In this study, corrosion fatigue crack propagation was investigated in pH buffer environment using the giga strength steel and its heat-affected zone, and the results were compared with theoretical model prediction. Also, the pure corrosion effect on fatigue crack propagation in a corrosive environment was compared with the modified Forman equation. As results, the average value of corrosion rate obtained as the ratio of the net corrosion-induced crack length to the total crack length under cyclic loading in the base metal and heat-affected zone under experimental loading conditions. These results exhibit a new theoretical method for corrosion fatigue crack propagation that predicts a purely corrosion effect on the behavior to be determined.

Engine components subjected to cyclic thermal and mechanical loads may experience low-cycle or high-cycle fatigue failures. In particular, both of these failures can easily occur in aluminum cylinder heads, which are exposed to high temperatures and combustion pressures. Predicting the fatigue characteristics of the cylinder head are very important in the design stage of engine development. In this study, a finite element analysis was performed to predict the low-cycle thermal fatigue around exhaust ports of the cylinder head. Temperature distributions are obtained through the heat transfer analysis considering thermal cyclic test. The analysis result involves large plastic deformations, indicating compressive stresses at high temperatures and subsequently turn into tensile stresses at cold conditions. And the results showed that the critical regions such as exhaust port with large plastic strains coincided well with crack locations from thermal cyclic test. Next, design changes were made to the critical areas of the exhaust ports, and the results showed that the durability was improved by about 60% over the initial model and there were no problems in the thermal fatigue test.

In this study, we optimized Pb-free Sn/Ni plating thickness and conditions were optimized to counteract the environmental regulations, such as RoHS and ELV(End-of Life Vehicles). The B10 life verification method was also suggested to have been successful when used with the accelerated life test(ALT) for assessing Pb-free solder joint life of piezoelectric (PZT) ceramic resonator. In order to evaluate the solder joint life, a modified Norris-Landzberg equation and a Coffin-Manson equation were utilized. Test vehicles that were composed of 2520 PZT ceramic resonator on FR-4 PCB with Sn-3.0Ag-0.5Cu for ALT were manufactured as well. Thermal shock test was conducted with 1,500 cycles from (-40±2)˚C to (120±2)˚C, and 30 minutes dwell time at each temperature, respectively. It was discovered that the thermal shock test is a very useful method in introducing the CTE mismatch caused by thermo-mechanical stress at the solder joints. The resonance frequency of test components was measured and observed the microsection views were also observed to confirm the crack generation of the solder joints.

원자력발전소에서는 열교환 파이프에서 발생하는 열피로 균열을 비파괴 탐상장비를 이용하여 조기에 발견하는 것이 안전을 위해 매우 필요하며, 따라서 이를 모사한 인공균열시편 제작에 많은 노력을 기울이고 있다. 그러나 이러한 균열은 일반 기계가공으로 제작하는 것이 불가능하여 실제 조건과 유사한 열 반복하중 하에서 제작될 수밖에 없는데, 이를 위해 많은 시간이 소요된다. 본 연구에서는 크랙성장 시뮬레이션 기법을 이용하여 이러한 균열 제작시간을 단축하기 위한 최적의 열하중 조건을 찾고자 하였다. 이를 위해 임의조건에서 시뮬레이션 및 열피로균열 발생 기초실험을 수행하여 균열 초기수명과 진전수명을 검증하였고, 이를 바탕으로 다양한 가열 및 냉각시간을 시뮬레이션 함으로써 제작시간을 최소화하는 열하중 조건을 구하였다. 시뮬레이션에서는 응력해석을 위해 상용 소프트웨어 ANSYS를 초기균열수명 계산을 위해 수치계산용 소프트웨어 ZENCRACK을 이용하여 코딩을 균열진전수명 평가를 위해 ZENCRACK 소프트웨어를 이용하였다. 그 결과 1mm 균열 제작에 소요되는 시간은 초기의 418시간에서 319시간으로 24% 단축되는 것으로 예측되었다.

자동차, 항공기 및 기타 산업에서 복합재료의 사용은 증가되어 왔고 활발한 연구가 진행되고 있다. 이러한 복합재료중의 하나인 Carbon-epoxy 복합재료의 열 특성에 관하여 알아보았다. 반복적인 냉각과 가열이 부가되는 열 피로에서 복합재료의 탄성계수의 변화를 관찰하여 봄으로써 복합재료가 가지고 있는 여러 열 특성에 관하여 연구하였다. 일반적으로 복합재료는 온도가 증가하면 탄성계수가 감소한다고 알려져 있다. 이러한 결과와는 달리 본 연구에서 수행한 실험에서는 열 피로가 부가되었을 때에는 어느 정도 온도까지는 탄성계수가 증가하다가 다시 감소하는 특이한 현상을 관찰할 수 있었다.