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Title: Fatigue performance of downgauged high strength steel automotive suspension component
Author: Ellwood, R. D.
Awarding Body: University of Wales Swansea
Current Institution: Swansea University
Date of Award: 2003
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Work has been carried out to determine whether the weight of a current production suspension component can be reduced, without a reduction in the fatigue performance, through the use of high strength steels and modern welding technologies. The reliability and accuracy of Finite Element (FE) modelling and fatigue prediction techniques have also been investigated. The three steels used in this study, 2.25 mm mild steel, 2.0 mm HSLA and a 1.8 mm dual phase grade showed increasing fatigue performance with tensile strength for unwelded samples. Fusion Metal Active Gas (MAG) welded H-beam samples showed the 2.0mm HSLA material to exhibit better fatigue performance than the mild steel and dual phase materials. Calculating the fatigue lives of these samples using a type F weld from BS7608 significantly overestimated the fatigue performance. Testing the full-scale component biaxially with CARLOS road load data showed the fatigue performance to increase with increasing thickness with the mild steel sample exhibiting a crack length of 5 mm at approximately 3 million km. FE modelling fatigue predictions using a Type F weld curve from BS7608 showed extremely good correlation with the experimental results with an minimum error of only 8% obtained for the mild steel samples.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (D.Eng.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available