Interactions between mechanical and environmental variables for short fatigue cracks in a 2024-T3 aluminum alloy in 0.5M NaCl solutions

An investigation of the interactions between mechanical and environmental variables on the shortfatigue-crack growth rate (FCGR) for a 2024-T3 aluminum alloy in 0.5M NaCl solution was carried out. Fatigue-crack growth tests were performed under a constant stress-intensity-factor range (‡K) control using single-edge-cracked tension specimens. The relationship between FCGR and crack length (0.5 to 15 mm) was determined at a cyclic frequency of 10 Hz over six ΔK levels (4,5,6,7, 8, and 10 ), two load ratios (R) (0.1 and 0.5), and three dissolved oxygen concentrations (0, 7, and 30 ppm). Tests in gaseous environments (namely, high-purity oxygen) were also conducted for comparison. Short-crack effects were observed, with the FCGR in the short-crack regime accelerated by as much as a factor of 2. The observed crack-size effects tend to appear only at the lower loading levels (ΔK<10 and R=0.1) and are more pronounced at higher oxygen levels. Fractographic examinations suggested that hydrogen embrittlements is responsible for the environmental enhancement of the FCGR for both short and long cracks in this material/environment system. A transport model was developed to estimate the crack-tip oxygen concentration and to examine its correlation to changes in the FCGR with crack length. The model correctly accounted for the decrease in short-crack effect on the FCGR with crack length under a given mechanical condition at each oxygen level, but did not explain the disappearance of short-crack effects at ΔK≥10 .     

Interactions between mechanical and environmental variables for short fatigue cracks in a 2024-T3 aluminum alloy in 0.5M NaCl solutions

An investigation of the interactions between mechanical and environmental variables on the short-fatigue-crack growth rate (FCGR) for a 2024-T3 aluminum alloy in 0.5M NaCl solution was carried out. Fatigue-crack growth tests were performed under a constant stress-intensity-factor range (ΔK) control using single-edge-cracked tension specimens. The relationship between FCGR and crack length (0.5 to 15 mm) was determined at a cyclic frequency of 10 Hz over six ΔK levels (4, 5, 6, 7, 8, and 10 MPa ), two load ratios (R) (0.1 and 0.5), and three dissolved oxygen concentrations (0, 7, and 30 ppm). Tests in gaseous environments (namely, high-purity oxygen) were also conducted for comparison. Short-crack effects were observed, with the FCGR in the short-crack regime accelerated by as much as a factor of 2. The observed crack-size effects tend to appear only at the lower loading levels (ΔK<10 MPa and R=0.1) and are more pronounced at higher oxygen levels. Fractographic examinations suggested that hydrogen embrittlement is responsible for the environmental enhancement of the FCGR for both short and long cracks in this material/environment system. A transport model was developed to estimate the crack-tip oxygen concentration and to examine its correlation to changes in the FCGR with crack length. The model correctly accounted for the decrease in short-crack effect on the FCGR with crack length under a given mechanical condition at each oxygen level, but did not explain the disappearance of short-crack effects at ΔK≥10 MPa .     

高强度织构对2524铝合金疲劳性能的影响

对分别含有高强度高斯织构和高强度立方织构状态的2种2524-T4铝合金板材的疲劳裂纹扩展速率和短裂纹扩展行为进行研究,用扫描电镜(SEM)观察疲劳试样断口形貌和疲劳短裂纹的扩展路径,研究织构类型对合金疲劳性能的影响。结果表明:高斯取向晶粒能够提高材料疲劳裂纹扩展的门槛值及增强疲劳裂纹的扩展抗力,使材料在更高的应力强度因子下发生失稳扩展;而高强度立方织构对疲劳性能的影响相对较小。在近门槛区,高斯晶粒通过裂纹偏转的形式有效阻碍短裂纹扩展,在稳态扩展区,高斯晶粒能明显降低疲劳裂纹的扩展速率,高斯织构还能延长合金疲劳裂纹稳态的扩展区,提高合金的疲劳损伤容限。因此,高强度高斯织构的2524-T4铝合金板材比立方织构的合金具有更好的疲劳性能。     

On the development of crack closure and the threshold condition for short and long fatigue cracks in 7150 aluminum alloy

In an attempt to analyze the behavior of physically “short” cracks, a study has been made of the development, location, and effect of crack closure on the behavior of fatigue cracks arrested at the “long” crack threshold stress intensity range, ΔK _TH , in underaged, peak aged, and overaged microstructures in a 7150 aluminum alloy. By monitoring the change in closure stress intensity,K _cl, during thein situ removal of material left in the wake of arrested threshold cracks, approximately 50 pct of the closure was found to be confined to a region within ∼500 μm of the crack tip. Following wake removal, previously arrested threshold cracks recommenced to propagate at low load ratios even though nominal stress intensity ranges didnot exceed ΔK _TH , representing the behavior of physically short cracks emanating from notches. No such crack extension at ΔK _TH was seen at high load ratios. With subsequent crack extension, crack closure was observed to redevelop leading to a deceleration in growth rates. The development of such closure was found to occur over crack extensions comparable with microstructural dimensions, rather than those associated with local crack tip plasticity. Such results provide further confirmation that the existence of a fatigue threshold and the growth of physically short cracks are controlled primarily by crack closure, and the data are discussed in terms of the micro-mechanisms of closure in precipitation hardened alloy systems. Formerly Graduate Student with the Department of Mechanical Engineering, University of California, Berkeley     

Friction-stir welding effects on microstructure and fatigue of aluminum alloy 7050-T7451

Aluminum alloy 7050 was friction-stir welded (FSW) in a T7451 temper to investigate the effects on the microstructure and mechanical properties. Results are discussed for the as-welded condition (as-FSW) and for a postweld heat-treated condition consisting of 121 °C for 24 hours (as-FSW + T6). Optical microscopy and transmission electron microscopy (TEM) examination of the weld-nugget region show that the FS welding process transforms the initial millimeter-sized pancake-shaped grains in the parent material to fine 1 to 5 μm dynamically recrystallized grains; also, the FS welding process redissolves the strengthening precipitates in the weld-nugget region. In the heat-affected zone (HAZ), the initial grain size is retained, while the size of the strengthening precipitates and of the precipitatefree zone (PFZ) is coarsened by a factor of 5. Tensile specimens tested transverse to the weld show that there is a 25 to 30 pct reduction in the strength level, a 60 pct reduction in the elongation in the as-FSW condition, and that the fracture path is in the HAZ. The postweld heat treatment of 121 °C for 24 hours did not result in an improvement either in the strength or the ductility of the welded material. Comparison of fatigue-crack growth rates (FCGRs) between the parent T7451 material and the as-FSW + T6 condition, at a stress ratio of R = 0.33, shows that the FCG resistance of the weldnugget region is decreased, while the FCG resistance of the HAZ is increased. Differences in FCGRs, however, are substantially reduced at a stress ratio of R = 0.70. Analysis of residual stresses, fatigue-crack closure, and fatigue fracture surfaces suggests that decrease in fatigue crack growth resistance in the weld-nugget region is due to an intergranular failure mechanism; in the HAZ region, residual stresses are more dominant than the microstructure improving the fatigue crack growth resistance.     

Gel electrode imaging of metal fatigue: Part i. cracks in 6061-T6 aluminum

A simple electrochemical technique is described which produces high-resolution, visible images of fatigue cracks in aluminum alloys, without conventional metallographic surface preparation. The only preparation required is the formation of a thin (14 nm) anodic oxide film on the surface. After fatigue cycling, a semisolid electrolyte is placed in contact with the specimen and a voltage applied. As the current flows to the fatigue cracks a clearly defined image is formed. The capabilities of the technique are demonstrated by measurements on6061-T6 aluminum, and the images are correlated with scanning electron micrographs of the specimens. The images are reproducible and record features of the cracks which are barely discernible with a scanning electron microscope. Fatigue cracks only ∼30 μm long have been detected. Measurement of the charge flow during imaging is a quantitative measure of the crack length. These measurements indicate that considerably smaller cracks should also be detectable.     

Chemical and metallurgical aspects of environmentally assisted fatigue crack growth in 7075-T651 aluminum alloy

A comprehensive study has been carried out on a 7075-T651 alloy to examine the influence of water vapor on fatigue crack growth. The kinetics of fatigue crack growth were determined as a function of water vapor pressure at room temperature and at 353 K. Detailed fractographic analyses and surface chemistry studies were carried out to identify the micromechanisms and to quantify the chemical interactions for corrosion fatigue crack growth in this alloy. Experiments were also carried out in ultra-high vacuum and in oxygen to provide for comparisons. Two regions of fatigue crack growth response were identified. In the low pressure region (below 67 Pa at 5 Hz), crack growth is controlled by the rate of transport of water vapor to the crack tip, and the response can be described by a model for transport controlled crack growth. At pressures above 67 Pa, additional increases in crack growth rate occurred, which are attributed to the further reactions of water vapor with segregated magnesium in this alloy. Different micromechanisms for crack growth have been identified for vacuum, oxygen, and water vapor. These micromechanisms are considered in relation to the environmental parameters through a modified superposition model for corrosion fatigue.     

Small and large fatigue cracks in aluminum alloys

Crack opening loads and the displacements near the crack tip have been measured by stereoimaging for large (through) cracks and small (surface) cracks. These results have been published. The present paper combines these observations and considers them in a new way, showing the relationship between small and large cracks, and provides a method for computing an effective driving force (ΔK_eff) for small and large fatigue cracks.     

Growth rate models for short surface cracks in AI 2219-T851

Rates of fatigue propagation of short Mode I surface cracks in Al 2219-T851 are measured as a function of crack length and of the location of the surface crack tips relative to the grain boundaries. The measured rates are then compared to values predicted from crack growth models. The crack growth rate is modeled with an underlying assumption that slip responsible for early propagation does not extend in significant amounts beyond the next grain boundary in the direction of crack propagation. Two models that contain this assumption are combined: 1) cessation of propagation into a new grain until a mature plastic zone is developed; 2) retardation of propagation by crack closure stress, with closure stress calculated from the location of a crack tip relative to the grain boundary. The transition from short to long crack growth behavior is also discussed.     

Growth of slip bands during fatigue of 6061-T6 aluminum

The growth of persistent slip bands (psb), the initial surface manifestation of metal fatigue, was measured with a photoelectron microscope equipped with a fatigue stage. Once the psb had been identified and located, the specimen was subjected to a final detailed examination by scanning electron microscopy. In 6061-T6 aluminum psb initiated within a grain, usually at the site of an inclusion. The psb appeared as a small extrusion and elongated across the grain by the sequential addition of new extrusions. As the psb elongated, the initial extrusions became more pronounced and eventually microcracks developed. Under constant amplitude loading, the rate of elongation of a psb in polycrystalline material varied inversely as the length, whereas in a large grain specimen the rate remained constant. This difference is attributed to the constraints imposed upon a small grain by the surrounding material. The growth laws can be accounted for in terms of a simple two phase model in which the psb has a much lower yield stress than the matrix of the grain.     

The effect of solidification rate on the growth of small fatigue cracks in a cast 319-type aluminum alloy

A study was conducted to investigate the effect of solidification rate on the growth behavior of small fatigue cracks in a 319-type aluminum alloy, a common Al-Si-Cu alloy used in automotive castings. Fatigue specimens were taken from cast material that underwent a hot isostatic pressing (HIP) process in order to eliminate shrinkage pores and to facilitate the observation of surface-initiated cracks by replication. Naturally initiated surface cracks ranging in length from 17 μm to 2 mm were measured using a replication technique. Growth rates of the small cracks were calculated as a function of the elastic stress-intensity-factor range (ΔK). Long-crack growth-rate data (10 mm≤length≤25 mm) were obtained from compact-tension (CT) specimens, and comparison to the small-crack data indicates the existence of a significant small-crack effect in this alloy. The solidification rate is shown to have a significant influence on small-crack growth behavior, with faster solidification rates resulting in slower growth rates at equivalent ΔK levels. A stress-level effect is also observed for both solidification rates, with faster growth rates occurring at higher applied-stress amplitudes at a given ΔK. A crack-growth relation proposed by Nisitani and others is modified to give reasonable correlation of small-crack growth data to different solidification rates and stress levels.     

Growth behavior of microstructurally short cracks in the 6061 aluminum alloy with and without 22 Vol Pct SiC whiskers

Short crack growth behavior of the 6061 Al alloy with and without SiC whiskers was investigated. Fluctuations in the growth rate of short cracks converge with growth of the cracks and become substantially constant between 25 and 40 μm in the metal matrix composite (MMC) and 110 and 183 μm in the unreinforced alloy. This is attributed to the release of the short cracks from the microstructural effects,i.e., the interaction with reinforcement structure in the MMC and grain boundaries in the unreinforced alloy. Furthermore, there exists slowing down of short crack advance in the MMC, and this was explained from rapid development of crack closure obtained in this study.     

Observation of short fatigue crack-growth process in SiC-fiber-reinforced Ti-15-3 alloy composite

The microscopic fatigue damage characteristics and short fatigue crack growth of an unnotched SiC(SCS-6) fiber-reinforced Ti-15-3 alloy composite were investigated in tension-tension fatigue tests (R = 0.1) carried out at room temperature for applied maximum stress of 450, 670, and 880 MPa.In situ observation of the damage-evolution process was done using optical and scanning laser microscopies, which were attached in the fatigue machine. The first damage for the composite started from a cracking of the reaction layer followed by fiber fracture. The matrix cracking initiated near the broken fiber when the microhardness of the matrix just to the side of the fracture fiber reached ≈6 GPa, and the number of cycles for the initiation of this cracking decreased with the increase of applied stress. The slope of the relation of surface crack growth lengthvs number of cycles fell into two characteristic stages; in the first stage, the rate was lower than the second stage and accelerated. The surface crack growth rate,d(2c)/dN,vs surface crack length relation also fell into two stages (stages I and II). With the increase in surface crack length, the crack-growth rate,d(2c)/dN, decreased in stage I and increased in stage II. The transition from stage I to stage II occurred due to the fracture of fibers located around the first fractured fiber. It was concluded that the fatigue crack growth resistance of the composite in the short-crack region was controlled by the fiber fracture and matrix work hardening near the fractured fiber. When the fiber fracture occurred, the surface crack growth rate was accelerated and became faster than that of the monolithic matrix.     

6061-T6铝合金薄板的搅拌摩擦焊接

采用搅拌摩擦焊(FSW)技术对1 mm厚6061-T6铝合金薄板进行了对接.研究了焊接工艺参数的范围,实验测试了焊接接头的强度、硬度和延伸率,利用金相显微镜、扫描电镜和透射电镜分析了接头的微观组织.结果表明:对于1 mm厚度6061-T6铝合金,FSW的最优工艺参数为旋转速度1 800 r·min^-1,焊接速度1000 mm·min^-1;在此参数下,接头的硬度值达到母材的80%左右,抗拉强度达到母材的103%,延伸率达到母材的54%;接头的力学性能与微观结构相符.     

Fractography of fatigue crack propagation in 2024-T3 and 7075-16 aluminum alloys in air and vacuum

Electron fractography and transmission electron microscopy were used to study fatigue crack propagation processes in 2024-T3 and 7075-T6 aluminum alloys in vacuum and air. There was evidence that crack growth occurs cycle-by-cycle in vacuum, but only for fa tigue in air was it possible to relate dislocation substructure band spacings, immediately below the fracture surface, to cyclic crack growth. A discussion of crack propagation mechanisms suggested that the Tomkins and Biggs model of striation formation comes closest to explaining the fractographic features.     

Fractography of fatigue crack propagation in 2024-T3 and 7075-16 aluminum alloys in air and vacuum

Metallurgical and Materials Transactions A - Electron fractography and transmission electron microscopy were used to study fatigue crack propagation processes in 2024-T3 and 7075-T6 aluminum alloys...