Prediction of short fatigue crack growth of Ti‐6Al‐4V

It is observed that the short fatigue cracks grow faster than long fatigue cracks at the same nominal driving force and even grow at stress intensity factor range below the threshold value for long cracks in titanium alloy materials. The anomalous behaviours of short cracks have a great influence on the accurate fatigue life prediction of submersible pressure hulls. Based on the unified fatigue life prediction method developed in the authors' group, a modified model for short crack propagation is proposed in this paper. The elastic–plastic behaviour of short cracks in the vicinity of crack tips is considered in the modified model. The model shows that the rate of crack propagation for very short cracks is determined by the range of cyclic stress rather than the range of the stress intensity factor controlling the long crack propagation and the threshold stress intensity factor range of short fatigue cracks is a function of crack length. The proposed model is used to calculate short crack propagation rate of different titanium alloys. The short crack propagation rates of Ti‐6Al‐4V and its corresponding fatigue lives are predicted under different stress ratios and different stress levels. The model is validated by comparing model prediction results with the experimental data.     

Residual stress effects on fatigue crack growth in a Ti‐6Al‐4V friction stir weld

Recent studies have illustrated a predominant role of the residual stress on the fatigue crack growth in friction stir welded joints. In this study, the role of the residual stress on the propagation of fatigue cracks orthogonal to the weld direction in a friction stir welded Ti‐6Al‐4V joint was investigated. A numerical prediction of the fatigue crack growth rate in the presence of the residual stresses was carried out using AFGROW software; reasonable correspondence between the predictions and the experimental results were observed when the effects of residual stress were included in the simulation.     

Initiation and growth behaviour of small internal fatigue cracks in Ti‐6Al‐4V via synchrotron radiation microcomputed tomography

Small internal fatigue cracks initiated in Ti‐6Al‐4V in the very high cycle regime were detected by synchrotron radiation microcomputed tomography (SR‐μCT) at SPring‐8 in Japan. The initiation and growth behaviours of the cracks were nondestructively observed, and the da/dN‐ΔK relationship was measured and compared with that obtained in a high vacuum environment. SR‐μCT revealed that more than 20 cracks were initiated in one specimen. The crack initiation life varied widely from 20% to 70% of the average fatigue life and had little influence on the growth behaviour that followed. The initiation site size of each internal crack detected in one specimen was comparable with the size of the fracture origins obtained in ordinary fatigue tests. These results suggest that the surrounding microstructures around the initiation site are likely a dominant factor on the internal fracture rather than the potential initiation site itself. The internal crack growth rates were lower than 10^?10 m/cycle, and extremely slow rates ranging from 10^?13 to 10^?11 m/cycle were measured in a lower ΔK regime below 5 MPa√m. The internal crack growth rate closely matched that of surface cracks in a high vacuum, and the reason for the very long life of internal fatigue fractures was believed to result from the vacuum‐like environment inside the internal cracks.     

Fracture toughness and fatigue crack growth in Ti‐6Al‐4V friction stir welds

Friction stir welding of titanium holds the promise for producing joints with microstructures and mechanical properties that are more comparable to wrought material than traditional fusion welding processes. Extensive data exist on the microstructure and static mechanical properties of titanium friction stir welds, but very little are available on the durability (fatigue) and even less on the damage tolerance (fracture toughness and fatigue crack growth). This paper presents the results of an investigation into the damage tolerance of friction stir welds made in 6 mm thick Ti‐6Al‐4V after a post‐weld heat treatment. It was found that the apparent fracture toughness was lower than the wrought base material, 7–25% depending on the crack orientation relative to the weld, but the crack growth performance (ΔK vs. da/dN) of the weld in the absence of weld‐induced residual stresses was identical to the base material.     

Low‐cycle fatigue/high‐cycle fatigue interactions in notched Ti‐6Al‐4V*

Combined low‐cycle fatigue/high‐cycle fatigue (LCF/HCF) loadings were investigated for smooth and circumferentially V‐notched cylindrical Ti–6Al–4V fatigue specimens. Smooth specimens were first cycled under LCF loading conditions for a fraction of the previously established fatigue life. The HCF 10⁷ cycle fatigue limit stress after LCF cycling was established using a step loading technique. Specimens with two notch sizes, both having elastic stress concentration factors of K_t = 2.7, were cycled under LCF loading conditions at a nominal stress ratio of R = 0.1. The subsequent 10⁶ cycle HCF fatigue limit stress at both R = 0.1 and 0.8 was determined. The combined loading LCF/HCF fatigue limit stresses for all specimens were compared to the baseline HCF fatigue limit stresses. After LCF cycling and prior to HCF cycling, the notched specimens were heat tinted, and final fracture surfaces examined for cracks formed during the initial LCF loading. Fatigue test results indicate that the LCF loading, applied for 75% of total LCF life for the smooth specimens and 25% for the notched specimens, resulted in only small reductions in the subsequent HCF fatigue limit stress. Under certain loading conditions, plasticity‐induced stress redistribution at the notch root during LCF cycling appears responsible for an observed increase in HCF fatigue limit stress, in terms of net section stress.     

Fretting fatigue crack analysis in Ti–6Al–4V

A study was conducted to verify the efficacy of a fracture mechanics methodology to model the crack growth behavior of fretting fatigue-nucleated cracks obtained under test conditions similar to those found in turbine engine blade attachments. Experiments were performed to produce cracked samples, and fretting fatigue crack propagation lives were calculated for each sample. Cracks were generated at 10⁶ cycles (10%-of-life) under applied stress conditions previously identified as the fretting fatigue limit conditions for a 10⁷ cycle fatigue life. Resulting cracks, ranging in size from 30 to 1200 μm, were identified and measured using scanning electron microscopy. Uniaxial fatigue limit stresses were determined experimentally for the fretting fatigue-cracked samples, using a step loading technique, for R=0.5 at 300 Hz. Fracture surfaces were inspected to characterize the fretting fatigue crack front indicated by heat tinting. The shape and size of the crack front were then used in calculating ΔKth values for each crack. The resulting uniaxial fatigue limit and ΔKth values compared favorably with the baseline fatigue strength (660 MPa) for this material and the ΔKth value (2.9 MPa√m) for naturally initiated cracks tested at R=0.5 on a Kitagawa diagram.Crack propagation lives were calculated using stress results of FEM analysis of the contact conditions and a weight function method for determination of ΔK. Resulting lives were compared with the nine million-cycle propagation life that would have been expected in the experiments, if the contact conditions had not been removed. Scatter in the experimental results for fatigue limit stresses and fatigue lives had to be considered as part of an explanation why the fatigue life calculations were unable to match the experiments that were modeled. Analytical life prediction results for the case where propagation life is observed to be very short experimentally were most accurate when using a coefficient of friction, μ=1.0, rather than for the calculations using μ=0.3     

Nanograin layer formation at crack initiation region for very‐high‐cycle fatigue of a Ti–6Al–4V alloy

The microstructural features and the fatigue propensities of interior crack initiation region for very‐high‐cycle fatigue (VHCF) of a Ti–6Al–4V alloy were investigated in this paper. Fatigue tests under different stress ratios of R = ?1, ?0.5, ?0.1, 0.1 and 0.5 were conducted by ultrasonic axial cycling. The observations by SEM showed that the crack initiation of VHCF presents a fish‐eye (FiE) morphology containing a rough area (RA), and the FiE and RA are regarded as the characteristic regions for crack initiation of VHCF. Further examinations by TEM revealed that a layer of nanograins exists in the RA for the case of R = ?1, while nanograins do not appear in the FiE outside RA for the case of R = ?1, and in the RA for the case of R = 0.5, which is explained by the Numerous Cyclic Pressing model. In addition, the estimations of the fatigue propensities for interior crack initiation stage of VHCF indicated that the fatigue life consumed by RA takes a dominant part of the total fatigue life and the related crack propagation rate is rather slow.     

Effects of Shot‐Peening on Fretting Fatigue Crack Growth Behavior in Ti‐6Al‐4V

Abstract: The effects of shot‐peening on fretting fatigue crack growth behaviour in titanium alloy, Ti‐6A1‐4V were investigated. Three shot‐peening intensities: 4A, 7A and 10A were considered. The analysis involved the fracture mechanics and finite element sub‐modelling technique to estimate crack propagation lives. These computations were supplemented with the experimentally measured total fretting fatigue lives of laboratory specimens to assess the crack initiation lives. Shot‐peening has significant effect on the initiation/propagation phases of fretting fatigue cracks; however this effect depends upon the shot‐peening intensity. The ratio of crack initiation and total life increased while the ratio of the crack propagation and total life decreased with an increase of shot‐peening intensity. Effects of residual compressive stress from shot‐peening on the crack growth behaviour were also investigated. The fretting fatigue crack propagation component of the total life with relaxation increased in comparison to its counterpart without relaxation in each shot‐peened intensity case while the initiation component decreased. Improvement in the fretting fatigue life from the shot‐peening and also with an increase in the shot‐peening intensity appears to be not always due to increase in the crack initiation resistance from shot‐peened induced residual compressive stress.     

Effect of build direction on the fracture toughness and fatigue crack growth in selective laser melted Ti‐6Al‐4 V

Experimental investigation was conducted to evaluate the fracture toughness and fatigue crack growth characteristics in selective laser‐melted titanium 6Al‐4 V materials as a follow‐on to a previous study on high cycle fatigue. For both the fracture toughness and crack growth evaluation, the compact tension specimen geometry was used. It was found that the fracture toughness was lower than what would be expected from wrought or cast product forms in the same alloy. This was attributed to the rapidly cooled, martensitic microstructure, developed in the parts. At low stress ratios, the crack growth rates were faster than in wrought titanium but became comparable at higher ratios. The fracture toughness appears to be higher when the crack is oriented perpendicular to the build layers. The difference in the average threshold and critical stress intensity values for the crack growth results for the three orientations was within the scatter of the data, so there was essentially no difference. The same was true for the empirically derived Paris Law constants. Residual stresses were likely to have overshadowed any variation in crack growth because of microstructural directionalities associated with build orientation.     

Fracture toughness and fatigue crack growth rate properties in wire + arc additive manufactured Ti‐6Al‐4V

This paper presents an experimental investigation of the fracture and fatigue crack growth properties of Ti‐6Al‐4V produced by the Wire + Arc Additive Manufacture (WAAM®) process. First, fracture toughness was measured for two different orientations with respect to the build direction; the effect of wire oxygen content and build strategy were also evaluated in the light of microstructure examination. Second, fatigue crack growth rates were measured for fully additive manufactured samples, as well as for samples containing an interface between WAAM® and wrought materials. The latter category covers five different scenarios of crack location and orientation with respect to the interface. Fatigue crack growth rates are compared with that of the wrought or WAAM® alone conditions. Crack growth trajectory of these tests is discussed in relation to the microstructure characteristics.     

Probabilistic modeling of fatigue crack growth in Ti–6Al–4V

This paper proposes an approximate approach to efficient estimation of some variabilities caused by the material microstructural inhomogeneities. The approach is based on the results of a combined experimental and analytical study of the probabilistic nature of fatigue crack growth in Ti–6Al–4V. A simplified experimental fracture mechanics framework is presented for the determination of statistical fatigue crack growth parameters from two fatigue tests. The experimental studies suggest that the variabilities in long fatigue crack growth rate data and the Paris coefficient are well described by the log-normal distributions. The variabilities in the Paris exponent are also shown to be well characterized by a normal distribution. The measured statistical distributions are incorporated into a probabilistic fracture mechanics framework for the estimation of material reliability. The implications of the results are discussed for the probabilistic analysis of fatigue crack growth.     

Local texture and fatigue crack initiation in a Ti-6Al-4V titanium alloy

ABSTRACT Fatigue crack initiation was studied in a bimodal TA6V titanium alloy. A ghost structure inherited from the forging process, the scale of which is roughly 100 times the apparent grain size, was found to govern the initiation process. In these macrograins, that we have labelled macrozones, most of the primary alpha grains (α_p) are found to display the same crystallographic orientation. Fatigue cracks are initiated on the basal plane or, if basal slip is difficult, on the prismatic plane. Thus in macrozones, where basal or prismatic slip is easy, numerous neighbouring tiny cracks appear over the whole macrozone, which have the size of the primary α_p grains. In these macrozones the contribution of crack coalescence to crack growth is consequently very significant. On the contrary, if basal and prismatic slips are both difficult in the macrozone, no crack can be found in the corresponding macrozone. The crack initiation process is thus highly heterogeneous at the scale of the macrozone. Furthermore, this microstructure is found to induce a large scatter in the fatigue life of notched samples.     

Influence of microstructure on fatigue crack propagation under bending in the alloy Ti–6Al–4V after heat treatment

The paper presents the test results obtained for fatigue crack growth in Ti–6Al–4V titanium alloy subjected to bending. The tests were performed in plane specimens with the stress concentrators being a one‐sided sharp notch. The tested specimens were made of the oxygenated Ti–6Al–4V subjected to various variants of heat treatment. The tests were carried out at the fatigue test stand MZGS‐100 under loading frequency 28.4 Hz. From the obtained results of fatigue and structural tests it appears that schemes of crack propagation and fatigue lives of the considered alloy are different depending on a structure obtained as a result of a given heat treatment.     

Small fatigue crack growth behavior of titanium alloy TC4 at different stress ratios

In this paper, the small fatigue crack behavior of titanium alloy TC4 at different stress ratios was investigated. Single‐edge‐notch tension specimens were fatigued axially under a nominal maximum stress of 370 MPa at room temperature. Results indicate that fatigue cracks in TC4 initiate from the interface between α and β phases or within α phase. More than 90% of the total fatigue life is consumed in the small crack initiation and growth stages. The crack growth process of TC4 can be divided into three typical stages, ie, microstructurally small crack stage, physically small crack stage, and long crack stage. Although the stress ratio has a significant effect on the total fatigue life and crack initiation life at constant σ_max, its effect on crack growth rate is indistinguishable at R = ?0.1, 0.1, and 0.3 when crack growth rate is plotted as a function of ?K.     

Effects of microstructural through‐thickness non‐uniformity and crack size on fatigue crack propagation and fracture of rolled Al‐7075 alloy

Some of the fatigue tests performed using the standard compact tension (CT) and a non‐standard specimen made of rolled 7075 aluminium alloy exhibit fatigue crack growth (FCG) lagging in a small region along the crack front. Through‐thickness microstructural evaluation shows that material grains in this region did not flatten as much as other regions. In the non‐standard specimen, surface cracks are either grown under fatigue loading or broken under monotonically increasing quasi‐static loads at different crack sizes. The aforementioned lagging also exists in a narrow region of 3‐D FCG for specimens with microstructural through‐thickness non‐uniformity. A more important feature for this type of specimen with surface crack is the deflection of fast fracture direction into the grain interfaces, namely from L‐T orientation to S‐L and S‐T directions. It is proved that this is due to significant levels of second principal stresses near the free surface for small cracks and lower fracture toughness of the material in S‐L and S‐T directions.     

Effects of stress ratio and temperature on fatigue crack growth in a Ti–6Al–4V alloy

Fatigue thresholds and fatigue crack growth (FCG) rates in corner notched specimens of a forged Ti–6Al–4V aero-engine disk material were investigated at room temperature and 350 °C. The threshold stress intensity range, ΔK_th, was determined by a method involving a step change in stress ratio (the ‘jump in’ method). It was found that for three high stress ratios (R=0.7–0.9), where crack closure effects are widely accepted to be negligible, there were similar ΔK_th values at room temperature and 350 °C under the same R. For a given temperature, ΔK_th was observed to decrease from 3.1 to 2.1 MPam with R increasing from 0.7 to 0.9. The fatigue crack growth rate was influenced by increasing temperature. For high stress ratios, FCG rate at 350 °C was higher than that at room temperature under the same ΔK. For a low stress ratio (R=0.01), higher temperature led to higher FCG rates in the near-threshold regime, but showed almost no effect at higher ΔK. The influence of stress ratio and temperature on threshold and FCG rates was analysed in terms of a K_max effect and the implication of this effect, or related mechanisms, are discussed. In light of this, an equation incorporating the effects of the K_max and fatigue threshold, is proposed to describe FCG rates in the near-threshold and Paris regimes for both temperatures. The predictions compare favourably with experimental data.     

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.     

Fretting fatigue behavior of shot-peened Ti–6Al–4V under seawater environment

The fretting fatigue behavior of the shot-peened titanium alloy, Ti–6Al–4V, was investigated under a seawater environment using a servo-hydraulic fatigue test machine equipped with a rigid fretting fixture. Fretting fatigue tests were performed over a wide range of stress levels to characterize the effects of seawater at high and low cycle fatigue regimes. The results of this study showed that (1) seawater reduces the fretting fatigue life of shot-peened Ti–6Al–4V in both high and low cycle fatigue regimes relative to their counterparts in ambient laboratory condition, and (2) shot-peening increases the fretting fatigue life of Ti–6Al–4V when tested under dry or seawater condition relative to its counterpart of unpeened Ti–6Al–4V. The seawater environment promotes an increase in crack propagation rate; however the crack initiation depends upon the combination of the detrimental effect from seawater environment and the beneficial effect from the residual compressive stress from shot-peening. In the present study, it appears that their cumulative effects were dominated by the residual compressive stress in both low cycle and high cycle fatigue regimes. On the other hand, the seawater environment has detrimental effect on the fretting fatigue life of unpeened Ti–6Al–4V than that in ambient laboratory condition in the low cycle fatigue regime while it improves slightly the life in the high cycle fatigue regime.     

Influence of foreign object impact mode on fatigue performance of 2198‐T8 Al‐Li alloy thin sheets for fuselage

The 2198‐T8 is the advanced aircraft aluminium‐lithium alloy used for airframe construction. Based on the digital image correlation technique, the postimpact fatigue performance of 2198‐T8 aluminium‐lithium alloy sheets was analysed. The foreign object impact mode includes a single impact, continuous twice‐impacts at the same position and impacts at two parallel positions. For each mode, the collapse behaviours with different impact energies and insert dimensions were investigated. The results could show that residual fatigue life is sensitive to the impact mode, and through digital image correlation (DIC) nephogram analysis, on the surface of dented specimens, there exists the redistribution of strain field. For three types of impact modes, the concept of average damage volume is introduced to fit the effect of dent depth and width on residual fatigue life; the goodness of fit for the whole average damage volume is 89.5%. The crack initiation and propagation of the postimpact fatigue specimen will be affected by the stress concentration and microstructure, and the local multiaxial strain status around the dent will accelerate the crack propagation.     

High‐cycle fatigue properties of beta Ti alloy 55Ti–30Nb–10Ta–5Zr,gum metal

This paper describes the fatigue properties of the beta titanium alloy 55Ti–30Nb–10Ta–5Zr, generally referred to as ‘Gum Metal’. Rotating bending fatigue tests have been performed in laboratory air and in a 3% NaCl aqueous solution. The results obtained were compared with those of a conventional beta titanium alloy, Ti–22V–4Al. In tensile tests, 55Ti–30Nb–10Ta–5Zr indicated elasticity and microplasticity in the elastic region. Thus, the elastic modulus slightly decreased with an increasing strain, and the work hardening was minimal during plastic deformation. The mechanical properties of both of the alloys were comparable. The fatigue strength of 55Ti–30Nb–10Ta–5Zr in laboratory air was higher than that of Ti–22V–4Al, which could be attributed to the higher fatigue crack initiation resistance of 55Ti–30Nb–10Ta–5Zr than Ti–22V–4Al, while the resistance to small fatigue crack growth was similar. The fatigue strength of 55Ti–30Nb–10Ta–5Zr in laboratory air and in the 3% NaCl aqueous solution was analogous. In addition, corrosion pits were not observed in the run‐out specimen in the 3% NaCl aqueous solution, indicating a high resistance of 55Ti–30Nb–10Ta–5Zr against corrosion fatigue.