uniaxial expansion of up to 300%, caused by the ingress of & AP;700 water molecules per electron-ion pair. The material retains its state when turned off, which is ideal for electrotunable membranes as the inherent coupling between the expansion and mesoporosity enables electronic control of permeability for adaptive separation, fractionation, and distribution. Used as electrochemical osmotic hydrogel actuators, they achieve an electroactive pressure of up to 0.7 MPa (1.4 MPa vs dry) and a work density of & AP;150 kJ m-3 (2 MJ m-3 vs dry). This new materials system paves the way to integrate actuation, sensing, and controlled permeation into advanced soft intelligent systems. The unique properties of hydrogels enable the design of life-like soft intelligent systems. This work demonstrates how the swelling of hydrogels from cellulose nanofibrils and carbon nanotubes can be electrochemically controlled to achieve electrochemical osmotic actuation. This new materials system paves the way for integrated actuation, sensing, and controlled permeation in electrotunable separation membranes or soft actuators.image

Multidisciplinary frameworks are needed to develop products that fit the human. Ergonomics is a multifaceted field that encompasses physical, cognitive and organizational aspects, and it is therefore a suitable subject to be taught to design engineering students.

The objective of this paper was to describe and reflect upon how a systems perspective on Ergonomics is developed and conveyed in a course in Product Ergonomics to engineering students at the Design and Product Development (DPD) programme at Linköping University, Sweden. The paper is based on the authors’ experiences from teaching the course in Product Ergonomicsas well ason 52 students’ written reflections about their view on Ergonomics before and after taking the course.

Means and ideas for teaching Ergonomics with a systems perspective included organizing a theoretical introduction into weekly themes and thereafter integrating and applying these themes in a product concept project under supervision of a multidisciplinary teacher team.

The paper also reflects on how the systems perspective of Ergonomics is planned for and realized in the intended, implemented and attained curriculum.

One fundamental challenge in choosing an examination form to assess student achievements is to find an examination which, both encourages students to continuously elaborate the course content and constitutes a learning process itself. The objective of this paper is to share and reflect on the development and implementation of a new theme-based examination in a six credit course in Product Ergonomics given in the engineering programme Design and Product Development at Linköping University, Sweden. The course runs during four months and has two parts: one theoretical and one applied. The former focuses on theoretical ergonomic topics, models and methods while the latter is a project aiming at consolidating the students’ understanding of the theory by implementing the knowledge in a product development case. To encourage the students to adapt a deep learning approach, the traditional written mid-term exam for the theoretical part was abandoned and another concept developed. In the new concept, the theoretical part was split onto six weekly themes. Each theme was introduced at the beginning of the week by high-lighting main theories and models followed by a group-work assignment to be elaborated on by the students during the week. The theme was examined at the end of the week through a short written exam and a seminar to discuss and reflect upon the theme. From a student perspective, the positive outcome of the theme-based examination was peer learning and a more active learning style. The students appreciated the theme-based structure of the course. Occasionally, some students commented that weekly examinations could be perceived as stressful. The teachers perceived the students to be more acquainted with ergonomics theory and methods which increased the quality of the course project. The reported theme-based assessment is one example of implementing among others the CDIO syllabus parts 2.2 and 3.1and CDIO standards 8 and 11.

Modelling the full event of an underwater explosion (UNDEX) is complex and requires advanced modelling methods in order to achieve accurate responses. The process of an UNDEX includes a series of events that has to be considered. When a detonation is initiated, a shock-wave propagates and the rest products from the explosive material creates a gaseous bubble with high pressure which pulsates and impacts the surroundings. Reflections of the initial shock-wave can also appear if it hits the sea floor, water surface or other obstacles.

There are different approaches how to numerically model the impact of an UNDEX on a structure, some with analytical approaches without a water domain and others where a water domain has to be modelled. This master’s thesis focuses on two modelling methods that are available in the finite element software LS-DYNA. The simpler method is called Sub-Sea Analysis (SSA) and does not require a water domain, thus it can be beneficial to use in an early design stage, or when only approximated responses are desired. To increase the accuracy, a more complex method called S-ALE can be used. By implementing this method, the full process of an UNDEX can be studied since both the fluid domain and explosive material are meshed. These methods are studied separately together with a combination of them.

Another important aspect to be considered is that oscillations of a structure submerged in water differs from the behavior it has in air. Depending on the numerical method used, the impact of the water can be included. Natural frequencies of structures submerged in water are studied, how it changes and how the methods takes this into account.

To verify the numerical models, experiments were executed with a cylindrical test object where the distance and weight of charge were altered through out the test series. It was found that multiple aspects affects the results from the experiments, that are not captured in the numerical models. These aspects have for instance to do with reflections, how accurate the test object is modelled and the damping effects of the water.

It is concluded that the numerical models are sensitive when small charges and fragile structures are studied. High frequency oscillations were not triggered in the experiment but found for both methods. It should be further investigated if the methods are more accurate for larger charges and stronger structures. Experiments with larger water domain would also be beneficial to reduce effects from reflections, as well as a more accurate model of the cylinder in the simulations.

This master's thesis is focused on the structural response due to blast loading, where the geometry used was arbitrary but heavily inspired by Siemens Energy. The aim of the thesis is to gain a better understanding on how to model the blast load and how it affects the structure, as well as to study the modeling of bolts with both pre-tension and a damage criteria in an explicit analysis. Lastly, the importance of strain rate dependent material models was studied. Other aspects such as mass scaling and Rayleigh damping were also investigated. The software used to solve these tasks were Hypermesh, Abaqus and Python. To conclude, the conclusions drawn from this thesis was that bolts should be modeled using connector elements, and including pre-tension is more conservative than not using it for the case studied. However, for the material modeling it gives more conservative results when using a strain rate independent material model compared to the strain rate dependent model, and is advised to be used in the future.  

This thesis explores the structural optimization of a triboelectric energy harvester inspired by the natural motion of plant leaves. The device harnesses using the triboelectric effect, where electrical energy is generated through the contact and separation of an artificial silicone composite leaf and a plant leaf. The primary goal of this study was to enhance energy production by optimizing the design of the artificial leaf to maximize its oscillation frequency caused by wind. A comprehensive mathematical model, integrating aerodynamic and structural dynamics, was developed. Subsequent optimization techniques were then used to find the best structural configuration for maximizing oscillations. Experimental results later confirmed the model's predictions, demonstrating improvements in the harvester's performance. These findings provide insights into designing efficient triboelectric energy harvesters, contributing to sustainable energy solutions.

This Licentiate of Engineering thesis is a product of the results generated in the research project KME-702, which comprises modelling, microstructure investigations and material testing of cast nickel-base superalloys.

The main objective of this work is to model the fatigue crack propagation behaviour in single-crystal nickel-base superalloys. To achieve this, the influence of the crystal orientations on the cracking behaviour is assessed. The results show that the crystal orientation is strongly affecting the material response and must be accounted for. Furthermore, a linear elastic crack driving force parameter suitable for describing crystallographic cracking has been developed. This parameter is based on resolved anisotropic stress intensity factors and is able to predict the correct crystallographic cracking plane after a transition from a Mode I crack. Finally, a method to account for inelastic deformations in a linear elastic fracture mechanics context was investigated. A residual stress field is extracted from an uncracked finite-element model with a perfectly plastic material model and superimposed on the stress field from the cracked model with a linear elastic material model to account for the inelastic deformations during the determination of the crack driving force. The modelling work is validated by material testing on two different specimen geometries at different temperatures.

This Licentiate of Engineering thesis consists of two parts, where Part I gives an introduction and background to the research area, while Part II consists of three papers.

This dissertation was produced at the Division of Solid Mechanics at Linköping University and is part of a research project, which comprises modelling, microstructure investigations and material testing of cast nickel-base superalloys. The main objective of this work was to deepen the understanding of the fracture behaviour of single-crystal nickel-base superalloys and to develop a model to predict the fatigue crack growth behaviour. Frequently, crack growth in these materials has been observed to follow one of two distinct cracking modes; Mode I like cracking perpendicular to the loading direction or crystallographic crack growth on the octahedral {111}-planes, where the latter is associated with an increased fatigue crack growth rate. Thus, it is of major importance to account for this behaviour in component life prediction. Consequently, a model for the prediction of the transition of cracking modes and the correct active crystallographic plane, i.e. the crack path, and the crystallographic crack growth rate has been developed. This model is based on the evaluation of appropriate crack driving forces using three-dimensional finite-element simulations. A special focus was given towards the influence of the crystallographic orientation on the fracture behaviour. Further, a model to incorporate residual stresses in the crack growth modelling is presented. All modelling work is calibrated and validated by experiments on different specimen geometries with different crystallographic orientations. This dissertation consists of two parts, where Part I gives an introduction and background to the field of research, while Part II consists of six appended papers.