Comparative analysis of cutting methods and their impact on fatigue properties of armor steel

Umut Yaşar Uzunali; Hamdullah Çuvalcı; Ümit Kartal

doi:10.1515/mt-2024-0268

Article

Comparative analysis of cutting methods and their impact on fatigue properties of armor steel

Umut Yaşar Uzunali
Umut Yaşar Uzunali born in 1984, studied metallurgical and materials engineering at Yıldız Technical University from 2003 to 2008. Before he became an academician, he had been working in a company manufacturing armoured vehicles for 3 years. He is also welding engineer and non-destructive expert.
, Hamdullah Çuvalcı
Hamdullah Çuvalcı born in 1965, studied mechanical engineering at Karadeniz Technical University from 1982 to 1986. He worked as a research assistant at Karadeniz Technical University after the graduate. After he obtained his doctorate, he has been working since 2004 at the department of metallurgical and materials. In addition, he has been working as a rector at the Karadeniz Technical University since 2019.
and Ümit Kartal
Ümit Kartal born in 1983, studied metallurgical and materials engineering at Istanbul Universtiy from 2002 to 2007. He completed his master’s degree in the same department in 2013. He has worked on casting and heat treatment in various sectors. He has been working as a quality manager and laboratory manager at the university since 2022.

Published/Copyright: February 5, 2025

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal Materials Testing Volume 67 Issue 3

Abstract

Armor steel is widely used in various industries due to its exceptional yield strength and hardness. However, the cutting processes employed to shape these materials, such as laser and waterjet cutting, may exert a substantial influence on the fatigue resistance of the end product. Fatigue strength is a critical property in materials science, particularly when it comes to high strength steel. As industries strive for lighter and more efficient structures, the demand for materials with superior fatigue resistance becomes paramount. In this article, it is aimed to investigate the effects of laser and waterjet cutting processes on the fatigue strength of armor steel based on experimental results, highlighting the implications for structural integrity and performance. The samples cut by water jet and laser cutting processes were subjected to fatigue tests with and without anti-buckling apparatus. Fatigue tests were carried out at least four different stress values and S–N diagrams were created for 4 different situations. As a result of this study, it was determined that the fatigue strength of samples obtained by laser cutting method is lower than that of waterjet cutting samples. Additionally, it was observed that the fatigue strength of the samples using anti-buckling apparatus was higher.

Keywords: armor steel; cutting processes; fatigue test; S–N curve

Corresponding author: Umut Yaşar Uzunali, Metallurgical and Material Engineering, 52976 Karadeniz Technical University , Trabzon, Türkiye, E-mail: uuzunali@ktu.edu.tr

About the authors

Umut Yaşar Uzunali

Umut Yaşar Uzunali born in 1984, studied metallurgical and materials engineering at Yıldız Technical University from 2003 to 2008. Before he became an academician, he had been working in a company manufacturing armoured vehicles for 3 years. He is also welding engineer and non-destructive expert.

Hamdullah Çuvalcı

Hamdullah Çuvalcı born in 1965, studied mechanical engineering at Karadeniz Technical University from 1982 to 1986. He worked as a research assistant at Karadeniz Technical University after the graduate. After he obtained his doctorate, he has been working since 2004 at the department of metallurgical and materials. In addition, he has been working as a rector at the Karadeniz Technical University since 2019.

Ümit Kartal

Ümit Kartal born in 1983, studied metallurgical and materials engineering at Istanbul Universtiy from 2002 to 2007. He completed his master’s degree in the same department in 2013. He has worked on casting and heat treatment in various sectors. He has been working as a quality manager and laboratory manager at the university since 2022.

Research ethics: The authors of this article declare that the materials and methods used in this study do not require ethical committee permission and/or legal-special permission.
Informed consent: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission. Hamdullah Çuvalcı, Umut Yaşar Uzunali and Ümit Kartal performed the experiments and organized whole paper.
Use of Large Language Models, AI and Machine Learning Tools: None declared.
Conflict of interest: The authors have no conflicts of interest to declare that are relevant to the content of this article.
Research funding: None declared.
Data availability: The authors confirm that data supporting the findings are available within the article. Raw data that support the findings of this study are available from the corresponding authors, upon reasonable request.

References

[1] Z. Xuewen, W. Kaiming, and F. Hanguang, “Microstructure and properties of fiber laser welded high strength steel butt joints,” Mater. Test., vol. 62, no. 2, pp. 172–176, 2020, https://doi.org/10.3139/120.111466.Search in Google Scholar

[2] H. Liu, C. Zan, and L. Zong, “Corrosion fatigue behaviour of Q690D high-strength steel considering the effect of coupling,” Int. J. Fatig., vol. 183, https://doi.org/10.1016/j.ijfatigue.2024.108243.Search in Google Scholar

[3] J. Hensel, A. Kromm, T. Nitschke-Pagel, J. Dixneit, and K. Dilger, “Capability of martensitic low transformation temperature welding consumables for increasing the fatigue strength of high strength steel joints,” Mater. Test., vol. 62, no. 9, pp. 891–900, 2020, https://doi.org/10.3139/120.111562.Search in Google Scholar

[4] B. Kroeger, H. Hetzner, S. Klose, T. Mehner, R. Holbein, and T. Lampke, “Mechanical test procedures for the evaluation of hydrogen-assisted damage in high-strength steel,” Mater. Test., vol. 61, no. 11, pp. 1061–1071, 2019, https://doi.org/10.3139/120.111432.Search in Google Scholar

[5] J. K. Larsson and L. Bengtsson, “Joining of high-and extra high-strength steels: pitfalls and possibilities,” Mater. Test., vol. 45, nos. 1–2, pp. 9–18, 2003, https://doi.org/10.1515/mt-2003-451-205.Search in Google Scholar

[6] S. R. Nathan, V. Balasubramanian, A. Gourav Rao, T. Sonar, M. Ivanov, and C. Rajendran, “Influence of tool plunging rate on mechanical properties and microstructure of friction stir welded DMR249A high strength low alloy (HSLA) steel butt joints,” Mater. Test., vol. 65, no. 10, pp. 1528–1538, 2023, https://doi.org/10.1515/mt-2023-0043.Search in Google Scholar

[7] Y. Sarafraz, M. Brink, N. Baak, A. Koch, and F. Walther, “Influence of pre-deformation on fatigue life of high strength steels by means of micromagnetic Barkhausen noise,” Mater. Test., vol. 65, no. 5, pp. 641–651, 2023, https://doi.org/10.1515/mt-2022-0425.Search in Google Scholar

[8] O. Watanabe, S. Matsumoto, Y. Nakano, and Y. Saito, “Fatigue strength of welded joints in high strength steel – effects of stress concentration factor and welding residual stress,” Weld. Int., vol. 10, no. 3, pp. 201–206, 1996, https://doi.org/10.1080/09507119609548979.Search in Google Scholar

[9] P. Diekhoff, J. Hensel, T. Nitschke-Pagel, and K. Dilger, “Investigation on fatigue strength of cut edges produced by various cutting methods for high-strength steels,” Weld. World, vol. 64, no. 1, pp. 545–561, 2020, https://doi.org/10.1007/s40194-020-00853-y.Search in Google Scholar

[10] K. Mäntyjärvi, A. Väisänen, and J. A. Karjalainen, “Cutting method influence on the fatigue resistance of ultra-high-strength steel,” Int. J. Mater. Form., vol. 2, no. 1, pp. 547–550, 2009, https://doi.org/10.1007/s12289-009-0583-9.Search in Google Scholar

[11] H. Liang, Y. Kan, H. Chen, R. Zhan, X. Liu, and D. Wang, “Effect of cutting process on the residual stress and fatigue life of the welded joint treated by ultrasonic impact treatment,” Int. J. Fatig., vol. 143, pp. 342–354, 2021, https://doi.org/10.1016/j.ijfatigue.2020.105998.Search in Google Scholar

[12] S. Cicero, et al.., “Definition and validation of Eurocode 3 FAT classes for structural steels containing oxy-fuel, plasma and laser cut holes,” Int. J. Fatig., vol. 87, pp. 50–58, 2016, https://doi.org/10.1016/j.ijfatigue.2016.01.012.Search in Google Scholar

[13] Y. Shimatani, K. Shiozawa, T. Nakada, T. Yoshimoto, and L. Lu, “The effect of the residual stresses generated by surface finishing methods on the very high cycle fatigue behavior of matrix HSS,” Int. J. Fatig., vol. 33, no. 2, pp. 122–131, 2011, https://doi.org/10.1016/j.ijfatigue.2010.07.009.Search in Google Scholar

[14] K. Lipiäinen, A. Ahola, T. Skriko, and T. Björk, “Fatigue strength characterization of high and ultra-high-strength steel cut edges,” Eng. Struct., vol. 228, pp. 544–555, 2021, https://doi.org/10.1016/j.engstruct.2020.111544.Search in Google Scholar

[15] M. Thum, V. H. Basavarajappa, and P. Haefele, “Influence of edge cutting process on fatigue behaviour of spectrum loaded aluminum sheets,” Int. J. Fatig., vol. 150, pp. 330–339, 2021, https://doi.org/10.1016/j.ijfatigue.2021.106330.Search in Google Scholar

[16] M. S. Khan, S. J. Alkemade, G. M. Weston, and D. G. Wiese, “Variable-amplitude fatigue testing of a high hardness armour steel,” Int. J. Fatig., vol. 20, no. 3, pp. 233–239, 1998, https://doi.org/10.1016/S0142-1123(97)00112-6.Search in Google Scholar

[17] S. Keeler and M. Kimchi, Advanced High-Strength Steels Application Guidelines V5, 6th ed., World Auto Steel, 2015.Search in Google Scholar

[18] DIN EN 1522, “Classification standards. Windows, doors, shutters, and blinds. Bullet resistance. Requirements and classification.” ANSI.org. [Online]. https://webstore.ansi.org/standards/din/dinen15221999?gad_source=1&gclid=CjwKCAiAxea5BhBeEiwAh4t5K4rYhpYPzFuRm47ylhlcpzjxdSpjwDyTRKHYXzP3y8h57orXI24mxBoCd60QAvD_BwE [accessed Nov. 11, 2024].Search in Google Scholar

[19] STANAG 4569, “Procedures for evaluating the protection levels of logistic and light armoured vehicles for KE and artillery threats,” Eurolab.net, [Online]. https://www.eurolab.net/en/sektorel/askeri-testler/stanag-4569-lojistik-ve-hafif-zirhli-araclarin-yolculari-icin-koruma-seviyeleri/ [accessed Nov 11, 2024].Search in Google Scholar

[20] Protection 500, “Miilux Protection Datasheet,” Miilux.com, [Online]. https://www.miilux.fi/esitteet/protection380400450500_datasheet_miilux.pdf [accessed Nov 11, 2024].Search in Google Scholar

[21] A. Stournaras, P. Stavropoulos, K. Salonitis, and G. Chryssolouris, “An investigation of quality in CO2 laser cutting of aluminum,” CIRP J. Manuf. Sci. Technol., vol. 2, no. 1, pp. 61–69, 2009, https://doi.org/10.1016/j.cirpj.2009.08.005.Search in Google Scholar

[22] B. C. Fabien, M. Ramulu, and M. Tremblay, “Dynamic modelling and identification of a waterjet cutting system,” Math. Comput. Model. Dyn. Syst., vol. 9, no. 1, pp. 45–63, 2003, https://doi.org/10.1076/mcmd.9.1.45.16513.Search in Google Scholar

[23] W. Schütz, “A history of fatigue,” Eng. Fract. Mech., vol. 54, no. 2, pp. 263–300, 1996, https://doi.org/10.1016/0013-7944(95)00178-6.Search in Google Scholar

[24] W. A. J. Albert, “Uber Treibseile am Harz.” Arch. Mineral. Georgn. Bergbau Huttenkd., vol. 10, no. 215, pp. 82–86, 1837, https://doi.org/10.2207/qjjws1943.72.424.Search in Google Scholar

[25] F. Braithwaite, “On the fatigue and consequent fracture of metals,” Min. Proc. Inst. Civil Eng., Vol. 54, no. 13, pp. 463–467, 1854, https://doi.org/10.1680/imotp.1854.23960.Search in Google Scholar

[26] O.H. Basquin, “The exponential law of endurance tests,” Proc. Am. Soc. Test Mater., vol. 10, no. 1, pp. 625–630, 1910.Search in Google Scholar

[27] Y. L. Lee, Fatigue Testing and Analysis: Theory and Practice, 1st ed., Elsevier Butterworth-Heinemann, 2005.Search in Google Scholar

[28] R. Ulewicz, F. Novy, М. Mazur, and P. Szataniak, “Fatigue properties of the HSLA steel in high and ultra-high cycle region,” in 2014 Production Engineering Conference, Czestochowa, Poland, 2014, pp. 18–21.10.30657/pea.2014.04.05Search in Google Scholar

[29] R. Ulewicz and F. Nový, “Fatigue resistance and influence of cutting technology on the mechanical properties of modern steels used in the automotive industry,” Procedia Eng., vol. 192, no. 1, pp. 899–904, 2017, https://doi.org/10.1016/j.proeng.2017.06.155.Search in Google Scholar

[30] ASTM A 751, Chemical Analysis. Standard Test Methods and Practices for Chemical Analysis of Steel Products, ASTM.org, [Online]. https://www.astm.org/a0751-07.html [accessed Nov 11, 2024].Search in Google Scholar

[31] ASTM E3, “Standard Guide for Preparation of Metallographic Specimens,” ASTM.org, [Online]. https://www.astm.org/e0003-01.html [accessed Nov 11, 2024].Search in Google Scholar

[32] ASTM E10, “Standard Test Method for Brinell Hardness of Metallic Materials,” ASTM.org, [Online]. https://www.astm.org/e0010-18.html [accessed Nov 11, 2024].Search in Google Scholar

[33] ISO 6507-1, “Vickers hardness test method,” ISO.org, [Online]. https://www.iso.org/standard/83898.html [accessed Nov 11, 2024].Search in Google Scholar

[34] MIL-DTL-46100E, “Armor steel. Detail specification: armor plate, steel, wrought, high-hardness,” Everyspec, [Online]. http://everyspec.com/MIL-SPECS/MIL-SPECS-MIL-DTL/MIL-DTL-46100E_20495/ [accessed Nov 11, 2024].Search in Google Scholar

[35] BS EN 10160, “Non-destructive testing. Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm,” EN-standard.eu, [Online]. https://landingpage.bsigroup.com/LandingPage/Undated?UPI=000000000019972302 [accessed Nov 11, 2024].Search in Google Scholar

[36] ISO 6892-1, “Destructive testing. Tensile testing method of test at room temperature,” ISO.org, [Online]. https://www.iso.org/standard/78322.html [accessed Nov 11, 2024].Search in Google Scholar

[37] ASTM E466, “Destructive testing. Standard practice for conducting force controlled constant amplitude axial fatigue tests of metallic materials,” ASTM.org, [Online]. https://www.astm.org/standards/e466 [accessed Nov 11, 2024].Search in Google Scholar

Published Online: 2025-02-05

Published in Print: 2025-03-26

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/mt-2024-0268

Keywords for this article

armor steel; cutting processes; fatigue test; S–N curve