Structural Integrity of Energy Devices Through Replica-based Microscopy and Finite Element Analysis

Abstract

Cracks and mechanical defects are very common in the service of engineering structures. In dynamic loading, the defects and scratches may turn into propagating cracks owing to stress concentration around these areas. Surface replica is applied to surface discontinuities for understanding the stress concentration factors. Replicated samples have been transformed into CAD models through the Faro Arm. The CAD model was used in a finite element model to evaluate the stress concentration factor (Kt) and the corresponding reduction of the factor of safety of structural components. It was found that the technique is extremely powerful for the prediction of the residual life of components and structures with surface damage.