Explanation of an apparent abnormality in fatigue crack growth rate curves in titanium alloys

A surprising phenomenon is investigated where titanium alloys exhibit no threshold fatigue crack growth value if K_max in the K_max-constant testing procedure exceeds a certain value. The crack growth rate increases with decreasing ΔK up to final fracture. The phenomenon was found repeatedly for Ti–6Al–2Sn–4Zr–6Mo above K_max=21 MPa√m (equal to 72% of K_IC), and its causes were investigated. The same crack growth rates as in the K_max-constant test were reproduced by two independent experimental procedures, the so-called “jump” test and sustained K cracking experiments along with a calculation. It is demonstrated that the observed phenomenon is not a special crack growth feature or a new phenomenon, but simply caused by time-dependent crack growth, which is known to exist in titanium alloys or steels. Fractographic work revealed that intergranular crack growth along α and transformed β grain boundaries increases with decreasing ΔK and increasing K_max value, accompanied by creep deformation in the transformed β grains. The conditions for time-dependent cracking are believed to be a sufficiently high stress and strain field in the crack tip region, along with hydrogen-assisted cracking.     

The characteristics of hydrogen diffusion and concentration around a crack tip concerned with hydrogen embrittlement

Previously, we proposed a physical model for hydrogen diffusion and accumulation around the crack tip and performed accurate numerical analysis which takes account of the effects of both hydrogen diffusion and accumulation due to the stress gradient. Based on this analysis, the characteristics of hydrogen accumulation around the crack tip were clarified.Since the characteristics of stress corrosion cracking and corrosion fatigue are dominated by chemical anodic reaction, hydrogen embrittlement and dislocation mechanism, to perform the analysis on the competitive phenomenon by these mechanism and to relate the sensitivity of hydrogen embrittlement to the characteristics of corrosion fatigue, it is necessary to construct a exact physical law on the characteristics of hydrogen diffusion and concentration and to formulate the characteristics as a simple function such as diffusion constant, D, yield stress σ_ys, and stress intensity factor, K. The effect of stress field such as plane strain and plane stress on the hydrogen embrittlement is necessary to be clarified as the effect of specimen thickness on the hydrogen embrittlement.In this paper, based on this view point, the effect of D, σ_ys, and K on hydrogen embrittlement were investigated and formulated. A quantitative parameter which characterize hydrogen embrittlement was proposed for both cases of plane strain and plane stress conditions as the effect of specimen thickness on the hydrogen embrittlement.     

A dislocation model for the two critical stress intensities required for threshold fatigue crack propagation

We have examined the variations, with decreasing load ratio, of threshold peak and cyclic stress intensities required for fatigue crack growth in stage I (mainly mode II loading) using a simple model simulating dislocation motion near a crack tip. In this model the crack grows by dislocations running into the crack during loading and unloading phases. Initially we have studied the behaviour of a crack with a dislocation source relatively far away from the crack tip. Crack propagation rates showed a Paris regime at high ΔK, and an abrupt threshold value ΔK_th below which no crack growth occurred. The variation with load ratio of the peak (K_th) and cyclic (ΔK_th) stress intensities at the fatigue threshold showed that two different processes controlled the behaviour. At high load ratios dislocations are generated readily during loading and the threshold is controlled by the need for sufficient unloading to allow dislocations to run back into the crack, so that the criterion ΔK ≥ ΔK∗ results. At negative load ratios it is the generation of dislocations during the loading phase that controls the threshold condition, since once generated, the large unloading and reversed loading easily forces dislocations back to the crack. Under these conditions the threshold criterion becomes K_max ≥ K∗.     

Hydrogen-assisted fatigue crack growth of AISI 316L stainless steel weld

The fatigue crack growth behaviors of AISI 316L stainless steel (SS) welds in air and gaseous hydrogen were evaluated, and further compared with the base plate. In air, the fatigue crack growth rate (FCGR) of the weld after heat-treatment at 1050 ^oC/1 h was similar to that of the base metal. Furthermore, all specimens became susceptible to hydrogen-accelerated crack growth. Mainly quasi-cleavage fracture related with the strain-induced martensite accounted for the accelerated crack growth in hydrogen. A smaller amount of martensite in the weld was responsible for the decreased susceptibility to hydrogen-enhanced fatigue crack growth relative to the base metal.     

Micromechanisms of fatigue crack growth in a single crystal Inconel 718 nickel-based superalloy

The fatigue crack growth behavior of an experimental, single crystal alloy, of equivalent nominal chemical composition to Inconel 718 is presented. Fracture modes under cyclic loading were determined by scanning electron microscopy. The results of the fractographic analyses are presented on a fracture mechanism map that shows the dependence of the fatigue fracture mechanisms on the maximum stress intensity factor, K_max, and the stress intensity factor range, ΔK. Crack-tip deformation mechanisms associated with fatigue crack growth were studied using transmission electron microscopy. The relative effects of ΔK and K_max on the fatigue crack growth behavior of this material are discussed within the context of a two-parameter crack growth law. The influence of grain boundaries on the fatigue crack growth resistance of materials such as Inconel 718 is also discussed in light of the results of this investigation.     

Effects of stress ratio on fatigue crack propagation properties of submicron-thick free-standing copper films

The dominant mechanics and mechanisms of fatigue crack propagation in ca. 500 nm thick free-standing copper films were evaluated at the submicron level using fatigue crack propagation experiments at three stress ratios, R = 0.1, 0.5 and 0.8. Fatigue cracking initiated at the notch root and propagated stably under cyclic loading. The fatigue crack propagation rate (da/dN) vs. stress intensity factor range (ΔK) relation was dependent on the stress ratio R;da/dN, increases with increasing R. Plots of da/dN vs. the maximum stress intensity factor (K_max) exhibited coincident features in the high-K_max region (K_max ? 4.5 MPa m^1/2) irrespective of R, indicating that K_max is the dominant factor in fatigue crack propagation. In this region, the fatigue crack propagated in tensile fracture mode irrespective of the R value. The region ahead of the fatigue crack tip is plastically stretched by tensile deformation, causing necking deformation in the thickness direction and consequent chisel-point fracture. In contrast, in the low-K_max region (K_max < 4.5 MPa m^1/2), the da/dN vs. K_max function assumes higher values with decreasing R; in this region, the fracture mechanism depends on R. At the higher R value (R = 0.8), the fatigue crack propagates in the tensile fracture mode similar to that in the high-K_max region. On the other hand, at the lower R values (R = 0.1 and 0.5), a characteristic mechanism of fatigue crack propagation appears: within several grains, intrusions/extrusions form ahead of the crack tip along the Σ3 twin boundaries, and the fatigue crack propagates preferentially through the intrusions/extrusions.     

A plasticity-corrected stress intensity factor for fatigue crack growth in ductile materials

In this paper, a plasticity-corrected stress intensity factor range ΔK_pc is developed on the basis of plastic zone toughening theory. Using this new mechanical driving force parameter for fatigue crack growth (FCG), a theoretical correlation of Paris’s law with the crack tip plastic zone is established. Thus, some of the important phenomena associated with the plastic zone around the fatigue crack tip, such as the effects of load ratio R, overload and T stress on the FCG behavior, can be incorporated into the classical Paris’s law. Comparisons with the experimental data demonstrate that ΔK_pc as a single and effective mechanical parameter is capable of describing the effects of the load ratio, T stress and overload on the FCG rate. The FCG rate described as a function of ΔK_pc tested under a simple loading condition can also be used for other complex loading conditions of the same material.     

Measurements of fibre bridging during fatigue crack growth in Ti/SiC fibre metal matrix composites

High spatial resolution synchrotron X-ray strain mapping has been used to map the elastic matrix and fibre strains in the vicinity of a fatigue crack in a Ti–6Al–4V/SCS6 SiC fibre composite. A 0.61 mm fatigue crack was initiated and grown in three-point-bending. By using an in-situ loading stage it was possible to map the crack opening (longitudinal) strain distribution at K_appl=K_max and K_appl=0. In the far field region, significant thermally induced stresses were evident, being compressive in the fibres and tensile in the matrix. Around the notch and in the wake of the crack tip essentially no residual strain and only small interfacial shear stresses were found in the unloaded case, indicative of a debonded/damaged interface. At K_max the maximum tensile stress in the matrix is in the vicinity of the crack tip, whereas for the SiC fibres the maximum stress is in the bridging zone in the wake of the crack. The perturbed zone extends about ±1.5 mm either side of the crack. It was at the boundary of this zone that the maximum interfacial shear stresses (∼80 MPa) were measured in the loaded stage. A small area of tensile strain in front of the crack tip in the unloaded condition suggests frictional resistance from the bridging fibres acts to keep the crack slightly open. A simple three-dimensional finite element model has been developed to help interpret the results. The crack is introduced statically by node release and the Coulomb friction law governs the interface strength. The results of the model are compared to the synchrotron strain measurements. This comparison confirms the degradation of the interface strength in the wake of the crack.     

Fatigue crack growth behavior of laser-annealed IN 718 alloy in hydrogen

The effect of hydrogen embrittlement on the fatigue crack growth of IN 718 plate and laser-annealed specimens in hydrogen containing environment were investigated. Although the differences in tensile strength and impact toughness between solution-annealed (S) and aged (A) IN 718 specimens were significant, the experimental results indicated that both specimens within the low ΔK regime exhibited a similar fatigue behavior. As the ΔK increased above 30 MPa , the solution-annealed specimen revealed a higher fatigue crack growth rate (FCGR) than the aged one. In general, the IN 718 alloy had a low sensitivity to hydrogen-enhanced fatigue crack growth, independent of hydrogen sources. Residual compressive stresses ahead of the crack tip were responsible for the improved resistance to fatigue crack growth in a laser-annealed specimen. For alloys with similar strength, IN 718 alloy trapped a huge amount of hydrogen in the matrix showing a less susceptibility to hydrogen-enhanced fatigue crack growth in comparison with the maraging steel. Additionally, fatigue-fractured appearance near crack initiation sites reveals quasi-cleavage fracture in embrittled specimens.     

On the fatigue crack growth behavior of WC–Co cemented carbides: kinetics description,microstructural effects and fatigue sensitivity

The influence of microstructure and load ratio (R) on the fatigue crack growth (FCG) characteristics of WC–Co cemented carbides are studied. In doing so, five hardmetal grades with different combinations of binder content and carbide grain size are investigated. Attempting to rationalize microstructural effects, key two-phase parameters, i.e. binder thickness and carbide contiguity, are used. On the other hand, the effect of load ratio is evaluated from the FCG behavior measured under R values of 0.1, 0.4 and 0.7. Experimental results indicate that: (1) WC–Co cemented carbides are markedly sensitive to fatigue; and (2) their FCG rates exhibit an extremely large dependence on K_max. Furthermore, both fatigue sensitivity and relative prevalence of K_max over ΔK, as the controlling fatigue mechanics parameter, are found to be significantly dependent upon microstructure. As mean binder free path increases, predominance of static over cyclic failure modes diminishes and a transition from a ceramic-like FCG behavior to a metallic-like one occurs (conversely in relation to contiguity). Consequently, the trade-off between fracture toughness and FCG resistance becomes more pronounced with increasing binder content and carbide grain size. The observed behavior is attributed to the effective low ductility of the constrained binder and its compromising role as the toughening and fatigue-susceptible agent in hardmetals, the latter on the basis that cyclic loading degrades or inhibits toughening mechanisms operative under monotonic loading, i.e. crack bridging and constrained plastic stretching.     

Effect of austenite instability on the hydrogen-enhanced crack growth of austenitic stainless steels

Fatigue crack growth tests were performed to assess the fatigue behavior of AISI 316L and 254 SMO stainless steels (SSs) in air and gaseous hydrogen. 254 SMO SS generally exhibited a greater resistance to fatigue crack growth than 316L. Sensitization treatment had only a marginal effect on the fatigue crack growth behavior of both alloys in air. Moreover, 316L SS exhibited significant hydrogen-enhanced crack growth but 254 SMO, even sensitized 254 SMO specimens, did not. A thin layer of strain-induced martensite was formed on the fatigue-fractured surface of the 316L SS, and its content increased when raising the stress ratio. The thin martensite layer was responsible for the hydrogen-enhanced fatigue crack growth of the 316L SS. By contrast, the extremely stable austenite was responsible for the low susceptibility of 254 SMO SS to hydrogen-accelerated crack growth. The trapping of hydrogen at the grain boundaries and the transformed martensite in the sensitized 316L specimens led to increased fatigue crack growth rates and intergranular fracture of the material.     

Effect of stress ratio on fatigue lifetime and crack growth behavior of WC–Co cemented carbide

Two types of fatigue tests, a rotating bending fatigue test and a three- or four-point bending fatigue test, were carried out on a fine grained WC–Co cemented carbide to evaluate its fatigue crack growth behavior and fatigue lifetime. From successive observations of the specimen surface during the fatigue process, it was revealed that most of the fatigue lifetime of the tested WC–Co cemented carbide was occupied with crack growth cycles. Using the basic equation of fracture mechanics, the relationship between the fatigue crack growth rate (da/dN) and the maximum stress intensity factor (K_max) was derived. From this relation, both the values of the threshold intensity factor (K_th) and the fatigue fracture toughness (K_fc) of the material were determined. The fatigue lifetime of the WC–Co cemented carbide was estimated by analysis based on the modified linear elastic fracture mechanics approach. Good agreement between the estimated and experimental fatigue lifetimes was confirmed.     

Effect of hydrogen on dislocation structures around a mixed-mode fatigue crack tip in a single-crystalline iron–silicon alloy

The effect of hydrogen on dislocation structures around a mixed-mode fatigue crack tip in a single-crystalline iron–silicon alloy was investigated by cross-sectional electron backscatter diffraction and high-voltage electron microscopy. In contrast to the previously reported results in an inert environment, no dislocation cells were formed around the crack tip in a hydrogen environment. The microscopic features around the crack tip suggest that hydrogen promotes a mode I-type crack growth mechanism, which reasonably explains the observed macroscopic crack growth property.     

Fatigue crack growth behaviour of A533B steel in simulated pwr water

Fatigue crack growth data are reported for A533B material in a simulated primary PWR loop environment. Marked environmentally enhanced crack growth, characterised by the formation of a plateau in the growth rate versus ΔK curve, was observed in sinusoidal tests but was not evident in triangular waveform tests. Detailed fractography showed that inclusions can play an important role in fatigue crack growth behaviour. Of the two basic mechanisms suggested for environmentally enhanced crack growth, namely, dissolution-controlled and hydrogen induced cracking, the latter can more readily explain the results of the present investigation. At low R ratio, changing the waveform from triangular to sinusoidal induced environmentally enhanced crack growth and a possible explanation is given in terms of crack tip closure effects.     

The effect of sensitization on the hydrogen-enhanced fatigue crack growth of two austenitic stainless steels

Fatigue crack growth tests were performed to evaluate the susceptibility to hydrogen-enhanced crack growth of AISI 304 and 316 stainless steels (SSs). Sensitization treatment at 650 °C 100 h played little effect on the fatigue crack growth behavior in air, regardless of testing specimens. However, hydrogen accelerated the fatigue crack growth of various specimens to different degrees; sensitized specimens were more susceptible as compared with the un-sensitized ones.

Fatigue fracture appearance of various specimens tested in air exhibited mainly transgranular fatigue fracture together with rarely intergranular fracture and twin boundary separation. Meanwhile, intergranular fracture was found for sensitized specimens tested in hydrogen. Extensive quasi-cleavage fracture related to the strain-induced martensite accounted for the hydrogen-accelerated fatigue crack growth of unstable austenitic SSs. On the other hand, the lower susceptibility of 316H specimens could be attributed to the partial austenite transformation, as evidenced by a mixture of transgranular fracture feature and quasi-cleavage.     

Fatigue crack growth behaviour of 4130X steel in H2S environment

Abstract

Fatigue crack growth rates of 4130X steel used for compressed natural gas vessels were investigated in this paper. Considering the operating conditions, corrosion fatigue tests at a low frequency of 0·0067 Hz, in H₂S saturated, H₂S unsaturated and air environments were conducted on modified wedge opening load specimens by using a home made low cycle fatigue test system. Curve fitting was applied to the fatigue test data of da/dN–ΔK according to Paris formula. A correlation study between fracture surface and stress intensity factor range was conducted and K values for three stages in different environments were characterised quantitatively. The results show that da/dN in H₂S environment is more than 20 times faster than in an air environment. When the H₂S concentration reaches a certain range, the increase of da/dN becomes slower than that of the H₂S concentration. da/dN differs by 2·4 times while the concentration differs by 11 times. The corrosive environment accelerates the fatigue failure.     

Crack tip chemistry and electrochemistry of environmental cracks in AA 7050

The role of the crack environment in establishing environment-assisted crack (EAC) propagation in AA 7050 alloys is elucidated. A suite of mini-electrodes provided real-time in situ measurements of the crack potential, pH, and chloride concentration during stage II cracking in a chromate-chloride electrolyte under electrochemical control. For material aged to an EAC-susceptible condition, crack growth during an incubation period is characterized by tip polarization to near the applied electrode potential (E_App) and bulk-like chemistry near the crack tip. In contrast, establishment of high-rate crack growth coincided with the development of an acidic, high chloride concentration tip environment and tip depolarization. During steady state high rate crack growth, the tip potential was ∼−0.85V_SCE; near-tip potential gradients were ∼1 V/cm. Large ohmic potential drop within fast-growing cracks is indicative of net anodic current in the near tip region and increased mass transport resistance within the crack due to solid corrosion products and/or hydrogen bubble formation. Microinjection of a corrosion-inhibiting or corrosion-promoting solution at the tip suppresses or prompts, respectively, the transition from incubation to high-rate cracking, highlighting the intimate dependence of the crack growth kinetics on the local chemistry. The exceptional EAC resistance of over-aged AA 7050 is intrinsic; injection of an acidic aluminum chloride solution at the tip of a crack of this material while polarized to a high E_App failed to induce brittle crack advance.     

Discrete dislocation plasticity modeling of short cracks in single crystals

The mode-I crack growth behavior of geometrically similar edge-cracked single crystal specimens of varying size subject to both monotonic and cyclic axial loading is analyzed using discrete dislocation dynamics. Plastic deformation is modeled through the motion of edge dislocations in an elastic solid with the lattice resistance to dislocation motion, dislocation nucleation, dislocation interaction with obstacles and dislocation annihilation incorporated through a set of constitutive rules. The fracture properties are specified through an irreversible cohesive relation. Under monotonic loading conditions, with the applied stress below the yield strength of the uncracked specimen, the initiation of crack growth is found to be governed by the mode-I stress intensity factor, calculated from the applied stress, with the value of K_init decreasing slightly with crack size due to the reduction in shielding associated with dislocations near a free surface. Under cyclic loading, the fatigue threshold is ΔK-governed for sufficiently long cracks. Below a critical crack size the value of ΔK_I at the fatigue threshold is found to decrease substantially with crack size and progressive cyclic crack growth occurs even when K_max is less than that required for the initiation of crack crack growth in an elastic solid. The reduction in the fatigue threshold with crack size is associated with a progressive increase in internal stress under cyclic loading. However, for sufficiently small cracks, the dislocation structure generated is sparse and the internal stresses and plastic dissipation associated with this structure alone are not sufficient to drive fatigue crack growth.     

An intrinsic effect of hydrogen on cyclic slip deformation around a {1 1 0} fatigue crack in Fe–3.2 wt.% Si alloy

The effect of gaseous hydrogen on cyclic slip behavior around a fatigue crack tip introduced along the {1 1 0} plane in a Fe–3.2 wt.% Si alloy is precisely investigated by cross-sectional transmission electron microscopy and fractography. The results clearly suggest that the fatigue crack growth rate is promoted by hydrogen, whereas the number of dislocations emitted per load cycle is reduced. In addition, dislocation distribution is localized around the crack, causing quasi-brittle crack morphology. A sustained load test confirms that no subcritical crack growth caused by cleavage or micro-void coalescence exists along the {1 1 0} plane, which indicates that the observed increase in the fatigue crack growth rate is correlated solely to the intrinsic effect of hydrogen on the cyclic slip-off process around the crack tip.     

Crack growth behaviour and crack tip chemistry of X70 pipeline steel in near-neutral pH environment

In this paper, crack growth behaviour and the crack tip chemistry of X70 pipeline steel in the near-neutral pH environment were investigated using the in-situ measurements. The stress corrosion crack propagated forward under the cyclic load, with a mean crack growth rate (CGR) of 4.28?×?10^–3?mm/cycle. The CGR da/dN obeys well with the stress corrosion fatigue mechanism. During the crack propagation, the crack tip environment differed significantly from the bulk solution. An aggressive electrolyte with low pH (about 4.0) and high concentration of Cl^– (about 3.8?M) was produced near the crack tip. These results provided the direct evidence for simulating the crack tip solution and investigating the crack tip anodic dissolution.