The Application of Neural Computing Methods To The
The Application of Neural Computing Methods To The
Neural Networks
In recent years there has been an increased interest in the ability to Artificial neural networks are computational tools based on the
model the mechanical properties of alloys from compositional and structure and function of the brain [Z]. They are composed of
processing data in order to reduce the cost and time required for simple computational elements (called neurons or nodes) which
alloy development. Increased expectations of engine performance, imitate the most basic function of a biological neuron. These
in terms of speed and range, have led to the need for higher artificial neurons are then connected to others by a series of
performance alloys, while the financial climate has forced a connections broadly analogous to, although much simpler than,
reduction in the cost of new products. those in the brain. The nodes are arranged in layers, with each node
being connected to every node in the adjacent layers (figure 1). The
Good fatigue crack growth resistance is an essential property for simplest node sums N weighted inputs, performs a non-linear
superalloys operating in the high temperature stage of gas turbine function on the sum, and then passes the result to the nodes in the
engines; hence over the last thirty years many studies on the fatigue next layer [3]. Data flow forwards only through the network.
crack growth behaviour of Ni-base superalloys have been
conducted. The general trends in fatigue crack growth behaviour There are two phases in the development of a neural network model
with variations in test conditions (load ratio, temperature and [4]. Initially the network is ‘taught’ using a number of example
environment), microstructure and processing route are well datasets - this process is referred to as training. The training
established. In general such alloys exhibit two stages of long crack datasets consist of a series of inputs paired with the corresponding
fatigue behaviour: Stage I facetted crack growth. occurring along output (the ‘target’ output). An input dataset is applied, the network
crystallographic ( 111 r planes corresponhing to persist&t sli: calculates an output and compares it with the target. The error
bands; and more homogeneous Stage II crack growth resulting in between output and target is calculated, and the weights in the
essentially flat fracture &faces [l]. -Inspection mtervals for turbine network are then adjusted using an algorithm (in the case of the
comuonents are often determined on the basis of Stage II fatigue network used in this work, a ‘back propagation’ algorithm) in order
crack growth rates, assuming an initial crack length Equal to The to improve the output. The data are fed through repeatedly until the
smallest detectable flaw size. Such flaws might be surface network output is deemed sufficiently accurate (the solution has
scratches, coating cracks or casting defects such ai pores. In this ‘converged). After this training the network is tested on a set of
paper Stage II crack growth is concentrated on as the regime of previously unseen data.
most interest with respect to lifing procedures.
Superalloys 1996
Edited by R. D. Kissinger, D. J. Deye, D. L. Anton.
A. D. C&l, M. V. Nathal, T. M. Pollock, and D. A. Woodford
The Minerals, Metals &Materials Society, 1996
409
Input Hidden output relationships between variables. The ability of networks to
layer layer layer generalise and find patterns in large quantities of often noisy data is
also a major advantage. However the number of sets of training
A data requjred to establish a robust network is dependent on the
number of inuut variables (the ‘dimensionalitv’ of the data).
Previous studies have suggested that the size of ihe training data
should be between three and ten times the input dimensionaIity[5].
It is possible to vary the number of nodes in the hidden layer of the Feedforward neural networks can be very useful in picking out
network (the ‘architecture’), and care must be taken when deciding patterns of behaviour and property relationships from a quantity of
the network architecture, as it is possible to overmodel or experimentally produced data, and their ability to generalise can
undermodel the data. If too complex a network is chosen, then the make them useful in predicting the behaviour of a potential new
training data will appear to be excellently modelled, however the material before it is made. Work on the strength properties of Ni-
network will be modelling the noise in the data as well as the trends, base superalloys [6] has shown that trends in behaviour with
so that when the model is-tested it will not be robust enough to cope varying composition, temperature and material condition can be
with the new data presented to it. On the other hand, if too simple a modelled, and within error limits absolute values of strength may be
network is chosen it will fail to model the trends in enough detail, estimated.
and predictions will again be very inaccurate. Examples of this type
of behaviour are shown in figure 2. In this work, therefore, the This paper describes work carried out on the modelling of the
network is trained over a number of different architectures and the Stage II fatigue properties of such alloys using a supervised
results are compared. feedforward neural network as described above.
The datasets
A number of input variables have been considered for presentation
to the network. These are: temperature, yield stress, Young’s
modulus, ultimate tensile strength and NV number.
Sixtv-four sets of inuut data were gathered from a Rolls-Rovce
database [27], for wb&h fatigue testsare conducted at a frequency
of 0.25 Hz using a l-l-l-l trapezoidal wave form. The network
picked out
A.
c) overmodelling - too
many nodes in hidden layer
where ni is the normalised value of datapoint i and xi, xmM and Xmin
are the actual values of datapoint i, and the maximum and minimum
valued datapoints. This is to prevent a variable from swamping the
network simply by virtue of having a large absolute value rather than
as a result of the effect of its variation on the result.
Figure 2 - the effect of number of nodes on modelling accuracy
Each set of input data is presented to the network along with a
A point to note is that a neural network learns from experience, and corresponding expected output. In this case the chosen output was a
hence while it may interpolate between data with some confidence. ‘life’ calculated from crack-C and crack-n values where crack-n is
it cannot accurately extrapolate into regions for which it has no the slope of the log dafdN vs. log AK fatigue curve in the Stage II
information, and any attempts at such predictions should be treated
with extreme caution. region and crack-C is the intercept of this line on the da/dN axis<see
figure 3). All fatigue data were uroduced at a load ratio R=O.1. and
The main advantage of neural networks over conventional I&es were calculated using a prediction program for a semi-elliptical
regression analysis techniques is that the network finds an optimum crack [IO]. These ‘life’ values were also normahsed.
solution without the need to specify the relationships or the form of
410
random number generator which is started using a ‘seed’. This
seed can have any positive value, and using different seeds may
produce slightly different models. In order to ensure that all
potential model types are generated the network is trained using a
number of seed values for each architecture.
0 200 400 600 800 1000 500 900 1100 140 160 180200 220 240 260
Range (“C) Rz\e (MPadm) Range (GPa)
(4 (b) (cl
Life (cycles)
UTS (MPa)
25,
5 5
0 0
0 .5
Range Range (cycles)
(4 (4 (0
Figure 4 - graphs to show the range of the input and output data
411
relevance - this is a value which is produced for each input to the
network, and is a measure of how important that input is in the
0.18t + + + + + + *
model produced. A highly important input would have a 0.16 - +
relevance of the order of 1, whereas an input which is perceived 0.14 - Simple model
to be irrelevant would be assigned a relevance of the order of
10e3or less.
0.12 -
Energy values are calculated from the following equation: g 0.1 - +
0.4
The basic database
A review of literature on Stage II Paris regime fatigue crack growth 0.2
and crack tip opening displacement (CTOD) models for crack
growth indicates that the most important properties affecting fatigue
crack growth are likely to be yield strength and Young’s modulus
[12, 13, 14, 15, 16, 17, 18, 191. CTOD theory suggests the
following form of equation for fatigue crack growth rate: -0.2
da AK2 -0.4
dlv OccrsE
where da/dN is the crack growth rate, AK is the stress intensity -0.6
factor range, ors is the yield stress and E is the Young’s modulus -0.6 -0.4 -0.2 0 0.2 0.4 0.6
[17, 181. The literature also suggests that test temperature is an Target
important factor affecting fatigue crack growth rates [20, 211.
Hence initial modelling used an input dataset consisting of
Figure 5b) - Graph of network output vs. target output for a type-B
temperature, o,, and E. model
The network was trained for 2-8 hidden nodes. For each number of The second set of models on the other hand display a decreasing
nodes seeds of 0,20,40, 60 and 99 were used. noise level, reaching a minimum of about 0.034 at four hidden
nodes, indicating the formation of a more complex model. Training
A plot of uriU vs. number of nodes is shown in figure Sa. Two and test energies again followed a similar pattern, with values of
different types of model are generated by the network, depending training energy around 0.015 and test energy around 0.03. When
on the initial random weights (determined by the ‘seed’). The first the relevance values of the input variables for the two different types
of model were compared it was found that the simple models all had
type tend to have relatively high onu values (0.18, or 18% of the
very low relevance for Young’s modulus (e.g. 1*10-4,.c.f. 0.6 for
range of the output data), this value being independent of the yield stress) whereas the more complex models attributed a much
number of nodes. This indicates that an over-simple model is being higher relevance to Young’s modulus (e.g.1.4, c.f. 2.2 for yield
produced which is just as accurately described with two nodes as stress), more in accordance with CTOD theon, and experimental
with five or seven: Training and lest energies for these models evidence. A graph of predicted output vs. iarget output for a
followed a similar pattern and were also high, with values of about comulex model is shown in figure 5b. It can be seen that
0.5 in both cases. This type of model will be referred to as the predictions are good, with most oflthe predictions lying very close
simple model. to the line for output = target.
412
When predictions of varying yield stress are examined, however, an
unexpected result is obtained, as life is predicted to decrease rapidly
as yield stress increases from 700-800 MPa, followed by a slight
it!: increase to 1000 MPa and then a further gentle decrease in life
8 (figure 6b). CTOD theory on the other hand would indicate an
0 .‘a increase in life with increasing yield stress in a similar manner to
. q that seen in the Young’s modulus predictions. There are two
4 possible reasons for this apparent anomaly. It is possible that it
q
may be explained by the fact that these predictions were made for a
i”, temperature of 600 “C, and the data contain only two alloys with a
yield stress less than 800 MPa at this temperature, both of which
-0.6 - have a Young’s modulus of about 170 GPa, rather than the
195 GPa used for prediction. Hence attempting to predict life in
the data range used may effectively be an extrapolation into an
unknown area. While such extrapolations may not necessarily be
totally misleading, this example illustrates that care is needed if
attempting them. It also indicates the importance of constructing,
where possible, a database which would cover the possible range of
200 300 400 500 600 700 800 data of interest if neural network modelling is to be used as a design
tool. That is not to say however that a neural network could not be
T ("Cl used to reduce experimentation - if an unexpected result is found,
1 then one or two experiments in the area of interest may suffice to
test the proposed model, without an entire test matrix being
(b) required. The results could then be added to the training dataset.
413
A Type-ii
q Low E
1.5 0 relevance
. Type-i
-0.2 q 8
A q
A 0.
-0.3 A u
A 0
A q
600 700 800 900 1000 1100 1200 200 300 400 500 600 700 800
Yield stress (MPa) T (“C)
4
-0.25
-0.3
a
.s -0.4
1
2 -0.45
-0.5
J . , Typ,e-i
160 170 180 190 200 210 220 230 1100 1200 1300 1400 1500 1600
4 E (GPa) UTS (MPa)
4
Figure 8 - Predictions of life generated using a database containing UTS for (a) varying yield stress
(b) varying temperature (c) varying Young’s modulus (d) varying UT.9
Refining the data base an empirical relationship between ‘hardenability’ and the ratio of
ultimate tensile strength (UTS) to yield stress. Materials with a ratio
The model produced so far has been somewhat simplistic, with only greater than 1.4 are proposed to cyclically harden, those with a ratio
three input variables used, and while some success has been less than 1.2 to cyclically soften, and those with a ratio between 1.2
obtained it was thought useful to add further parameters to see and 1.4 to be cyclically stable. Therefore UTS was added to the
whether network performance improved. However, collecting data database as an input to the network to provide a measure of
can be problematic as in order to use a given dataset it is necessary deformation characteristics.
to have values for all the inputs. It would have been informative to
look at grain size and other microstructural parameters, as Stage II The addition of UTS as an input produced three types of low noise
fatigue is expected to be microstructurally sensitive to some extent models, which had comparable noise levels and training and test
[20]. Unfortunately, microstructural information is difficult to energies to those produced previously. In this instance a number of
obtain-from reports, papers and standards to a sufficient degree of the models (about half) assigned a low relevance to E. Of those that
accuracy to be useful in the network. Hence material property data did not, again the best six models were chosen, ranked by test
and such data as are calculable from thermodynamic phase error, and were then compared with a model with low relevance for
calculation programs such as MTDATA are used as inputs, as these E. When predictions of variation in life with yield stress are made
am more readily available/determinable. (using a mean UTS value of 1360 MPa), it may be seen that the
models fall broadly into two groups, those that predict a large drop
in life with yield stress increasing from 700-800 MPa (type-i) and a
group which indicates a more linear dependence of life on yield
Accountine for cvclic hardening. stress (type-ii) (figure8a). Above 800 MPa the two sets of models
agree reasonably well. While the type-ii models at first seem
In equation 3, the yield stress in the denominator is that at the crack promising, examination of predictions for temperature and Young’s
tip. This may or may not be similar to the bulk yield stress, as modulus calculation cast doubt on their validity (figure Sb &c). The
repeated yielding of material in tension and compression may cause prediction of temperature dependence shows a different form from
cyclic hardening or softening. Hence the cyclic yield stress may previous models, and indicates a lessening of the effect of
differ from the bulk yield stress. Data for cyclic yield stress are not temperature as temperature increases, whereas observations on
readily available. However Manson and Hirschberg [23] proposed increased dislocation mobility with temperature would indicate an
414
increasing effect of temperature as demonstrated by type-i. Addition of NV to the database again produces two types of
Dependence of life on Young’s modulus for type-ii models is the complex model, similar in form to those described above (e.g.
reverse of that predicted by CTOD theory and experimental figure 9, Nv=2.27). The relevance attributed to NV is quite high,
observation. and life is predicted to increase roughly linearly with NV by both
models (figure 10). The difference in life is not predicted to be very
The dependence of life on UTS is shown in figure 8d. The type-i large as the range of NV values in the database is quite small. This
models uredict an evident but modest deuendence of life on UTS. indicates that, although there is an effect of NV on fatigue
indicating some importance of UTS,&although it seems less resistance, the benefits obtained by trying to alter NV within the Ni-
important than temperature and E. The type-ii models however based alloy system would not be great as this class of alloys tends
indicate a strong dependence of life on UTS below about 1250 to exhibit a restricted range of NV values.
MPa, above which value the two types of model agree reasonably
well. When the values of predicted life are examined it is noted that
below 1250 MPa the values fall well outside the range of the dataset
(-0.75 as opposed to a limit on the data of -0.5). Again it is
possible that the model is trying to extrapolate too far from the
known database, and so such predictions should be regarded with
care, as in the case of the yield stress predictions described above.
Examination of the database reveals that at 600 “C the alloys with
low UTS also have very low Young’s modulus (about 170 GPa as
opposed to the value of 195 GPa used for predictions).
Of the three models, type-i best reflects the actual trends in the data.
The existence of two complex models with low noise and test
energy indicates that within the experimental noise in the data there
is more than one way to mathematically model the data. However,
only one of these models makes physical sense. This difference in
prediction by two sets of models which are ostensibly similar
shows the importance of thoroughly examining a neural network
model in the light of metallurgical knowledge.
205 210 215 220 225 230 235 240 245
NV
The effect of allov instabilitv
Figure 10 - Prediction of variation of life with NV
It has been observed that some alloys which are unstable to the
formation of the detrimental sigma phase have an increased
resistance to fatigue crack propagation [24]. It is possible to
express this instability in terms of an electron valency number (NV) Summarv and Conclusions
of the matrix, which can be readily calculated from alloy
composition [25]. This parameter, NV, was used as an input to the A possible limitation on use of neural networks as predictive tools
network in order to investigate this dependence. NV has the for design purposes is the amount of data required - large numbers
advantage, along with yield stress, of being a means of entering of inputs require large, complete datasets which are difficult to
compositional information without needing to enter the composition compile. However success has been achieved in modelling
itself (which would vastly increase the input dimensionality and Stage II fatigue crack growth behaviour in Ni-based superalloys.
hence the number of datasets needed to produce a robust model). A basic dataset containing temperature, yield stress and Young’s
modulus models trends adequately, while refining the database to
0 include ultimate tensile strength improves the performance.
n.
-0.1 0.
The importance of careful construction of a database has been
00.
stressed, in order as far as possible to cover areas OFinput space
that may be interesting, as extrapolative predictions must be treated
-0.2 0 with caution. Experimental results that may be of use in a database
0 . n
a? 0 0 should be carefully logged to ensure that relevant inputs, such as
3 . microstructural information, are recorded accurately. It has been
z -0.3 0
0. l!i seen that it is important to validate any neural network model
produced to ensure that its predictions are in line with experience.
B -0.4 o*P**
r2 It has been shown that it is possible to use a neural network to
-0.5 investigate and model trends in fatigue crack growth behaviour with
0 UTS type-i ,” variation in material properties, based either on proposed
0 UTS type-ii mechanisms or on observed empirical trends. A trend for increased
-0.6 . Nv type-i 0 Stage II fatigue life with increased instability to sigma-phase
. formation (indicated by electron valency number, NV) has been
8 NV type-ii .
-0.7 shown to exist, although the observed effect is small due to the
small range of NV in Ni-based superalloys.
200 300 400 500 600 700 800
T ("Cl While further work on validation of such networks is required
before they can be used in design, if such work is done neural
Figure 9 - comparison of predictions using data-base containing networks may prove to be of great benefit in future alloy design
UTS and database with NV added programmes.
415
Acknowlednements 15 J.N.Hall, J.W.Jones & A.K.Sachdev, “Particle size, volume
fraction and matrix strength effects on fatigue behaviour and
Professor C.J.Humphries is thanked for provision of research particle fracture in 2124 aluminium-SiCp composites”, &&
facilities at the University of Cambridge. Rolls-Royce plc are Sci. & Erie., Al83 (1994), ~~69-80
thanked for financial support for this work and for the provision of
data. Thanks are also due to Joy Jones of the University of 16 A.J.McEvily, “Current aspects of fatigue”, Metal Sci., 1977,
Cambridge for helpful discussion and advice. ~274
R.P.Lippman, “An introduction to computing with neural nets”, 20 S.D.Antolovich & N.Jayaraman, “The effect of microstructure
IEEE Acoustics. Sueech and Signal Processing Maaazine, 4 (2) on the fatigue behaviour of Ni-base superalloys”, Fatigue -
(1987), ~~4-22 - Environment and temuerature effects, J.J.Burke & V.Weiss
eds., Plenum 1983, ~~119-144
J.A.Powell, “Preface: Neural networks, neuro-fuzzy and other
learning systems for engineering application and research”, 21 J.E.King, “Fatigue crack propagation in nickel-base superalloys
Neural Networks, Neuro-Fuzzy and Other Lear&z Systems - effects of microstructure, load ratio and temperature”, Mat.
for Enaineering Anulications and Research Conference, Institute Sci. & Tech., 3 (1987), ~~750-764
of Civil Engineers, London (1994), pp.i-iv
22 M.O.Spiedel in High temnerature materials in gas turbines,
T.J.Stonham, “Neural networks, how they work, their M.O.Spiedel & P.R.Sahm eds., Elsevier 1974, ~~207-251
strengths and weaknesses”, Neural Networks. Neuro-Fuzzv
and Other Learnine Svstems for Engineering Annlications and 23 S.S.Manson & M.H.Hirschberg, “Fatigue behaviour in strain
Research Conference, Institute of Civil Engineers, London cycling in the low- and intermediate-cycle range”, Fatigue - an
(1994), ppl-7 interdiscinlinarv anoroach, J.J.Burke, N.L.Reed & V.Weiss
eds., Syracuse University Press 1964, ~~133-178
J.Jones, “Neural network modelling of the tensile properties of
Ni-base superalloys” (CPGS dissertation, University of 24 A.James, Personal communication, Rolls-Royce, 1995
Cambridge, 1994)
35
-- J.P.Michalisin & D.L.Pasquire, “Phase transformations in Ni-
H.K.D.H.Bhadeshia, D.J.C.Mackay & L.-E.Svensson, base superalloys”, Proc. Conf. on Structural Stabilitv in
“Impact toughness of C-Mn steel arc welds - Bayesian neural Superallovs, Seven Springs, PA, Sept 1968, ~~134-170
network analysis”, Mat. Sci. and Tech, 11 (1995), pp1046-
1051 26 S.Suresh, Fatigue of Materials, Camb. Uni. Press (1991),
~~255-258
A.Mukherjee, S.Schmauder, M.Rtihle, “Artificial neural
networks for the prediction of mechanical behaviour of metal 27 Rolls-Royce design database
matrix composites”, Acta Metall. Mater., 43 (1995), 11,
~~4083-409 1
U.Bork, R.E.Challis, “Nondestructive evaluation of the
adhesive fillet size in a T-peel joint using ultrasonic lamb waves
and a linear network for data discrimination”, Meas. Sci. &
Tech., 6 (1995), ~~72-84
416