The effect of angle on dovetail fretting experiments in Ti-6Al-4V

The objective of this work was to compare the fretting fatigue performance of Ti‐6Al‐4V dovetail specimens on Ti‐6Al‐4V pads having various contact angles typical of engine hardware; 35°, 45° and 55° dovetail angles were considered. The dovetail fixtures were instrumented with strain gages so that the local normal and shear contact forces could be calculated. The contact force hysteresis loops were recorded showing the stick‐slip history. At R= 0.1, gross slip was observed for several thousand cycles followed by partial slip after the average coefficient of friction increased. At R= 0.5, gross slip was present only during the first half cycle. During partial slip, the slope of the shear versus normal force was a function of the dovetail angle. The local contact loads, therefore, differed for the same remotely applied force. Despite this, the fretting fatigue life depended primarily on the remotely applied load not dovetail angle.     

Failure analysis of Ti6Al4V gas turbine compressor blades

The failure mechanism of Ti6Al4V compressor blades of an industrial gas turbine was analysed by means of both experimental characterisations and numerical simulation techniques. Several premature failures were occurred in the high pressure section of the compressor due to the fracture of the blade roots. Metallurgical and mechanical properties of the blade alloy were evaluated. A 2D finite element model of the blade root was constructed and used to provide accurate estimates of stress field in the dovetail blade root and to determine the crack initiation in the dovetail.

The results showed no metallurgical and mechanical deviations for the blade materials from standards. SEM fractography showed different aspects of fretting fatigue including multiple crack initiation sites, fatigue beach marks, debris particles, and a high surface roughness in the edge of contact (EOC). The numerical model clearly showed the region of highest stress concentration at the front EOC of the blade root in the dovetail region, correlated closely with the experimentally characterised fatigue crack region. It was concluded that this failure has occurred due to the tight contact between the blade root and the disk in the dovetail region as well as low wear resistance of the blade root.     

Fretting fatigue behaviour of shot-peened Ti-6Al-4V at room and elevated temperatures

Fretting fatigue behaviour of shot‐peened titanium alloy, Ti‐6Al‐4V was investigated at room and elevated temperatures. Constant amplitude fretting fatigue tests were conducted over a wide range of maximum stresses, σ_max= 333 to 666 MPa with a stress ratio of R= 0.1 . Two infrared heaters, placed at the front and back of specimen, were used to heat and maintain temperature of the gage section of specimen at 260 °C. Residual stress measurements by X‐ray diffraction method before and after fretting test showed that residual compressive stress was relaxed during fretting fatigue. Elevated temperature induced more residual stress relaxation, which, in turn, decreased fretting fatigue life significantly at 260 °C. Finite element analysis (FEA) showed that the longitudinal tensile stress, σ_xx varied with the depth inside the specimen from contact surface during fretting fatigue and the largest σ_xx could exist away from the contact surface in a certain situation. A critical plane based fatigue crack initiation model, modified shear stress range parameter (MSSR), was computed from FEA results to characterize fretting fatigue crack initiation behaviour. It showed that stress relaxation during test affected fretting fatigue life and location of crack initiation significantly. MSSR parameter also predicted crack initiation location, which matched with experimental observations and the number of cycles for crack initiation, which showed the appropriate trend with the experimental observations at both temperatures.     

Mechanics of two-stage crack growth in fretting fatigue

Motivated by experimental observations, we carry out a numerical analysis of the two-stage crack growth under fretting fatigue by using an efficient and accurate boundary element method. To start with, the variation of stress field during a loading cycle is analyzed. Various values of friction coefficient in the contact zone are considered, which is shown to considerably affect the stress field. Then, by assuming crack initiation to occur in the shear mode, a surface-breaking crack is introduced to the specimen at the location of highest shear-stress amplitude. The crack-tip stress intensity factors (SIFs) are calculated for various crack lengths and at various crack angles ranging from 25° to 45° about the contact surface. It is shown that, for a loading ratio of 0.5, the cyclic mode-II SIF amplitude decreases with increasing crack length, whilst its mean value increases. It suggests that the (first-stage) shear crack would sooner or later become dormant, or switch to another mode that can provide continuous support of growth. Then, the first-stage shear crack is manually kinked into a second-stage opening crack, and the follow-on driving force is analyzed. It is shown that the kinking event is only favored after the first-stage crack has grown to a certain length. The present study thus provides insights in the mechanics of two-stage crack growth that has been frequently observed in a typical dovetail joint under fretting fatigue. It also suggests an improved experimental setup to quantitatively investigate the fretting fatigue in dovetail joints.     

An apparatus for quantitative fretting testing

The design and construction of an apparatus for performing quantitative fretting fatigue experiments is described. The device allows accurate measurement and control of normal contact force, tangential contact force, relative displacement between contacting surfaces and bulk fretting loads, as well as measurement of average friction coefficients. Its design is simple, and includes interchangeable fretting contact pads, allowing the use of various pad geometries without major adjustment. The device incorporates many points of adjustment for alignment and compliance, making it a robust frame for a wide variety of fretting fatigue conditions involving different materials. The capabilities of this device are also verified by results of fretting fatigue experiments conducted on a 7075-T6 aluminium alloy.     

FRETTING FATIGUE OF AN AUSTENITIC STAINLESS STEEL IN SEAWATER

Abstract— Fretting fatigue tests of an austenitic stainless steel used for a propeller tail shaft were carried out in seawater and in air. In seawater, fretting significantly reduced the fatigue strength, however, the fretting fatigue lives at higher levels of stress were longer than those in air. The tangential force coefficient (defined as the ratio of the frictional force amplitude and the contact load) in seawater was much lower than that in air and varied in the range from 0.3 to 0.5 during the fretting fatigue tests. The lower tangential force coefficient in seawater seems to be the main reason for the longer fretting fatigue life in seawater. The prediction of fretting fatigue life was made on the basis of elastic-plastic fracture mechanics, where the frictional force between the specimen and the contact pad was taken into consideration. The predicted fatigue lives agreed well with the experimental results in both air and seawater.     

Cyclic plastic behavior of dovetail under fretting load

The high gradient stresses near the edge of contact zone in dovetail assemblies will result in the appearance of a small plastic zone, which makes it difficult to calculate the contact stresses accurately. These calculated stresses are the premise to evaluate the strength of dovetail assemblies, but the majority of previous research on the solution of contact stresses have been usually carried out under linear elastic conditions. Thus this study focuses on characterizing the plasticity occurred in the dovetail assemblies under cyclic loading. A viscoplastic constitutive model of the titanium alloy TC4 is established based on the Chaboche theory. Furthermore, the calculation of contact stresses is carried out by use of the finite element method (FEM) with the constitutive model. The distribution feature of the contact stresses along the contact surface and the depth direction is obtained. The results show that the cyclic stress characteristics i.e. stress gradient, cyclic peak stress, and stress ratio, are not the same at different locations, namely different nodes of the FE model along the contact surface and the depth direction. These differences would make it more difficult to select suitable parameters for life prediction and to identify the most important effect factor. It is meaningful that the results of the study could provide some useful data and an idea for obtaining suitable parameters in fretting fatigue life prediction. The life prediction method with the effect of stress gradient considered may become an efficient approach to predict the fretting fatigue life of dovetail assemblies.     

Influence of contact configuration on fretting fatigue behavior of Ti–6Al–4V under independent pad displacement condition

Fretting fatigue tests were conducted, using cylindrical pad and flat pad with rounded edges, at various applied pad displacements and at two normal forces on the pad under a constant bulk stress amplitude condition. The evolution of tangential force was independent of the contact configuration at a given normal force. The ratio of the tangential force to normal force increased and stabilized to a certain value with increasing applied pad displacement. The minimum fretting fatigue life was observed at the relative slip range between 50 and 60 μm and it was independent of both contact configuration and applied normal force. With increase in the applied pad displacement the response of the tangential force (Q) and the relative slip (δ) showed different fretting conditions, i.e. stick, stick-slip and gross slip. The gross slip condition was characterized by rectangular shape of the Q–δ curve with or without monotonically increasing value of Q with increasing fretting fatigue cycles. Surface profile on the fretting scar was affected by the contact configurations. For cylinder-on-flat contact, the profile showed surface damage (e.g. material loss or wear) along the entire contact area. However, the fretting damage in flat-on-flat (with rounded edges) contact was concentrated on the edge, not affecting much of the flat portion of the fretting scar.     

Fatigue of Low-Carbon and Low-Alloyed Steels for the Automotive Industry. Part 2. Estimation of the Fretting Effect on Fatigue Life by Measuring Electric Microcurrents in the Contact and Sliding Zone

The paper presents a procedure of measuring electric microcurrents in the contact and sliding zone during fretting fatigue. We show the experimentally found patterns of variation of electric currents in the course of testing. The electric currents in fretting fatigue in the case of low-alloyed steels are shown to be much higher than those in the case of low-carbon steels. This finding corresponds also to a more intense decrease in the fatigue characteristics of the low-alloyed steels. We propose to use the specified electric parameters for the comparative estimation of the compatibility of materials under fretting conditions.     

Fretting–fatigue behavior of steel wires in low cycle fatigue

The effect of strain amplitude on fretting–fatigue behavior of steel wires in low cycle fatigue was investigated using a fretting–fatigue test rig which was capable of applying a constant normal contact load. The fretting regime was identified based on the shape of the hysteresis loop of tangential force versus displacement amplitude. The variations of the normalized tangential force with increasing cycle numbers and fretting–fatigue lives at different strain amplitudes were explored. The morphologies of fretting contact scars after fretting–fatigue tests were observed by scanning electron microscopy and optical microscopy to examine the failure mechanisms of steel wires. The acoustic emission technique was used to characterize the fretting–fatigue damage in the fretting–fatigue test. The results show that the fretting regimes are all located in mixed fretting regimes at different strain amplitudes. The increase in strain amplitude increases the normalized tangential force and decreases the fretting fatigue life. The abrasive wear, adhesive wear and fatigue wear are main wear mechanisms for all fretting–fatigue tests at different strain amplitudes. The accumulative total acoustic emission events during fretting–fatigue until fracture of the tensile steel wire decrease with increasing strain amplitude. An increase of the strain amplitude results in the accelerated crack nucleation and propagation and thereby the decreased life.     

Fretting fatigue in engineering alloys

The experimental procedures which have been used to carry out fretting fatigue tests are reviewed and the preferred specimen and contact pad geometries and method of testing are identified. The S–N curves generated with and without fretting and subsequent analysis have been used to satisfy a number of objectives: (1) to establish the important variables which can significantly affect fretting fatigue behaviour; (2) to increase our fundamental understanding of the fretting fatigue process; and (3) to give a ranking of a diverse range of materials in terms of their resistance to fretting fatigue. The analytical methods which have been used to predict fretting fatigue crack initiation are briefly discussed. With some specimen/fretting pad material combinations, small fretting fatigue cracks are introduced at a very early stage in life and fracture mechanics methods are developed in order to model their growth. Analytical procedures for fretting fatigue based on either S–N endurance or fracture mechanics methodologies are discussed.     

微动疲劳中的应力状态参数和微动磨损参数的研究

本文对微动疲劳中的力学参数作出了研究。微动接触面上的力学参数可分为应力状态参数（SSP）和微动磨损参数（FWP）两类，并将应力状态参数综合为当量应力σ-1E,而将微动磨损参数用摩擦功W来表示．对桥式微动疲劳试件和燕尾型榫联接试件的数值分析表明，在微动接触面上疲劳断裂处的σ-1E和W值较大。因此，有可能使用了σ-1E和W值作为预测微动疲劳失效的两个基本参数。     

FRETTING FATIGUE AT ELEVATED TEMPERATURES IN TWO STEAM TURBINE STEELS

Abstract— —Fatigue tests and fretting fatigue tests of two steam turbine steels at room temperature and 773 K were carried out. The reduction of fatigue life and strength in the fretting test were significant at 773 K as well as at room temperature. The values of the friction coefficient at 773 K was almost equal to those at room temperature. The geometry of the fretting fatigue crack was flat in the early stage of fatigue life where a significant effect of fretting was observed. With increasing crack length and with a reducing effect of fretting, the fatigue crack shape changed to a semi-circular form. The fretting fatigue lives predicted on the basis of elastic-plastic fracture mechanics analysis, with the frictional force between the fretting pad and the specimen taken into consideration, agreed well with experimental results at both temperatures.     

Influence of contact pressure on fretting fatigue behaviour of AA 2014 alloy with dissimilar mating material

The effect of contact pressure on the fretting fatigue behaviour of 2014 Al alloy which has been solution heat treated and age hardened (T6 heat treatment) with dissimilar mating materials, was investigated. The fretting fatigue configuration involved bridge‐type contact pads on a flat fatigue specimen. Specimens were made of 2014 Al alloy and bridge‐type pads were made AISI 4140 steel. All the fatigue tests were conducted at a rotational speed of 5000 rpm with a rotating bending fatigue machine (R=?1), using S–N curves to evaluate the fatigue and fretting fatigue properties. The fretting fatigue strength of the material subject to a T6 heat treatment condition at 1 × 10⁷ cycles was dramatically reduced, as compared to that without fretting and with as‐cast. The fretting fatigue life exhibited a variable behaviour with an increase in the contact pressure. A scanning electron microscope was employed to observe the fretting scars and fracture surfaces of the specimens. This analysis showed that cracks originated at the contact surface and crack orientations were approximately ±56 ° from perpendicular to the loading direction.     

The effect of contact pad hardness on the fretting fatigue behaviour of AZ61 magnesium alloy

In the present study, the effect of hardness of contact material on fretting fatigue strength was experimentally investigated as a function of stress ratio. AZ61 magnesium alloy used in defense and transportation industries was used as the material for both the specimen and the contact pad. Two levels of hardness of contact material, 55.3 Vickers Hardness (HV) and 83.3 HV, were prepared by heat treatments. According to the results, with increasing hardness, the fretting fatigue strength decreased. The relative slip amplitude increased with increasing hardness, while the tangential force amplitude was not influenced by the hardness. It was speculated that because the local tangential stress at the contact edge increases with increasing hardness, the fretting fatigue strength decreases with increasing hardness.     

Effect of mean stress on fretting fatigue of Ti-6Al-4V on Ti-6Al-4V

Fretting fatigue tests of Ti‐6Al‐4V on Ti‐6Al‐4V have been conducted to determine the influence of stress amplitude and mean stress on life. The stress ratio was varied from R=−1 to 0.8. Both flat and cylindrical contacts were studied using a bridge‐type fretting fatigue test apparatus operating either in the partial slip or mixed fretting regimes. The fretting fatigue lives were correlated to a Walker equivalent stress relation. The influence of mean stress on fretting fatigue crack initiation, characterized by the value of the Walker exponent, is smaller compared with plain fatigue. The fretting fatigue knockdown factor based on the Walker equivalent stress is 4. Formation of fretting cracks is primarily associated with the tangential force amplitude at the contact interface. A simple fretting fatigue crack initiation metric that is based on the strength of the singular stress field at the edge of contact is evaluated. The metric has the advantage in that it is neither dependent on the coefficient of friction nor the location of the stick/slip boundary, both of which are often difficult to define with certainty a priori.     

Fretting fatigue behaviour of hard anodizing coated 2014‐T6 aluminium alloy with dissimilar mating materials under plane bending loading

The effect of hard anodizing coated 2014‐T6 aluminium alloy test samples with dissimilar mating materials on fretting fatigue was investigated. Fretting fatigue configuration involved bridge‐type pads on the flat specimen. Bridge‐type pads were made of AISI 4140 steel. All the fretting fatigue tests were conducted under plane bending loading with a stress ratio of R=?1. Coated and uncoated specimens were compared for microhardness, surface roughness, tangential force. The specimens were tested under both plain fatigue and fretting fatigue loading at ambient temperature. Micrographs obtained from scanning electron microscope showed that hard anodizing coating had tiny cracks through the thickness of the anodized layer. The hardness of hard anodized coating was higher than that of uncoated specimens and they also exhibited lower tangential force. However, the fretted region of the hard anodizing coated specimens was rougher than that of uncoated samples and despite lower tangential forces, fatigue lives of hard anodizing coated samples were inferior to those of uncoated samples. As the hard anodizing coating had pre‐existing tiny cracks and tension residual stress, cracks propagated from the hard anodizing coating through the interface into the substrate. We conclude that these may be the main reasons for inferior fretting fatigue lives compared with uncoated samples.     

微动疲劳研究进展

介绍了微动疲劳的概念和实验装置,详细综述了微动疲劳的国内外研究现状,全面地分析讨论了微动疲劳的影响因素(接触压力、滑移幅值、实验频率、摩擦力、环境、材料性质)、损伤机理、寿命评估方法和防护措施,并提出了今后研究的展望。     

High cycle fatigue mechanisms of aluminum self‐piercing riveted joints

A study examining the fatigue failure mechanism of self‐piercing riveted (SPR) joints between aluminum alloy 6111‐T4 and 5754‐O is presented in this paper. In particular, the high‐cycle fatigue behavior of the SPR joints in the lap‐shear configuration is characterized. Experimental fatigue testing revealed that failure of SPR joints occurred because of cracks propagating through the sheet thickness at locations away from the rivet. In‐depth postmortem analysis showed that significant fretting wear occurred at the location of the fatigue crack initiation. Energy dispersive X‐ray of the fretting debris revealed the presence of aluminum oxide that is consistent with fretting initiated fatigue damage. High‐fidelity finite element analysis of the SPR process revealed high surface contact pressure at the location of fretting‐initiated fatigue determined by postmortem analysis of failed coupons. Furthermore, fatigue modeling predictions of the number of cycles to failure based on linear elastic fracture mechanics supports the conclusion that fretting‐initiated fatigue occurred at regions of high surface contact pressure and not at locations of nominal high‐stress concentration at the rivet.     

Simulating fretting contact in single lap splices

Cracks in riveted lap splices commonly nucleate in regions of fretting damage around the fastener holes. The crack location is dependent upon the rivet squeeze force and the clamped faying surface area around the holes since fretting damage occurs at the edge of contact. Being able to predict the amount of faying surface clamping from rivet forming and the peaks in edge-of-contact stresses associated with fretting contact will help in the understanding of splice fatigue failure. This paper describes the development of a 3D finite element splice model that predicts the variation of contact area and edge-of-contact stresses in a loaded splice. The prediction is made for four rivet squeeze force levels and both universal and countersunk rivet styles.