• Design & Manufacturing
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• v.12 no.3
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• pp.36-41
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• 2018

Metal 3D printing is very useful for making the injection molds containing complex conformal cooling channels. The most important issue of the 3D printed molds is cost and life cycle. However, powder bed fusion (PBF) methods are vulnerable to fatigue loading because of the presence of pores and rough surfaces. In the present study, the fatigue test was performed to obtain fatigue analysis input data for predicting the durability of a 3D printed injection mold core. The metal 3D printer used to manufacture the specimen was OPM250L from Sodick, and the metal powder material was maraging steel. The ultrasonic fatigue testing method was adopted for the fatigue test. A key advantage of the ultrasonic fatigue method is that $10^8{\sim}10^9$ long cycle test data or more could be obtained within a relatively short period. Based on the results of the experiment, the effect of heat treatment was negligible. However, there was an apparent difference in durability depending on the presence or absence of the surface treatment.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2011.04a
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• pp.415-418
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• 2011

Thermal fatigue is one of the life-limiting damage mechanisms in the nuclear power plant conditions. The turbulent mixing of fluids of different temperatures induces rapid temperature changes to the pipe wall. The successive thermal transients cause varying cyclic thermal stresses. These cyclic thermal stresses cause fatigue crack nucleation and growth similar to the cyclic mechanical stresses. The aim of this study was to fulfil the need by developing an real crack manufacturing method, which would produce realistic cracks. The test material was austenitic STS 304, which is used as pipelines in the reactor coolant system of a nuclear power plants. In order to fabricate thermal fatigue crack similar to realistic crack, successive thermal transients were applied to the specimen. Thermal transient cycles were combined with heating (60sec) and cooling cycle (30sec). And, In order to identify ultrasonic characteristic, it was performed the ultrasonic reflection measuring method for the fabricated specimen. From the results of ultrasonic reflection measuring testing, it was conformed that A-scan results(average 83% of real crack depth) for the TFC reference specimen was more enhanced NDT reliability than results(average 38% of real crack depth) for the EDM notch reference specimen.

• Economic and Environmental Geology
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• v.30 no.3
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• pp.231-240
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• 1997

The behavior of rocks and microcrack development due to fatigue stresses are investigated using cyclic loading tests and ultrasonic velocity measurements. Twenty six medium-grained granite samples from the Pochon area are selected for measurements. Ultrasonic velocities are measured for samples before fatigue test to characterize the pre-existing microcracks. Then, thirteen different cycles of loadings with 70% and 80% dynamic strength are applied to the samples. The ultrasonic velocities are measured again to compare velocities after applications of fatigue stress with those before applications of fatigue stress. The results show that most microcracks are developed along the direction parallel to the axis of loading and that the amount of microcracks increases, as loading levels and numbers of cycle increase.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.7
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• pp.131-138
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• 2008

The microstructural effects on the ultrasonic nonlinearity were investigated in isothermally degraded ferritic 2.25Cr-1Mo steel and low cycle fatigued copper. The variation in ultrasonic nonlinearity (${\beta}/{\beta}_0$) was interpreted as resulting from microstructural changes supported by the electron microscopy and X-ray diffraction, in addition to the mechanical test (Victor's hardness and ductile-brittle transition temperature). The ultrasonic nonlinearity of 2.25Cr-1Mo steel increased abruptly in the initial 1,000 h of degradation, and then changed little due to the coarsening of carbide and precipitation of stable $M_6C$ carbide during isothermal degradation. The ultrasonic nonlinearity of copper increased with the fatigue cycles due to the evolution of dislocation cell substructure.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.8
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• pp.781-785
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• 2015

In this study, a newly developed ultrasonic fatigue test was performed for durability assessment of polyoxymethylene engineering plastic, which has a high crystallization rate and degree of crystallization. Fatigue strength of POM (polyoxymethylene) was performed on a piezoelectric UFT developed by Mbrosia Co., Ltd(1), operating at a high frequency of 20 kHz. The test results showed a fatigue limit of 5.0~6.0 MPa under fatigue testing at R = -1, 20kHz; and, electron microscopy revealed the size effect by risk volume and fractured dimple structure after the coalescence of micro-voids through the crazing effect, which occurs during the failure of a polymer.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.7
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• pp.711-717
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• 2014

An accelerated ultrasonic fatigue test (UFT) was used for analyzing very high cycle fatigue (VHCF, $N_f$ > $10^7$) behaviors of a specimen with a test resonance of 20 kHz. Using the finite element method (FEM), the dynamic behaviors of the specimen was studied by calculating the stresses along its gauge portion, with displacement. The shape of gauge portion profile was assumed to be a hyperbolic according to the stress equation of the UFT. However, as the specimen used in the test had a circular arc profile, the FEM was used for studying the local stresses for two cases of the gauge profile. The results were compared with those obtain from the stress equation of the UFT. The dynamic behavior of the gauge portion could be understood for further comparison with the actual results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2013.05a
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• pp.935-936
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• 2013

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.6
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• pp.707-712
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• 2012

Very high cycle fatigue (VHCF) behavior of aerospace components has emerged much attention due to their long service life. In this study, a piezoelectric ultrasonic fatigue testing (UFT) system has been developed by Mbrosiatec Co., Ltd. to study the high cycle fatigue (HCF) strength of Ti-6Al-4V alloy. Hourglass-shaped specimens have been investigated in the range from $10^6$ to $10^9$ cycles at room temperature under completely reversed R = -1 loading conditions,. Scanning electron microscopy (SEM) analysis revealed that failures occurred in the entire range up to the gigacycle regime, and the fractures have beenfound to be initiated from the surface, unlike in steels. However, it was found from the SEM microgprahs that microcracks transformed into intergranular fractures. Thus, it can be concluded from according to the results that this test method can be applicable to commercialized automotive and railroad parts that require high cycle fatigue strength.

• Nuclear Engineering and Technology
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• v.51 no.3
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• pp.867-876
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• 2019

Second harmonic generation using nonlinear ultrasonic waves have been shown to be an early indicator of possible fatigue damage in nuclear power plant components. This technique relies on measuring amplitudes, making it highly susceptible to variations in transducer coupling and instrumentation. This paper proposes an experimental procedure for in-situ surface wave nonlinear ultrasound measurements on specimen with permanently mounted transducers under high cycle fatigue loading without interrupting the experiment. It allows continuous monitoring and minimizes variation due to transducer coupling. Moreover, relations describing the effects of the measurement system nonlinearity including the effects of the material transfer function on the measured nonlinearity parameter are derived. An in-situ high cycle fatigue test was conducted using two 304 stainless steel specimens with two different excitation frequencies. A comprehensive analysis of the nonlinear sources, which result in variations in the measured nonlinearity parameters, was performed and the effects of the system nonlinearities are explained and identified. In both specimens, monotonic trend was observed in nonlinear parameter when the value of fundamental amplitude was not changing.

• Journal of the Korean Society for Nondestructive Testing
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• v.21 no.1
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• pp.32-38
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• 2001

Although the ultrasonic method has been developed and used widely in the fields, it has been used only for measuring the defect size and thickness loss. In this study, the relationship between surface wave attenuation through micro-crack growth and variation of velocity under repeated cyclic loading has been investigated. The specimens are adopted from 2.25Cr-1Mo steel, which is used for power plant and pipeline system, and have dimensions of $200{\times}40{\times}4mm$. The results of ultrasonic test with a 5MHz transducer show that surface wave velocity gradually decreases from the point of 60% of fatigue life and the crack length of 2mm with the increasing fatigue cycles. From the results of this study, it is found that the technique using the ultrasonic velocity change is one of very useful methods to evaluate the fatigue life nondestructively.