In an automobile braking system, the heating and cooling cycles that take place on the brake disc surface during braking action lead to thermomechanical fatigue (TMF). TMF, a type of non-isothermal fatigue, occurs when a material experiences simultaneous mechanical and thermal loads. Based on a material’s elastic and plastic deformation, the strain-life technique of fatigue analysis calculates how many TMF cycles a material will withstand before failing. However, it is challenging to effectively recreate the TMF process using conventional testing methods due to the cyclical changes in temperature, stress, and strain. So, in the current situation, all TMF life projections are based mostly on isothermal condition because low-cycle fatigue (LCF) data, which is normally used for design purposes, has been created isothermally. In the present work, a reliable test procedure is adopted to measure the TMF behavior of cast iron grade EN-GJL-250. The novel testing procedure closely resembles the field’s cyclical patterns of temperature and mechanical strain, in addition to online monitoring of the TMF cycles. The testing procedure complies with ISO 12111, ASTM E2368, and the European Code of Practice (CoP). The TMF behavior of EN-GJL-250 was characterized by hysteresis loops and cyclic stress-strain responses. Designers can use test data to help them simulate component behavior and validate current designs through numerical simulations.
KuangWWangHLiX, et al. Application of the thermodynamic extremal principle to diffusion-controlled phase transformations in Fe-C-X alloys: modeling and applications. Acta Mater2018; 159: 16–30.
2.
ZhaoYLiuKZhangH, et al. Dislocation motion in plastic deformation of nano polycrystalline metal materials: a phase field crystal method study. Adv Compos Hybrid Mater2022; 5(3): 2546–2556.
3.
ShaoLZhangXChenY, et al. Why do cracks occur in the weld joint of Ti-22Al-25Nb alloy during post-weld heat treatment?Front Mater2023; 10: 1135407.
4.
ZhangZChenJWangJ, et al. Effects of solder thickness on interface behavior and nanoindentation characteristics in Cu/Sn/Cu microbumps. Weld World2022; 66(5): 973–983.
5.
XuSJingXZhuP, et al. Equilibrium phase diagram design and structural optimization of SAC/Sn-Pb composite structure solder joint for preferable stress distribution. Mater Charact2023; 206: 113389.
6.
WangSChenXLuoK, et al. The design of low-temperature solder alloys and the comparison of mechanical performance of solder joints on ENIG and ENEPIG interface. J Mater Res Technol2023; 27: 5332–5339.
7.
QianWZhangWWuS, et al. In situ X-ray imaging and numerical modeling of damage accumulation in C/SiC composites at temperatures up to 1200 °C. J Mater Sci Technol2024; 197: 65–77.
8.
LongXChongKSuY, et al. Meso-scale low-cycle fatigue damage of polycrystalline nickel-based alloy by crystal plasticity finite element method. Int J Fatigue2023; 175: 107778.
9.
LongXLuCSuY, et al. Machine learning framework for predicting the low cycle fatigue life of lead-free solders. Eng Fail Anal2023; 148: 107228.
10.
YuhuaCYuqingMWeiweiL, et al. Investigation of welding crack in micro laser welded NiTiNb shape memory alloy and Ti6Al4V alloy dissimilar metals joints. Opt Laser Technol2017; 91: 197–202.
11.
XieJZhouYZhouC, et al. Microstructure and mechanical properties of Mg–Li alloys fabricated by wire arc additive manufacturing. J Mater Res Technol2024; 29: 3487–3493.
12.
YangZChenCLiD, et al. An additively manufactured heat-resistant Al-Ce-Sc-Zr alloy: microstructure, mechanical properties and thermal stability. Mater Sci Eng A2023; 872: 144965.
13.
ZhouJQiQLiuQ, et al. Determining residual stress profile induced by end milling from measured thin plate deformation. Thin-Walled Struct2024; 200: 111862.
14.
HuQLiuWSongY, et al. Influence of solid solution treatment on fatigue crack propagation behavior in the thickness direction of 2519A aluminum alloy thick plates. Eng Fract Mech2024; 302: 110069.
15.
GongQCaiMGongY, et al. Grinding surface and subsurface stress load of nickel-based single crystal superalloy DD5. Precis Eng2024; 88: 354–366.
16.
MackinTJNoeSCBallKJ, et al. Thermal cracking in disc brakes. Eng Fail Anal2002; 9(1): 63–76.
17.
HähnerPAffeldtEBeckT, et al. Validated code-of-practice for strain-controlled thermomechanical fatigue testing. Institute for Energy, Petten, 2006.
18.
ASTM E2368-04. Standard practice for strain controlled thermomechanical fatigue test.
ASTM E606-92. Standard practice for strain-controlled fatigue testing.
21.
PevecMOderGPotrčI, et al. Elevated temperature low cycle fatigue of grey cast iron used for automotive brake discs. Eng Fail Anal2014; 42: 221–230.
22.
KimDJSeokCSKooJM, et al. Fatigue life assessment for brake disc of railway vehicle. Fatigue Fract Eng Mater Struct2010; 33(1): 37–42.
23.
ŠamecBPotrčIŠramlM.Low cycle fatigue of nodular cast iron used for railway brake discs. Eng Fail Anal2011; 18(6): 1424–1434.
24.
GiganGNormanVAhlströmJ, et al. Thermomechanical fatigue of grey cast iron brake discs for heavy vehicles. Proc IMechE, Part D: J Automobile Engineering2019; 233(2): 453–467.
25.
SathishKTManirajJThangarasuVS. Study of friction, wear and plastic deformation of automotive brake disc subjected to thermo-mechanical fatigue. Matéria (Rio de Janeiro)2023; 28: e20220329.
26.
JIS D 0210:1995. Japanese Automobile Standard - general rules of brake test method of automobiles and motorcycles.
27.
SAE J2789. Surface vehicle recommended practice for inertia calculation for single-ended inertia-dynamometer testing. SAE International, 2018.
28.
SeikhAHSarkarASinghJK, et al. Corrosion characteristics of copper-added austempered grey cast iron (AGCI). Materials2019; 12(3): 503.
BS EN ISO7500-1:2004. Verification of static uniaxial testing machines. 2004.
31.
ASTM E1012. Standard practice for verification of testing frame and specimen alignment under tensile and compressive axial force application. 2020.
32.
ISO 23788:2012. Metallic materials - verification of the alignment of fatigue testing machines. 2012.
33.
QinJRacineDLiuK, et al. Strain-controlled thermo-mechanical fatigue testing of aluminum alloys using the Gleeble® 3800 system. In: Proceedings of the 16th international aluminum alloys conference (ICAA 16), Montreal, QC, Canada, 17–21 June 2018, pp.17–21. Canadian Institute of Mining, Metallurgy & Petroleum.
34.
HalfpennyAAndersonRLinX. Isothermal and thermo-mechanical fatigue of automotive components. SAE technical paper 2015-01-0548, 2015.
35.
KarlJ.Thermomechanical fatigue life prediction of notched 304 stainless steel. 2013.
36.
ASTM E8/E8M. Standard test methods for tension testing of metallic materials. 2024.
37.
SkeltonRPMaierHJChristHJ.The Bauschinger effect, Masing model and the Ramberg–Osgood relation for cyclic deformation in metals. Mater Sci Eng A1997; 238(2): 377–390.
38.
ASTM E739-23. Standard guide for statistical analysis of linear or linearized stress-life (S-N) and strain-life (ε-N) fatigue data.
39.
ChristHJ.Effect of environment on thermomechanical fatigue life. Mater Sci Eng A2007; 468: 98–108.
40.
MajM.Fatigue life assessment of selected engineering materials based on modified low-cycle fatigue test. Arch Foundry Eng2013; 13(1): 89–94.
41.
Mannan SL. Role of dynamic strain ageing in low cycle fatigue. Bull Mater Sci1993; 16: 561–582.
42.
ParkSYLeeJHeoJT, et al. Assessment of fatigue lifetime and characterization of fatigue crack behavior of aluminium scroll compressor using C-specimen. Appl Sci2020; 10(9): 3226.
43.
Le GiganGVernerssonTLundénR, et al. Disc brakes for heavy vehicles: an experimental study of temperatures and cracks. Proc IMechE, Part D: J Automobile Engineering2015; 229(6): 684–707.
44.
PanierSDufrénoyPWeichertD.An experimental investigation of hot spots in railway disc brakes. Wear2004; 256(7–8): 764–773.
