• International Journal of Automotive Technology
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• v.5 no.4
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• pp.297-302
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• 2004

This paper presents the low cycle thermal fatigue of the engine exhaust manifold subject to thermo-mechanical cyclic loading. As a failure of the exhaust manifold is mainly caused by geometric constraints of the less expanded inlet flange and cylinder head, the analysis is based on the exhaust system model with three-dimensional temperature distribution and temperature dependent material properties. The result show that large compressive plastic deformations are generated at an elevated temperature of the exhaust manifold and tensile stresses are remained in several critical zones at a cold condition. From the repetition of these thermal shock cycles, maximum plastic strain range (0.454%) could be estimated by the stabilized stress-strain hysteresis loops. It is used to predict the low cycle thermal fatigue life of the exhaust manifold for the thermal shock test.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.1
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• pp.139-145
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• 2007

This paper presents the low cycle thermal fatigue of the engine exhaust manifold subject to thermomechanical cyclic loadings. The analysis includes the FE model of the exhaust system, temperature dependent material properties, and thermal loadings. The result shows that at an elevated temperature, large compressive plastic deformations are generated, and at a cold condition, tensile stresses are remained in several critical zones of the exhaust manifold. From the repetitions of thermal shock cycles, plastic strain ranges could be estimated by the stabilized stress-strain hysteresis loops. The method was applied to assess the low cycle thermal fatigue for the engine exhaust manifold. It shows a good agreement between numerical and experimental results.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.6 no.2
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• pp.54-60
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• 2010

Piping failures due to thermal fatigue have been widely reported in normally stagnant non-isolable reactor coolant branch lines. Since the thermal fatigue due to thermal stratification was not considered in the piping fatigue design in old NPPs, it is important to evaluate the effect of thermal stratification on the integrity of branch lines. In this study, geometrical screening criteria for Up-horizontal branch lines in MRP-132 were applied to SI(Safety Injection) lines of KSNP 2-loop and WH 3-loop. Some computational fluid dynamic(CFD) analyses on the Reactor Coolant System(RCS) branch lines were also performed to develop the regulatory guidelines for screening criteria. As a result of applying MRP-132 screening criteria, KSNP 2-loop and WH 3-loop SI lines are determined to need further detailed evaluation. Results of CFD analyses show that both valve isolation and amount of leakage through valve can be used as technical bases for the screening criteria on the thermal fatigue analysis.

• Journal of Welding and Joining
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• v.16 no.4
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• pp.92-97
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• 1998

Because of the low melting temperature of solder, each temperature cycle initiates an irrecoverable creep deformation at the solder interconnection which connects the package body with the PCB. The crack starts and propagates from the position where the creep deformation is maximized. This work has tried to compare and analyze the thermal fatigue life of solder interconnection which is affected by the lead material, the size of die pad, chip thickness, and interface delamination of 48-Pin TSOP under the temperature cycle ($0^{\circ}C$~1$25^{\circ}C$). The crack initiation position and thermal fatigue life which are calculated by using FEA method are well matched with the results of experiments. The thermal Fatigue life of copper lead frame is extended around 3.6 times longer than that of alloy 42 lead frame. It is maximized when the chip size is matched with the length of the lead. It tends to be extended as the thickness of chip got thinner. As the interfacial delamination between die pad and EMC is increased, the thermal fatigue life tends to decrease in the beginning of delamination, and increase after the delamination grew after 45% of the length of die pad.

• Journal of the Korean Society of Safety
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• v.33 no.5
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• pp.164-169
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• 2018

A detailed fatigue evaluation procedure was developed to mitigate the excessive conservativeness of the conventional environmental fatigue evaluation method for the pressurizer spray line elbow of domestic new nuclear power plants. The pressurizer spray line is made of austenitic stainless steel, which is relatively sensitive to the environmentally assisted fatigue, and has a low degree of design margin in terms of environmentally assisted fatigue due to the thermal stratification phenomenon on the pipe cross section as a whole or locally. In this study, to meet the environmental fatigue design requirements of the pressurizer spray line elbow, the new environmental fatigue evaluation has been performed, which used the ASME Code NB-3200-based detailed fatigue analysis and the environmental fatigue correction factor instead of the existing NB-3600 evaluation method. As a result, the design requirements for environmentally assisted fatigue were met in all parts of the pressurizer spray line elbow including the fatigue weakened zones by thermal stratification.

• Journal of Welding and Joining
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• v.33 no.6
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• pp.6-12
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• 2015

Thermal fatigue life of the automobile exhaust manifold is directly affected by the restraint force according to the structure of exhaust system and bead shape of the welded joints. In the present study, the microstructural changes and precipitation behavior during thermal fatigue cycle of the 18wt% Cr ferritic stainless steel weld heat affected zone (HAZ) considering restraint stress were investigated. The simulation of weld HAZ and thermal fatigue test were carried out using a metal thermal cycle simulator under complete constraint force in the static jig. The change of the restraint stress on the weld HAZ was simulated by changing the shape of notch in the specimen considering the stress concentration factor. Thermal fatigue properties of the weld HAZ were deteriorated during cyclic heating and cooling in the temperature range of $200^{\circ}C$ to $900^{\circ}C$ due to the decrease of Nb content in solid solution and coarsening of MX type precipitates, laves phase, $M_6C$ with coarsening of grain and softening of the matrix. As the restraint stress on the specimen increased, the thermal fatigue life was decreased by dynamic precipitation and rapid coarsening of the precipitates.

• Journal of Welding and Joining
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• v.26 no.2
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• pp.43-49
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• 2008

Fatigue cracks due to thermal stratification or corrosion in pipelines of nuclear power plants can cause serious problems on reactor cooling system. Therefore, the development of an integrated technology including fabrication of standard specimens and their practical usage is needed to enhance the reliability of nondestructive testing. The test material was austenitic STS 304, which is used as pipelines in the Reactor Coolant System of a nuclear power plants. The best condition for fabrication of thermal fatigue cracks at the notch plate was selected using the thermal stress analysis of ANSYS. The specimen was installed from the tensile tester and underwent continuos tension loads of 51,000N. Then, after the specimen was heated to $450^{\circ}C$ for 1 minute using HF induction heater, it was cooled to $20^{\circ}C$ in 1 minute using a mixture of dry ice and water. The initial crack was generated at 17,000 cycles, 560 hours later (1cycle/2min.) and the depth of the thermal fatigue crack reached about 40% of the thickness of the specimen at 22,000 cycles. As a results of optical microscope and SEM analysis, it is confirmed that fabricated thermal fatigue cracks have the same characteristics as real fatigue cracks in nuclear power plants. The crack shape and size were identified.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2007.04a
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• pp.265-270
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• 2007

According to previous research, welding-induced residual stresses in steel structures can significantly affect the fatigue behaviour. Usually, high tensile residual stresses up to the yield strength are conservatively assumed at the weld toes. This conservative assumption can result in misleading fatigue assessments. Thee welding-induced residual stresses need be known in advance for a reliable fatigue assessment, which becomes possible to an increasing extent by numerical welding simulation. In this study, a fatigue Analysis technique for steel structures with welding induced residual stress is presented. First, We calculate the history of temperature according with welding process. Secondly, residual stress with a welding thermal history was evaluated by non-linear thermal stress analysis and lastly, fatigue strength is estimated with modified Goodman equation which can consider the effect of mean stress level.

• Korean Journal of Metals and Materials
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• v.46 no.2
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• pp.80-87
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• 2008

Many researches related to the reliability of Pb-free solder joints with PCB (printed circuit board) surface finish under thermal or vibration stresses are in progress, because the electronics is operating in hash environment. Therefore, it is necessary to assess Pb-free solder joints life with PCB surface finish under thermal and mechanical stresses. We have investigated 4-points bending fatigue lifetime of Pb-free solder joints with OSP (organic solderability preservative) and ENIG (electroless nickel and immersion gold) surface finish. To predict the bending fatigue life of Sn-3.0Ag-0.5Cu solder joints, we use the test coupons mounted 192 BGA (ball grid array) package to be added the thermal stress by conducting thermal shock test, 500, 1,000, 1,500 and 2,000 cycles, respectively. An 4-point bending test is performed in force controlling mode. It is considered that as a failure when the resistance of daisy-chain circuit of test coupons reaches more than $1,000{\Omega}$. Finally, we obtained the solder joints fatigue life with OSP and ENIG surface finish using by Weibull probability distribution.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.6
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• pp.677-684
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• 2004

Plastic and creep deformations of solder joints during thermal cycling are the main factors of misalignments and power losses in optical telecommunication components. Furthermore, the increased mismatch between solder Joint-bonded areas may cause severe failure in the components. Darveaux's creep model was implemented into a finite element program (ABAQUS) to simulate creep response of solder. Based on the finite element results, thermal fatigue reliability was predicted by using various fatigue life prediction models. Also, the effects of ramp conditions, dwelling time, and solder joint-embedding materials on the reliability were investigated under the thermal cycling conditions of the Telcordia schedule (-40∼75$^{\circ}C$).