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483.6 Fatigue TestingTo develop a better understanding of the fatigue behavior of wrought iron foundin many historic bridges, some limited fatigue testing was completed during this study.Four un-notched, smooth tensile coupon specimens were prepared from round bars of theAdams Mill Bridge. The larger diameter round bar material was machined to a reducedhalf inch diameter coupon, the same as tensile coupons as seen in Figure 3.9.The specimens were tested under constant-amplitude alternating stress until eitherfailure or three million cycles occurred. The stress ranges utilized in testing were 20 ksi,30 ksi, and 35 ksi (two specimens). The R value, which is the ratio of minimum tomaximum stress, was maintained at 0.05; hence, compressive loading was never placedon the specimens during testing. This simulates the type of loading that an actualwrought iron bridge tension member would experience throughout its life, since themember is typically under some tension stress to support the dead load of the bridge.The fatigue specimens were tested using a 220-kip MTS four-pole servohydraulictesting machine in the Kettelhut Structural Engineering Laboratory at PurdueUniversity. Each specimen was cycled at a rate of 2.5 Hz, in a sinusoidal pattern. Amechanical counter attached to the MTS testing machine was utilized to record thenumber of cycles each specimen had undergone. The amount of time passed was alsorecorded to serve as a back-up check of the counter accuracy. For each fatigue testperformed, the alternating stress and number of cycles were recorded.3.7 Charpy Impact TestingMaterial from the Bell Ford Bridge and Adams Mill Bridge were used to createspecimens for Charpy impact testing completed during this study. The specimensmachined from the eyebars in the Bell Ford Bridge where orientated in different
49directions. This was done to determine the fracture toughness in various directions of thematerial.The first type of orientation and specimen category is the Longitudinal Notched tothe Side specimen (LS). The long direction of this specimen type runs along the lengthof the eyebar. This direction is parallel to the direction in which the eyebar was “rolled”,and is the same direction in which the slag particles in the material are elongated. Thenotch of the LS specimens was orientated to the side of the eyebar, as shown in Figure3.17. This orientation of the notch evaluates the fracture toughness of the material toresist a crack if it was running against the longitudinal grain-like structure of the wroughtiron and propagating across the width of the eyebar.The second type of orientation and specimen category is the LongitudinalNotched to the Top specimen (LU). The long direction of these specimens, like the LSspecimens, runs along the length of the eyebar. The notch of the LU specimens wasfaced upward, toward the top or front of the eyebar, as seen in Figure 3.17. Thisorientation of the notch evaluates the material fracture toughness to resist a crack if it wasrunning through the thickness of the eyebar and against the longitudinal grain-likestructure of the wrought iron. LU specimens are similar to LS specimens, although thedirection of crack growth differs.The third type of orientation and specimen category is the Transverse Notchedspecimens (T). The long direction of this specimen type is perpendicular to thelongitudinal direction of the eyebar. The T specimens are therefore perpendicular to theother LU and LS specimens and the slag deposits that are deposited along the length ofthe eyebar. The notch of the T specimens was orientated to the side of the specimen, -seeFigure 3.17. This orientation of the notch evaluates the fracture toughness of the materialto resist a crack that runs along the longitudinal direction of the eyebar.
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Purdue UniversityPurdue e-PubsJTRP
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1. Report No. 2. Government Accessi
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epairing a bent wrought iron tensio
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vPageCHAPTER 3TEST PROCEDURES FOR M
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ixLIST OF FIGURESFigurePageFigure 1
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xiFigurePageFigure 3.30 Top View of
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xiiiFigurePageFigure 5.12 Typical T
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xvAppendix FigurePageFigure D.7 Ini
Page 18 and 19: viiiAppendix TablePageTable A.5 Det
Page 20 and 21: iiiThe authors would also like to t
Page 22 and 23: 2but also what material properties
Page 24 and 25: 4microstructure of the metal. The c
Page 26 and 27: 62. LITERATURE SEARCHBefore experim
Page 28 and 29: 8imperfections, the performance of
Page 30 and 31: 10wrought iron. Adding the slag aft
Page 32 and 33: 12method for manufacturing wrought
Page 34 and 35: 14patents for their process and tra
Page 36 and 37: 16This method of testing of structu
Page 38 and 39: 18plot of this percent elongation d
Page 40 and 41: 20significant variation in the perc
Page 42 and 43: 22The practice of restoring histori
Page 44 and 45: 24Elleby, Wallace W. Sanders, F. Wa
Page 46 and 47: 26From all the surveys that were di
Page 48 and 49: 28Table 2.1 Average Ultimate Streng
Page 50 and 51: 30Figure 2.3 Wrought Iron “Sponge
Page 52 and 53: 32Histogram of Kirkaldy Wrought Iro
Page 54 and 55: 34Percent Occurance in Range - %45.
Page 56 and 57: 3660Combined Wrought Iron BarsTensi
Page 58 and 59: 38The Bell Ford Bridge consisted of
Page 60 and 61: 40Two. These samples were taken fro
Page 62 and 63: 42specimens were of constant cross
Page 64 and 65: 44Along with rectangular tensile co
Page 66 and 67: 46After the initial test loading wa
Page 70 and 71: 50The final specimen category consi
Page 72 and 73: 52This analysis was completed using
Page 74 and 75: 54After the initial test was comple
Page 76 and 77: 56completed, but before the surface
Page 78 and 79: 58readings, load cell readings and
Page 80 and 81: 60Figure 3.3 Donated Eyebars 4 and
Page 82 and 83: 62Figure 3.7 Heated Areas in Blue o
Page 84 and 85: 64Figure 3.11 Detail Used in Groove
Page 86 and 87: 66900080007000y = 27.153xR 2 = 0.99
Page 88 and 89: 68Figure 3.19 Charpy Impact Testing
Page 90 and 91: 70Figure 3.23 Eyebar Connection in
Page 92 and 93: 72Figure 3.27 Eyebar A After Filler
Page 94 and 95: 74Figure 3.31 Side View of Finished
Page 96 and 97: 76Figure 3.35 Front View of Eyebar
Page 98 and 99: 78strength from the existence of pe
Page 100 and 101: 80The carbon content present in the
Page 102 and 103: 82value may not be very accurate bu
Page 104 and 105: 84strengths was found to be 29,940
Page 106 and 107: 86wrought iron bars were investigat
Page 108 and 109: 88stresses are induced. These perma
Page 110 and 111: 90toughness the material. The test
Page 112 and 113: 92From the finite element analysis,
Page 114 and 115: 94Table 4.1 Chemical Analysis of Ey
Page 116 and 117: 96Table 4.3 Tensile Coupon Test Res
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98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
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102Figure 4.1 Typical Micrograph of
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104Figure 4.5 Fracture Surface of D
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106Comparison of Tensile Strengthfo
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108Combined Wrought Iron Bar Histor
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110Figure 4.17 Macrograph of Weld u
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112Figure 4.21 Cleavage Fracture of
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Figure 4.25 Elongation of Hole in E
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116signs on or near the bridge that
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118testing of historic wrought iron
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120so that they would act in symmet
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122The reasons for the differences
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124The second corrosion pattern mod
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126Keating (1984) stated that the s
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128charcoal fire until it is red ho
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130Figure 5.3 Picture of Bottom Cho
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132Figure 5.7 Using Force After Usi
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134Figure 5.11 Reassembling a Pin C
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1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
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1424. The Charpy impact energy of t
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144connections are unsymmetrical, i
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146LIST OF REFERENCESAASHTO (1998).
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148Hodgkinson, Eaton (1840). Experi
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150Appendix A. Data Collected From
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152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
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156Table A.2 (continued) Wrought Ir
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158Table A.3 Wrought Iron Angle Ten
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160Table A.4 (continued) Summary of
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162Table A.4 (continued) Summary of
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164Table A.5 (continued) Detailed I
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184Table A.7 Tensile Strength Data
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186Table B.1 Example Historic Wroug
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188DepartmentofTransportationIf you
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190CountyIf your organizationdoes m
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192County 16: County bridge inspect
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194State 13: Included in original d
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196Figure C.1 Diagrams Showing Loca
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198Figure C.3 Heating of Eyebar fro
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200Figure C.7 Double V Butt Joint u
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202Figure C. 11 Welded Tensile Coup
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204Figure C.15 Tensile Coupon from
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206Figure C.19 Cooling Bath with Su
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208Figure C.23 Side View of Eyebar
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210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
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214D.2 Filler Weld for Eyebar Conne
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216Figure D.1 Weld Joint Detail Use
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Figure D.5 Completed Weld Before Su
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220Figure D.7 Initial Pass Pattern
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