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Caractérisation rapide des propriétés à la fatigue à grand nombre de cycle des assemblages métalliques soudés de type automobile : vers une nouvelle approche basée sur des mesures thermométriques

Abstract : Fatigue design of weld assemblies still remains of prior concern in the automotive industry, despite several decades of experimental, theoretical and numerical body of work. Actually, many complex components (e.g. front and rear axles) are embedded thanks to welding process. Such welded assemblies are expected to be designed as high-safety parts, for which any fatigue failure is supposed to be prevented. Despite numerical modelling is more and more effective, experimental tests are still necessary in order to provide basic design data and at last to prove the design reliability. Standard fatigue tests procedures are sensibly time consuming, are usually destructive and need for several specimens in order to manage reliable results. Conversely, the so-called self-heating tests offer the opportunity to dramatically shorten the test duration and save specimens because it is a non-destructive method. It consists in measuring the temperature evolution of the structure surface during cyclic loading. Such an approach allows to take advantage of the macroscopic thermal signature of microscopic plasticity processes responsible for fatigue damage. The purpose of the present work is the determination of a correlation between thermal measurement and fatigue properties of welded structures, and then studying the influence of parameters on fatigue properties with the developed method. An experimental protocol is first proposed to measure the temperature of the tested specimen under cyclic loading. A first analysis of the thermal response of standard steel sheet specimen under low load amplitude is proposed in order to validate a deterministic heat source model for both tensile and bending tests. These tests allow us to correctly describe the thermal behavior of the base material of welded specimen away from the joint. Then, the model is extended to welded specimen in order to take into account the dissipation of the welded area. Once the dissipative heat source is identified thanks to the model, its evolution with the applied loading leads to a self-heating curve allowing an estimation of the fatigue limit of the welded specimen after only few hours of test. The method is then applied to other configurations of welded specimens in order to study the effects of shot peening and stress gradient on fatigue properties. Finally, the testing procedure is applied for the determination of an industrial component fatigue properties, a welded car wishbone. Due to the bad heat boundary condition, another analysis is proposed to estimate the heat source along the entire component. This estimation leads to the determination of the weakest area of the structure concerned by fatigue and a first good estimation of its fatigue limit.
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Submitted on : Saturday, December 16, 2017 - 10:47:10 AM
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  • HAL Id : tel-01665540, version 1

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Pierrick Florin. Caractérisation rapide des propriétés à la fatigue à grand nombre de cycle des assemblages métalliques soudés de type automobile : vers une nouvelle approche basée sur des mesures thermométriques. Génie mécanique [physics.class-ph]. Université de Bretagne occidentale - Brest, 2015. Français. ⟨NNT : 2015BRES0100⟩. ⟨tel-01665540⟩

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