Enhanced fatigue crack propagation resistance of an Al–Cu–Mg alloy by artificial aging

The effect of artificial aging treatment on fatigue crack propagation (FCP) resistance of an Al–Cu–Mg alloy was investigated. It was shown that FCP rate of artificially aged alloy in the Paris region is lower than that of naturally aged alloy before and after thermal exposure. During the thermal exposure, tensile strength of artificially aged alloy remained unchanged. The results of three-dimensional atom probe (3DAP), transmission electron microscope (TEM) and differential scanning calorimeter (DSC) analysis showed that Cu–Mg co-cluster in artificially aged alloy are larger than that in natural aged alloy and can stably exist during thermal exposure. Size of Cu–Mg co-cluster was found to be the main factor influencing the thermal stability of Cu–Mg co-cluster and the FCP resistance.     

Role of hydrogen environment induced hydrogen embrittlement of Ti–8Al–1Mo–2V alloy

Structural analysis by mean of metallographic, SEM fractographic and TEM replica technique including acoustics-emission studies have been carried out on Ti–8Al–1Mo–2V alloy specimen tested at room temperature in gaseous hydrogen environment. The result provided evidences of the presence of face centred cubic titanium hydride at the fracture surfaces, with discontinuous nature of crack propagation. The present work confirmed that an essentially continuous path of β phase is necessary for the occurrence of slow crack growth in gaseous hydrogen. Metallographic and fractographic observation leave little doubt that cracks propagates along the α–β interface rather than through stable α phase.     

Mechanical properties of the hot-rolled Mg–12Gd–3Y magnesium alloy

Tensile and high cycle fatigue (HCF) properties of the hot-rolled Mg–12Gd–3Y (wt.%) magnesium alloy have been investigated. The magnesium alloy exhibits a fatigue strength of about 150 MPa, which is much higher than that of the commercial Mg–8Al–Zn alloy AZ80. Aging heat-treatment (T5) improved the fatigue life of the Mg–12Gd–3Y alloy. Fatigue cracks nucleated at the intense slip bands in the as-rolled alloy. After T5 treatment, however, the fatigue crack nucleation site shifted to the phase boundaries between MgGdY particles and Mg matrix. T5 heat-treatment retarded the crack initiation and thus improved the fatigue life of the Mg–12Gd–3Y alloy.     

Variability in room temperature fatigue life of alpha + beta processed Ti–6Al–4V

The variability in fatigue behavior is often what drives the design of components such as turbine engine blades and disks. These components are critical and must be designed with a very low probability of failure over the lifetime of the system. To meet that design criterion, the lower limit of fatigue life capability is typically used. The challenge is to reliably predict the lower limit of fatigue behavior. This study investigates the fatigue variability of an alpha + beta processed Ti–6Al–4V turbine engine alloy by conducting a statistically significant number of repeated tests at a few conditions. Testing includes three conditions including two maximum stresses, 675 and 635 MPa; and two surface conditions, electropolished and low stress grinding. All tests are constant amplitude with a stress ratio of 0.1. A similar approach has been performed on several other turbine engine material systems often revealing a bimodal behavior. It is proposed that crack propagation using small crack growth data can be used to predict the low life behavior mode and is demonstrated with the Ti–6Al–4V data.     

Fatigue crack growth behavior of X2095 Al–Li alloy

Microstructures and micro-textures of X2095 Al–Li alloy in as-received/superplastic state were characterized by means of SEM/BDS, X-ray diffraction and orientation imaging microscopy (OIM). It was observed that the microstructure of the alloy was typical of a particulate-reinforced composite material, consisting of aluminum matrix and homogeneously distributed T_B(Al₇Cu₄Li) particles with a volume fraction of about 10%. Brass-type texture was the dominant texture component. Both constant amplitude and near-threshold fatigue crack growth rates of the alloy in the L–T and T–L orientations were determined at different stress ratios. Particular attention was paid to the role of the T_B phase in the fatigue crack growth. When a fatigue crack approached a T_B particle, the crack basically meandered to avoid the particle. The T_B particles thus provided a strong resistance to the propagation of fatigue crack by promoting crack deflection and the related crack closure effects. The fatigue crack propagation behavior has been explained by the microstructural features, micro-textures, cracking characteristics and crack closure effects.     

Effects of temper condition and corrosion on the fatigue performance of a laser-welded Al–Cu–Mg–Ag (2139) alloy

The effects of temper condition and corrosion on the fatigue behavior of a laser beam welded Al–Cu–Mg–Ag alloy (2139) have been investigated. Natural aging (T3 temper) and artificial aging (T8 temper) have been applied prior to welding. Corrosion testing has been performed by exposing the welded specimens to a salt spray medium for 720 h. Aging influences the corrosion behavior of laser welds. In the T3 temper, corrosion attack is in the form of pitting in the weld area, while in the T8 temper corrosion is in the form of pitting and intergranular corrosion in the base metal. In the latter case corrosion is attributed to the presence of grain boundary precipitates. Corrosion degrades the fatigue behavior of 2139 welds. The degradation is equal for both the T3 and T8 tempers and for the corrosion exposure selected in this study corresponds to a 52% reduction in fatigue limit. In both cases fatigue crack initiation is associated with corrosion pits, which act as stress raisers. In the T3 temper, the fatigue crack initiation site is at the weld metal/heat affected zone interface, while for the T8 temper the initiation site is at the base metal. Fatigue crack initiation in uncorroded 2139 welds occurs at the weld toe at the root side, the weld reinforcement playing a principal role as stress concentration site. The fatigue crack propagates through the partially melted zone and the weld metal in all cases. The findings in this paper present useful information for the selection of appropriate heat treatment conditions, to facilitate control of the corrosion behavior in aluminium welds, which is of great significance for their fatigue performance.     

Effects of trace zirconium on the initiation and propagation behavior of fatigue cracks in Cu–6Ni–2Mn–2Sn–2Al alloy

The effects of trace Zr on the fatigue behavior of Cu–6Ni–2Mn–2Sn–2Al alloy were studied through the initiation and growth behavior of a major crack. When stress amplitude was less than σ_a = 350 MPa, the fatigue life of Zr-containing alloys was about 2 times larger than that of alloy without Zr. When σ_a = 400 MPa, the effects of Zr addition on fatigue life disappeared. Increased fatigue life due to Zr addition resulted from an increase in crack initiation life and microcrack growth life. Zr addition generated strengthened grain boundaries (GBs) that developed from the precipitation of SnZr compounds. Strengthened GBs contributed to the increase in crack initiation life. The effects of Zr addition on fatigue behavior were discussed with relation to the behavior of microcracks.     

Hydrogen induced premature failure of massive cast medium carbon steel anchor fluke

A 17 tons cast medium carbon steel anchor fluke of an ocean going container ship suffered catastrophic premature failure during demooring from anchorage made after maiden voyage of one month duration. It was evident upon recovery that the fluke simply fractured into halves. Microstructural analysis showed ferritic–pearlitic microstructure and decarburized ferritic surface with massive twinning around the crack initiation zone. Fractography showed brittle (intergranular mode dominating at the crack initiation zone at surface followed by cleavage mode towards the core) crack propagation suggesting embrittlement plausibly induced by hydrogen and grain boundary impurities. Casting process apparently incorporated the hydrogen and could not eliminate completely during the post-casting annealing considering the massive size. Embrittlement of decarburized surface was caused by trapping of diffusing out hydrogen in annealing process.     

Damage mechanisms of fatigue fracture in a metastable beta Ti-15-3 alloy

The mechanism of crack tip deformation in metastable beta Ti-15-3 alloy under fatigue loading has been examined. In spite of the small thickness of the test specimens (1 mm), the plastic zone revealed plane strain conditions which was transformed to a plane stress zone when its size became 0.25 of the crack length. Slip processes whose density increased with crack length were the dominant microscopic feature of crack tip plasticity. Microcracks emanating from the main crack appeared as a result of extensive slip damage. Transmission electron microscopy (TEM) and X-ray evidence indicate the absence of twinning or phase transformation and that dislocation processes constitute the microstructural origin of crack propagation resistance in the alloy. Energy calculations show that the specific energy of slip, 20 MJ m⁻³, exceeds that of microcracking by three orders of magnitude.     

Fatigue crack tip plastic zone of α + β titanium alloy with Widmanstatten microstructure

The recent studies had focused on the fatigue crack propagation behaviors of α?+?β titanium alloys with Widmanstatten microstructure. The fascinated interest of this type of microstructure is due to the superior fatigue crack propagation resistance and fracture toughness as compared to other microstructures, which was believed to be related to the fatigue crack tip plastic zone (CTPZ). In this study, the plastic deformation in fatigue CTPZ of Ti-6Al-4V titanium alloy with Widmanstatten microstructure was characterized by scanning electron microscope (SEM) and electron backscatter diffraction (EBSD). The results showed that large-scale slipping and deformation twinning were generated in fatigue CTPZ due to the crystallographic feature of the Widmanstatten microstructure. The activation of twinning was related to the rank of Schmid factor (SF) and the diversity of twin variants developing behaviors reflected the influence of SF rank. The sizes of CTPZ under different stress intensity factors (K) were examined by the white-light coherence method, and the results revealed that the range of the plastic zone is enlarged with the increasing K (or crack length), while the plastic strain decreased rapidly with the increasing distance from the crack surface. The large-scale slipping and deformation twinning in Widmannstatten microstructure remarkably expanded the range of fatigue CTPZ, which would lead to the obvious larger size of the observed CTPZ than that of the theoretically calculated size.     

Very-high-cycle fatigue crack initiation and propagation behaviours of magnesium alloy ZK60

The aim of this paper is to assess the very-high-cycle fatigue (VHCF) behaviour of a magnesium alloy (ZK60). Results indicate that the fatigue crack initiates from an area consisting of many distributed facets, while the region of early crack propagation is characterised by parallel traces, based on a fractographic analysis. The significant differences in morphology around the crack initiation area result from the interaction between the deformation twinning and the plastic zone at the crack tip. In addition, the fatigue crack propagation rate around the crack initiation site is also estimated based on a modified Murakami model. It is found that the formation stage for the fatigue crack is of great importance to the fatigue failure mechanism in the VHCF regime.     

Effect of the long periodic stacking structure and W-phase on the microstructures and mechanical properties of the Mg–8Gd–xZn–0.4Zr alloys

Microstructures and mechanical properties of the Mg–8Gd–xZn–0.4Zr (x = 0, 1 and 3 wt.%) alloys, in the as-cast condition and the as-extruded condition, have been investigated. The results show that both the 14H long periodic stacking structure and the W-phase coexist together in the cast Zn-containing alloys. The volume fraction of the W-phase increases with increasing the addition of Zn. This phase is the crack source of the fracture. The 6H long periodic stacking structure is observed in the extruded Zn-containing alloys. The Mg–8Gd–1Zn–0.4Zr alloy exhibits the highest elongation, and the value of its elongation is 130% at 300 °C due to the refined microstructure. The W-phase plays an important role in improving the mechanical properties via pinning the movement of the grains at elevated temperature.     

Strain hardening behavior of a Fe–18Mn–0.6C–1.5Al TWIP steel

The strain hardening behavior of a Fe–18Mn–0.6C–1.5Al TWIP steel was investigated through the modified Crussard–Jaoul (C–J) analysis and microstructural observations. The strain hardening rate obtained by modified C–J analysis was high up to the critical strain of 37% and then greatly decreased with further strain. The electron backscatter diffraction (EBSD) observation showed that the deformation twinning rate is greatly decreased beyond about 34% strain, indicating that the reduced strain hardening rate at the large strain region is attributed to the deceleration of deformation twinning rate. The volume fraction of twinned region was increased with tensile strain due to the increase in the number of deformation twins not to the lateral growth of each deformation twin.     

Design and deformation behavior of high strength Fe–Mn–Al–Cr–C duplex steel

The influence of cold rolling reduction on microstructures and mechanical properties at room temperature of the duplex Fe–28Mn–7Al–5Cr–0.3C steel was investigated. In the Fe–28Mn–7Al alloy system, the duplex microstructure was obtained by lowering the carbon content to about 0.3 wt.%. The steel was austenito-ferritic with a low to moderate stacking fault energy. Two thermomechanical cycles were performed, which included cold rolling/annealing at 1100 °C, and cold rolling/annealing at 1100 °C/cold rolling/annealing at 1000 °C.The effects produced by cold rolling on the duplex steel were grain refinement and different strain-induced marks within the ferrite and austenite phases. They were easily observed within the austenite phase at a relatively smaller reduction than within the ferrite phase. Mechanical twinning plays a dominant role within the austenite phase during deformation at room temperature, resulting in extreme mechanical properties. No edge or longitudinal cracks were observed during cold rolling of the duplex steel.     

Fracture behavior and mechanical properties of Mg–4Y–2Nd–1Gd–0.4Zr (wt.%) alloy at room temperature

The microstructure, mechanical properties and fracture behavior of gravity die cast Mg–4Y–2Nd–1Gd–0.4Zr (wt.%) (WNG421) alloy are studied at room temperature in different thermal conditions, including as-cast, solution-treated and different aging-treated (both isothermal and two-step aging) conditions. The results indicate that WNG421 alloy shows different behaviors of crack initiation and propagation in different thermal conditions during tensile test at room temperature. After pre-aged at 200 °C for 5 h, the hardness of WNG421 alloy first reduces and then increases when secondary aged at 250 °C (two-step aging). The peak hardness and corresponding tensile strength of the two-step aged alloy both increases compared with those in 250 °C isothermal peak-aged condition. Tensile strength of WNG421 alloy at room temperature in low temperature (200 °C) isothermal peak-aged condition is much higher than that in high temperature (250 °C) isothermal peak-aged condition.     

Analyses of the fatigue crack propagation process and stress ratio effects using the two parameter method

In situ SEM observations (Zhang JZ. A shear band decohesion model for small fatigue crack growth in an ultra-fine grain aluminium alloy. Eng Fract Mech 2000;65:665–81; Zhang JZ, Meng ZX. Direct high resolution in-site SEM observations of very small fatigue crack growth in the ultra fine grain aluminium alloy IN 9052. Script Mater 2004;50:825–28; Halliday MD, Poole P, Bowen P. New perspective on slip band decohesion as unifying fracture event during fatigue crack growth in both small and long cracks. Mater Sci Technol 1999;15:382–90) have revealed that fatigue crack propagation in aluminium alloys is caused by the shear band decohesion around the crack tip. The formation and cracking of the shear band is mainly caused by the plasticity generated in the loading part of a load cycle. This shear band decohesion process has been observed to occur in a continuous way over the time period during the loading part of a cycle. Based on this observation, in this study, a new parameter has been introduced to describe fatigue crack propagation rate. This new parameter, da/dS, defines the fatigue crack propagation rate with the change of the applied stress at any moment of a stress cycle. The relationship between this new parameter and the conventional da/dN parameter which describes fatigue crack propagation rate per stress cycle is given.Using this new parameter, it is proven that two loading parameters are necessary in order to accurately describe fatigue crack propagation rate per stress cycle, da/dN. An analysis is performed and a general fatigue crack propagation model is developed. This model has the ability to describe the four general type of fatigue crack propagation behaviours summarised by Vasudevan and Sadananda (Vasudevan AK, Sadananda K. Fatigue crack growth in advanced materials. In: Fatigue 96, Proceedings of the sixth international conference on fatigue and fatigue threshold, vol. 1. Oxford: Pergamon Press; 1996. p. 473–8).     

Titanium-silicon coatings and their influence on the efficiency of machine parts

The production of titanium-silicon coatings on VT8 titanium alloy and the effect of these coatings on the resistance to contact fatigue and fatigue crack propagation are investigated. It is established that such coatings increase the resistance of VT8 alloy to fatigue crack propagation and contact fatigue.Karpenko Physicomechanical Institute, Ukrainian Academy of Sciences, L'viv. Translated from Fiziko-Khimicheskaya Mekhanika Materialov, Vol. 29, No. 5, pp. 79–81, September–October, 1993.     

Microstructure characterization of the non-modulated martensite in Ni–Mn–Ga alloy

The microstructure of the non-modulated martensite in a Ni–Mn–Ga alloy has been characterized in detail by conventional transmission electron microscopy. Bright field images show that the martensite exhibits an internal substructure consisting of a high density of narrow twins. Using electron diffraction, it is found that the martensite has a tetragonal crystal structure. The lattice correspondence between the parent phase and the non-modulated martensite is investigated. Furthermore, the four twinning elements describing the microtwinning have been graphically and quantitatively determined. The results indicate that the microtwinning within the non-modulated martensite belongs to the compound type.     

Microstructure and mechanical properties of Mg–4.5Al–1.0Zn alloy sheets produced by twin roll casting and sequential warm rolling

Microstructure and mechanical properties of Mg–4.5Al–1.0Zn (designated as AZ41M in short) alloy sheets produced by twin roll casting, sequential warm rolling and post annealing at 350 °C were studied in this paper. Microstructure of twin roll casting strip consisted of dendrite structure, eutectics and intermetallic compounds located in the interdendritic region. AZ41M alloy sheets showed higher strength and lower elongation after sequential warm rolling, while post annealing after warm rolling induced the decrease of strength and increase of elongation. This results in the balance of strength and elongation in AZ41M alloy sheets. The grain refinement during manufacturing processes was attributed to the formation of heavy shear bands, high dislocation density, twinning, and precipitates of Al₂Ca/Mg₂Ca or Al₈Mn₅ and the Ca dissolution into Mg₁₇Al₁₂ phase.     

On damage accumulations in the cyclic cohesive zone model for XFEM analysis of mixed-mode fatigue crack growth

Predicting mixed-mode fatigue crack propagation is an important and troublesome issue in structure assessment for decades. In the present paper an extended finite element method (XFEM) combined with a new cyclic cohesive zone model (CCZM) is introduced for simulating fatigue crack propagation under mixed-mode loading conditions, which has been implemented in the commercial general purpose software ABAQUS. The algorithm allows introducing a new crack surface at arbitrary locations and directions in a finite element mesh, without re-meshing. The cyclic cohesive zone model is based on the known S–N curves and Goodman diagram for metallic materials and validated by uniaxial tension results. Furthermore, the sensitivity of the model parameter is investigated for mixed-mode fatigue. The virtual crack closure technique has been extended to the cohesive zone model and proposed to calculate the energy release rate for the generalized Paris’ law. Finally, the crack propagation rate and direction under mixed-mode fatigue loading conditions are studied.