Lv‐Yi Cheng

East China University of Science and Technology

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Kai-Shang Li

East China University of Science and Technology

Run‐Zi Wang

Tohoku University

Xiancheng Zhang

East China University of Science and Technology

Xuelin Lei

East China University of Science and Technology

Shan‐Tung Tu

East China University of Science and Technology

Wei Li

Zhengzhou Railway Vocational & Technical College

Fei Zeng

Wuhan University of Science and Technology

Shulei Yao

Second Hospital of Shanxi Medical University

Xian‐Cheng Zhang

Shaanxi University of Science and Technology

Cenyao He

East China University of Science and Technology

Cooperative Institutions

East China University of Science and Technology

Tohoku University

Ritsumeikan University

Chinese Academy of Sciences

Nanjing Tech University

University of Electronic Science and Technology of China

Commercial Aircraft Corporation of China (China)

Northwestern Polytechnical University

Xi'an Jiaotong University

Hefei General Machinery Research Institute (China)

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Design of a novel cold expansion tool for deep small holes based on FEM simulations and experimental study

Research Square (Research Square) (2023)

Jiachen Wang Xuelin Lei Fei Zeng Wei Li Cenyao He

Abstract Cold hole expansion is a crucial technology for enhancing the fatigue life of hole structures. This paper presents the design and optimization of a novel multi-convex hulls expansion tool for deep small holes in Inconel 718 superalloy using the finite element method (FEM) and experimental techniques. The results from the FEM model, which was used to investigate the compressive residual stress (CRS) distribution and contact force during the expansion process, indicate that the curved single convex hull(CSCH) structure is more suitable for deep small hole expansion (DSHE). However, accounting for the strength limitations of the actual expansion tool, a multi-convex hulls expansion tool structure was proposed. The FEM model was employed to compare the effects of various tool structures on the hole wall CRS distribution and the contact force during the expansion process. The obtained optimal parameters for enhancing deep small holes in Inconel 718 superalloy under high temperature and high load conditions are as follows: expansion section hull spacing l 1 = 0.4 mm, taper ratio C = 0.008, number of convex hulls in the sizing section n = 10, and sizing section hull spacing l 2 = 1 mm. Moreover, an optimized convex hull expansion amount allocation scheme was obtained through an experimental study. The results of the FEM simulations and experimental study demonstrate that the optimized multi-convex hulls expansion tool (with an expansion rate of 1.92%) can induce the formation of a high CRS layer and a refined surface without causing significant microcracks in the hole walls.

Inconel

10.21203/rs.3.rs-3457437/v1

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Citations (0)

Dislocation-based crystal plasticity modelling of a nickel-based superalloy under dwell-fatigue: From life prediction to residual life assessment

International Journal of Fatigue (2021)

Kai-Shang Li Run‐Zi Wang Lv‐Yi Cheng Tiwen Lu Xiancheng Zhang

Dwell time

Crystal Plasticity

Robustness

Low-cycle fatigue

10.1016/j.ijfatigue.2021.106569

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Citations (14)

A life prediction method and damage assessment for creep-fatigue combined with high-low cyclic loading

International Journal of Fatigue (2022)

Kai-Shang Li Ji Wang Zhichao Fan Lv‐Yi Cheng Shulei Yao

Failure assessment

Inconel

Low-cycle fatigue

10.1016/j.ijfatigue.2022.106923

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Citations (25)

Creep damage evolution by cavity nucleation and growth considering the cavity closure under cyclic loading conditions

Fatigue & Fracture of Engineering Materials & Structures (2024)

Le Xu Lv‐Yi Cheng Kai‐Shang Li Ken Suzuki Hideo Miura

Abstract Creep damage assessment is crucial for ensuring the long‐term reliability of key components operating at high temperatures. However, the existing studies on creep damage are mainly focused on constant loading conditions, while the effect of cyclic loading, which is a common loading mode in practice, remains unclear. In this paper, a series of stress‐controlled cyclic creep tests on the Inconel 718 superalloy were performed to investigate the influence of cyclic loading on creep damage evolution. The ex‐situ microstructural analyses, including fracture surface observations and EBSD measurements, were conducted to reveal the damage mechanisms under cyclic creep conditions. Furthermore, a cavity nucleation and growth model that accounts for the additional cavity closure was developed for the healing effect of cyclic creep damage evolution. The prediction results were consistent with the experimental data of cavity nucleation life and experimental life within a factor of 2.

Closure (psychology)

10.1111/ffe.14389

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Data-driven fatigue life prediction of small-deep holes in a nickel-based superalloy after a cold expansion process

International Journal of Fatigue (2024)

Chao-Zong Tang Hongwei Li Kai-Shang Li Xuelin Lei Lv‐Yi Cheng

10.1016/j.ijfatigue.2024.108159

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Citations (11)

Fatigue behaviors and life evaluation of AISI304 stainless steel under non-proportional multiaxial random loading

International Journal of Fatigue (2024)

Yu-Chen Wang Le Xu Lei He Lv‐Yi Cheng Shuai Chang

Fatigue tests on AISI304 stainless steel under non-proportional multiaxial random loading conditions were conducted with uniform hollow specimens at room temperature. The results revealed initial hardening and subsequent cyclic softening under uniaxial loadings and additional hardening under non-proportional multiaxial loadings. This shift from softening to additional hardening significantly reduced the failure life. Fractographic analysis and Electron Backscatter Diffraction (EBSD) observations identified planar slip as the dominant deformation mechanism under uniaxial loading. Multiple slip system activations, strong slip interactions, and martensitic transformation were key factors influencing changes in cyclic deformation behavior under non-proportional loadings. A novel life evaluation method based on the Itoh–Sakane (IS) method was established, demonstrating accurate evaluations for both uniaxial and non-proportional multiaxial fatigue life under random loading conditions.

10.1016/j.ijfatigue.2024.108417

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Citations (4)

High-temperature fatigue life improvement of small-deep holes by using a novel cold expansion process in a nickel-based superalloy

Journal of Manufacturing Processes (2023)

Wei Li Lv‐Yi Cheng Fei Zeng Xuelin Lei Cenyao He

10.1016/j.jmapro.2023.09.067

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Citations (10)

Process-performance-prediction integration for fatigue life improvement technologies: An implementation in cold expansion of hole structures

International Journal of Fatigue (2023)

Kai-Shang Li Run‐Zi Wang Xiancheng Zhang Shulei Yao Lv‐Yi Cheng