Lifetime simulation of thermo-mechanically loaded components

The estimation of the lifetime of thermo-mechanically loaded components by testing is very costly and time-consuming, since the high temperature cycle time in practical application dominates the test duration. Common frequencies for TMF (thermo-mechanical fatigue) tests are at about 0.01 Hz compared to 10-100 Hz at HCF (high cycle fatigue) and about 0.1-1 Hz at isothermal LCF (low cycle fatigue) tests. Therefore, the simulation of fatigue life is an important design step in the fast moving and competitive automotive industry, where the steady rise of engine power and the demand for lightweight construction concurrent with enhanced reliability require an optimised dimensioning process. Methods and models are usually derived from results made on tests with specimens, since it is possible to systematically and exactly define loading parameters and measurement categories. After an extensive test programme (tensile tests, creep tests, low cycle fatigue tests and thermo-mechanical fatigue tests with different influences on specimens) it was possible to develop material models for the simulation of the time- and temperature dependent stress-strain hystereses and damage models for the simulation of the TMF lifetime. Based on this knowledge the whole simulation chain to determine the TMF life of a component is introduced: thermal calculation, mechanical calculation and lifetime calculation. Furthermore the transferability of specimen based simulation models to real components (an alternative test piece and a cylinder head) is investigated.