A simulation study on fatigue with single and block overloads

An investigation into crack retardation behavior for variable magnitude single overloads and block overloads is conducted on some aluminum alloys. Plasticity zone interactions and plasticity induced crack closure has been used to obtain fatigue crack growth rates in the simulation study of this investigation. The relationship between Over Load Ratio (OLR) and retardation parameter is developed and provides an insight into nonlinear behavior of overloads on fatigue growth. Thus, the lacunae in Wheeler’s model pertaining to single overload applications and block overloads are addressed from the viewpoint of dependence of retardation phenomenon on the magnitude of overload ratio. The importance of introduction of overload ratios in the governing equations is emphasized. Thorough calibrations have been performed with the experimental results from various sources in open literature and the model is capable of simulating fatigue crack growth, delay cycles due to single over load and block overloads and the fidelity of the model is established. The predictions on number of delay cycles, Fatigue Crack Growth (FCG) and Fatigue Crack Growth Rate (FCGR) of the model are representative retardation behavior and agree with the experimental data. The computational analysis of load-interaction effects on fatigue crack growth is presented. The model shows that a combined effect of plasticity and crack closure is a controlling mechanism of crack growth for single overload and block overload problems. Model development is presented in Fig. 1 and some plasticity zones are given in Fig. 2, while other results obtained are provided in Figs.3, 4, 5 and 6.     

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold Fatigue Crack Growth Regime in Ni-Based Superalloys

Cyclic near-threshold fatigue crack growth (FCG) behavior of two disk superalloys was evaluated and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensity factor ranges to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover of FCG resistance curves in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased ?K_th values in the threshold region. High-resolution scanning and transmission electron microscopy were used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr-oxide and Ti-oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.     

The Small Fatigue Crack Growth Behavior of an AM60 Magnesium Alloy

The effects of thermomechanical processing and subsequent heat treatment on the small fatigue crack growth (FCG) behavior of an AM60 (Mg-6.29Al-0.28Mn wt pct) alloy were evaluated. The effects of mechanical loading parameters, such as maximum stress and load-ratio, on the small FCG behavior were also determined. Maximum stress did not appear to affect the crack propagation rate of small cracks in the stress and crack size ranges considered. Materials with different microstructures and yield stresses, introduced by different processing conditions, showed similar crack growth rates at equivalent stress intensity factor ranges. The effect of load ratio on small crack growth rates was recorded. Fracture surface characterization suggested that the fatigue crack propagation mechanism was a mixture of transgranular and intergranular cracking. Porosity and other material defects played respective important roles in determining the fatigue crack initiation and propagation behavior.     

Effect of mean stress (stress ratio) and aging on fatigue-crack growth in a metastable beta titanium alloy, Ti-10V-2Fe-3Al

The effect of mean stress, or the stress ratio (R), on the fatigue-crack growth (FCG) behavior of α-aged and ω-aged microstructures of the beta titanium alloy Ti-10V-2Fe-3Al was investigated. While the mean stress had a negligible effect on the FCG behavior of the α-aged microstructure, a strong effect was observed in the ω-aged microstructure. In particular, the values of the threshold stress-intensity range (ΔK _th ) exhibited a strong dependence on R in the ω-aged microstructure, while this dependence was weak in the α-aged microstructure. These effects seem to arise primarily from fracture-surface roughness-induced crack closure. The crack closure levels for the α-aged microstructure were found to be very low compared to those for the ω-aged microstructure. Transmission electron microscopy and scanning electron microscopy studies of microstructures and fracture surfaces were performed to gain insight into the deformation characteristics and crack propagation mechanisms, respectively, in these microstructures. The microstructure-induced differences in FCG behavior are rationalized in terms of the effect of aging on slip and crack closure.     

The influence of laser glazing on fatigue crack growth in Ti-24AI-11Nb

The influence of laser glazing on fatigue crack growth (FCG) in a titanium aluminide (Ti₃Al) alloy Ti-24A1-11Nb has been studied. Glazing leads to retention of beta phase in the melt zone and is accompanied by a significant increase in hardness as compared to that of the base microstructure. Laser glazing strongly influences the FCG behavior. Crack growth rates (CGRs) at a given stress intensity are reduced by up to three orders of magnitude. Maximum retardation in the CGR is observed when the crack front is around 4.0 mm ahead of the laser track. The observed slowing of CGR can be understood on the basis of the superposition principle that accounts for the influence of residual stresses on FCG. The equilibrating compressive stresses resulting from the tensile thermal residual stresses reduce the local effective stress intensity and, thereby, lead to reduced CGRs. In the absence of residual stresses, when subjected to a thermal treatment (650 °C/100 h), no observable variation in CGR is noticed over the entire crack length that encompassed two laser tracks. Leave from Defence Metallurgical Research Laboratory, Hyderabad, India,. U.S. government work not protected by u.s. copyright     

Effects of Processing Residual Stresses on Fatigue Crack Growth Behavior of Structural Materials: Experimental Approaches and Microstructural Mechanisms

Fatigue crack growth mechanisms of long cracks through fields with low and high residual stresses were investigated for a common structural aluminum alloy, 6061-T61. Bulk processing residual stresses were introduced in the material by quenching during heat treatment. Compact tension (CT) specimens were fatigue crack growth (FCG) tested at varying stress ratios to capture the closure and K _max effects. The changes in fatigue crack growth mechanisms at the microstructural scale are correlated to closure, stress ratio, and plasticity, which are all dependent on residual stress. A dual-parameter ΔK–K _max approach, which includes corrections for crack closure and residual stresses, is used uniquely to connect fatigue crack growth mechanisms at the microstructural scale with changes in crack growth rates at various stress ratios for low- and high-residual-stress conditions. The methods and tools proposed in this study can be used to optimize existing materials and processes as well as to develop new materials and processes for FCG limited structural applications.     

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.     

Effect of Hf and Zr Contents on Stress-rupture and Fatigue Crack Growth Rate Performances in FGH96PM Superalloy

Four experimental FGH96alloys with various contents of Hf and Zr(0and 0.04%,0.3% and 0.04%,0.6% and 0.04%,0.3%and 0.06%,respectively)were produced using PREP(plasma rotating electrode process)+HIP(hot isostatic pressing)route.The unnotched and notched stress-rupture properties and fatigue crack growth rate(FCGR)of all the experimental alloys were investigated to study the effect of Hf and Zr.Relevant fracture morphology and microstructure were observed by scanning electron microscopy and transmission electron microscopy.The results revealed that appropriate content of Hf could lengthen stress-rupture life,eliminate notch sensitivity and slower FCGR.Microstructure analysis showed that the amount ofγ′phase should be increased or decreased by adjusting Hf and Zr contents,and MC carbide and oxide coupled growth should be increased by adding Hf content,which caused oxycarbide to precipitate along grain boundary and strengthen the alloy.It was found that excessive Zr in Hfcontaining FGH96alloy had certain deleterious effects on stress-rupture property because there was strong Zr segregation at prior particle boundary,leaving a long chain of large-size oxides along the boundary.The optimal content of Hf and Zr in FGH96alloy was 0.6%and 0.04%,respectively.     

Effect of silicon particles on the fatigue crack growth characteristics of Al-12 Wt Pct Si-0.35 Wt Pct Mg-(0 to 0.02) Wt Pct Sr casting alloys

Fatigue crack growth (FCG) characteristics and mechanisms in Al-Si-Mg eutectic casting alloys containing 0.35 wt pct Mg and 0 to 0.02 wt pct Sr were investigated as a function of stress ratio,R, stress-intensity-factor range, ΔK, and silicon (Si) particle size. The fatigue crack propagation behavior was compared with that observed in commercial casting alloy A356. At the same applied ΔK level, the crack growth rate was found to increase with increasing stress ratio and Si particle size. Modified (fine Si morphology) and A356 alloys showed better FCG resistance than the unmodified (coarse Si morphology) ones, for a constant applied ΔK, due to increased closure. The effects of roughness-induced and plasticity-induced crack closures, crack branching, and crack meandering on the fatigue crack propagation observed in these alloys have been discussed. The fatigue crack propagation path is found to be dependent on the Si particle characteristics. The mechanisms of silicon particle decohesion and cracking are also discussed. Formerly Research Associate, Département des Sciences Appliquées, Université du Québec à Chicoutimi     

Effect of nitriding atmosphere on internal nitridation of superalloy

Under the nitriding condition of 1150??/20h, the ????155 alloy was subjected to different internal nitriding treatments. The effect of nitriding atmosphere on the nitriding process and nitriding surface was studied. The composition of the nitriding atmosphere was adjusted by mixing H2 and Ar in nitrogen, and the surface product and nitrided layer depth after nitriding were characterized by means of metallography, XRD and scanning electron microscopy. The results show that the residual oxygen in the high- purity N2 will lead to the existence of Cr and Ti- rich oxide films on the surface of the alloy after nitriding, but the oxide films can be eliminated by being mixed with 5 vol% H2; when N2 content in the mixed gas is high, Cr and Ti- rich nitrides exist on the surface of the alloy. As the N2 content in the gas decreases, the surface nitride decreases. When the volume fraction of N2 is lower than 40%, the surface nitrides disappear, meanwhile the depth of the nitriding layer increases with the increase of N2 content. It can be seen that the nitriding atmosphere has an important influence on the nitriding rate. Therefore, a combination of 40 vol%N2+5 vol%H2+55 vol% Ar nitriding atmosphere can achieve a combined effect of suppressing nitriding nitrides and increasing the nitridation rate.     

含有上贝氏体的ER8车轮钢的裂纹扩展行为

研究不同含量的上贝氏体对ER8车轮钢裂纹扩展行为的影响。利用激光共聚焦显微镜（LSCM）和扫描电镜（SEM）对ER8车轮钢的显微组织和裂纹扩展路径进行了研究。实验结果表明:ER8车轮钢中的组织除了有铁素体和珠光体,还存在上贝氏体;裂纹穿过上贝氏体和珠光体扩展,最终停止在珠光体区域;与珠光体组织相比,裂纹在上贝氏体中的扩展路径更曲折。利用扫描电镜（SEM）对ER8车轮钢的裂纹扩展变形进行原位观察。实验结果表明:含有80%上贝氏体的ER8车轮钢拉伸时,组织变形过程主要以铁素体和上贝氏体为主,裂纹在上贝氏体和珠光体中连续扩展,伴随着珠光体的变形;而含有50%上贝氏体的ER8车轮钢拉伸时,组织变形过程主要以铁素体和珠光体为主,并且上贝氏体对铁素体和珠光体的变形起到阻碍作用。上贝氏体能够有效地阻止裂纹扩展,在偏转裂纹路径和延缓裂纹扩展方面起着重要作用;并且对铁素体和珠光体的变形起到阻碍作用。      

Effect of phase morphology on fatigue crack growth behavior of α-β titanium alloy—A crack closure rationale

Effect of phase morphology on fatigue crack growth (FCG) resistance has been investigated in the case of an α-β titanium alloy. Fatigue crack growth tests with on-line crack closure measurements are performed in the microstructures varying in primary α (elongated/equiaxed/Widmanstätten) and matrix β (transformed/metastable) phase morphologies. The microstructures comprising metastable β matrix are observed to yield higher FCG resistance than those for transformed β matrix, irrespective of primary α phase morphology (equiaxed or elongated). But, the effect of primary α phase morphology is dictated by the type of β phase (transformed or metastable) matrix. It is observed that in the microstructures with metastable β matrix, the equiaxed primary α as second phase possesses higher FCG resistance as compared to that of elongated α morphology. The trend is reversed if the metastable β matrix is replaced by transformed β phase. The fatigue crack path profiles are observed to be highly faceted. The detailed fractographic investigations revealed that tortuosity is introduced as a result of cleavage in α or β or in both the phases, depending upon the microstructure. The crack closure concept has been invoked to rationalize the phase morphology effects on fatigue crack growth behavior. The roughness-induced and plasticity-induced crack closure appear to be the main mechanisms governing crack growth behavior in α-β titanium alloy.     

High-temperature fatigue crack growth behavior of 17-4 PH stainless steels

The fatigue crack growth (FCG) behavior was investigated for 17-4 PH stainless steels in three heat-treated conditions, i.e., unaged (condition A), peak-aged (condition H900), and overaged (condition H1150), at temperatures ranging from 300 °C to 500 °C. The high-temperature fatigue crack growth rates (FCGRs) of condition H1150 were increased with an increase in temperature. However, for conditions A and H900 tested at 500 °C, the FCGRs were lower than the lower temperature ones. At 300 °C and 400 °C, H1150 and H900 generally showed the lowest and highest FCGRs, respectively, with condition A demonstrating behavior between the two. At 500 °C, the FCGR curves for all material conditions merged together. The anomalous FCG behavior of 17-4 PH stainless steels at 500 °C was mainly caused by an in-situ precipitate-coarsening effect during test. This work was funded by the National Science Council of the Republic of China (Taiwan) under Contract Nos. NSC-90-2216-E-008-007 and NSC-91-2216-E-008-007.     

Environment-sensitive fracture of iron aluminides during cyclic crack growth

The present study investigates the fatigue-crack propagation resistance of an FeAl-based alloy, with a special emphasis placed on the analysis of the mechanisms involved in environmentally assisted crack growth. To this end, a series of tests have been conducted at room temperature in air, in high and low vacuum, and in argon. The results reveal a significant fatigue-crack growth (FCG) enhancement when the material is fatigued in a moist environment. This enhancement may, however, be inhibited by oxygen in the case of a low water-vapor partial pressure. Besides, the analysis of the results obtained under various exposure conditions suggests that the FCG enhancement in air is mostly controlled by water-vapor adsorption, which reduces the energy required to create a unit cracked area. Examination of dislocation structures within the plastic zone reveals a lower extent of plasticity in air, consistent with this mechanism. Predictions obtained by a model of adsorption-assisted propagation provide an additional support for the adsorption assumption. Finally, an FCG growth law is proposed to describe the intrinsic resistance as observed in inert environments and to account for the mechanism operative in fatigue-crack propagation in ambient air.     

Fatigue cracking characteristics of β-annealed large colony Ti-11 alloy

In order to better understand the large scatter in the fatigue results associated with β-annealed microstructures of α+ β titanium alloys, the fatigue crack initiation and propagation behavior of thin center notched Ti-11 specimens with a large colony α platelet microstructure was investigated. Colonies with a mean intercept diam of greater than 1 mm were grown in 2 mm thick specimens by means of a vacuum β-annealing process. This enabled crack path morphologies and crack propagation rates to be determined within single colonies by means of optical microscopy on the polished and etched surfaces. The results showed that the fracture is related to a shear mechanism across the colonies from the initiation stage through the overload fracture. Intense shear bands were observed ahead of and in the same direction as the propagating cracks. The density of the shear bands increased with increasing stress intensity. Since the colonies are randomly oriented, the fatigue cracks propagated at various angles with respect to the tensile axis. The crack propagation rate across a single colony is no faster than the propagation rate in the equiaxed α+ β microstructure of the same material. However, cracks were halted at the colony boundaries and forced to reinitiate through a cycle consuming process into the next colony. It is mainly this reinitiation process and microstructurally dependent growth which are responsible for the slower crack growth rates and large scatter band obtained for the β-annealed microstructures when compared to the α+ β microstructures. It is suggested that by reducing the colony size the crack growth rates will be reduced and the fatigue scatter band will be narrowed. Formerly with the Metals and Ceramics Division, Air Force Materials Laboratory, Wright-Patterson Air Force Base.     

316L不锈钢的疲劳裂纹扩展行为试验

 工程构件普遍承受疲劳载荷,从而导致疲劳失效。针对由316L不锈钢制成的标准紧凑拉伸试样,开展了一系列疲劳裂纹扩展试验。试验内容包括不同应力比下的常幅加载和在常幅加载过程中引入单个拉伸过载峰。试验结果表明：316L不锈钢具有很强的应力比效应,裂纹扩展速率随应力比的增大而增大。在引入单个拉伸过载峰后,观察到出现迟滞效应前发生了短暂的加速扩展现象。通过一种新的双参数模型来描述材料的应力比效应,并使用改进的Wheeler模型对过载后的裂纹扩展行为进行预测。预测结果表明：该方法能够更好地描述不同工况下316L不锈钢的疲劳裂纹扩展行为。     

The influence of Mo2C morphology and distribution on the fatigue crack initiation and propagation behavior of Fe-C-Mo dual-phase steels

Dual-phase microstructures consisting of ferrite with carbides (Mo₂C) surrounding equiaxed martensite packets have been developed in two alloys, Fe-O. 2C-4Mo and Fe-O. 2C-2Mo. These alloys were chosen because of the presence of two distinct carbide morphologies: (1) a needle-shaped interphase carbide structure, and (2) a fibrous carbide structure. Isothermal transformations were used to control the carbide morphology and distribution in the ferritic regions of the dual-phase microstructures. In the present research the effects of changes in carbide structure on low cycle fatigue (LCF) and fatigue crack growth (FCG) behavior were studied. Crack initiation was observed at prior austenite grain boundaries in the fibrous microstructure, and along intrusion/extrusion defects in the interphase needle microstructures for LCF tests. TEM studies revealed a carbide free region at prior austenite grain boundaries where initiation occurs for the fibrous case. The cyclic stress/strain response of the ferritic portions of the microstructure is determined by the ability of the carbides to homogenize the strain found there. This affects the stress/strain distribution in the composite ferrite-martensite microstructure by changing the hardness ratio of the two phases and subsequently alters the fatigue crack growth behavior and the macroscopic cyclic stress/strain response. Strain localization was also found to affect the roughness induced closure found for fatigue crack growth tests for low R tests (R = 0.1).     

Effect of Loading History on Stress Corrosion Cracking of 7075-T651 Aluminum Alloy in Saline Aqueous Environment

An experimental study of stress corrosion cracking (SCC) was conducted on 7075-T651 aluminum alloy in a chromate-inhibited, acidic 3.5 pct sodium chloride aqueous solution using compact tension specimens with a thickness of 3.8 mm under permanent immersion conditions. The effects of loading magnitude, overload, underload, and two-step high-low sequence loading on incubation time and crack growth behavior were investigated. The results show that the SCC process consists of three stages: incubation, transient crack growth, and stable crack growth. The incubation time is highly dependent on the load level. Tensile overload or compressive underload applied prior to SCC significantly altered the initiation time of corrosion cracking. Transition from a high to a low loading magnitude resulted in a second incubation but much shorter or disappearing transient stage. The stable crack growth rate is independent of stress intensity factor in the range of 10 to 22 MPa ?{\textm} . \sqrt {\text{m}} .     

基于有限元方法的疲劳裂纹闭合行为

裂纹闭合行为将很大程度改变疲劳裂纹扩展行为。针对316L不锈钢,结合常幅加载和单个拉伸过载试验和动态数值模拟方法,对疲劳裂纹扩展行为中的裂纹闭合现象开展了一系列研究工作。详细对比了不同扩展阶段的裂纹闭合行为随裂纹长度、应力比和过载影响因素的变化,以及对裂纹扩展速率的影响。同时,研究了单个拉伸过载和裂纹闭合行为之间的内在联系和机理。结合裂纹闭合理论和有限元计算结果,等效应力强度因子被用来描述316L不锈钢的裂纹扩展过程,并提出316L不锈钢的裂纹扩展速率的预测模型。     

Evolution of Surface Transversal Crack in Intermediate Slabs during Hot Rolling Deformation

In the continuous casting of steels,surface transversal cracks are often found.These defects may severely influence the final quality of the products.The evolution of transversal V-shaped cracks with different depth on the surface of a continuously cast steel slab during hot rolling was studied.The artificial V-shaped cracks were made on the surface.The rolling process parameters from an industrial rolling mill have been used as a reference.The specimens of rolled workpiece in intermediate slabs were obtained after different rolling passes.The morphology of surface crack and microstructure evolution in the rolling process were investigated by optical microscopy.The results show that the depth of surface transversal crack gradually decreased with the increase of rolling passes.The grain size of ferrite and pearlite on the sample surface also gradually reduced.The microstructures around cracks with the different depth are almost identical,without direct correlation with the initial crack depth.