Fatigue limit evaluation of notches,small cracks and defects: an engineering approach

In this paper, the average stress method for the fatigue limit evaluation of stress raising geometrical features is revised and extended. In particular, an analytical close‐form approach was used and the linear elastic stress equations were modified by taking into account the effect of nominal stress on the local stress distribution. Hence, the average tangential stress was correctly evaluated over a distance of 2a₀, where a₀ was El Haddad's short crack constant, for long and small notches as well as for crack‐like notches. When this model is applied to a wide range of geometrical features subjected to mode I fatigue loading, the classical shape of the curves of the Kitagawa–Takahashi diagram was obtained for changes in crack‐like notch size. Similarly, notch sensitivity was estimated by reducing the notch tip radius. The accuracy of the proposed method in predicting fatigue limits was then checked by using experimental data taken from the literature and generated on testing specimens weakened by rounded and sharp notches as well as by small artificial defects.     

具有阻力特性材料的σ_f－σ关系及一种新的阻力曲线测定方法

通过对相变增韧陶瓷及一种可切削玻璃－陶瓷动态疲劳（恒应力速率）试验中高应力速率区断裂应力下降现象的理论分析，发现这种现象与材料的阻力特性（Ｒ－ｃｕｒｖｅ）密切相关。确立的σ_ｆ－σ理论关系能够很好地描述整个应力速率区间内的动态疲劳试验结果。高应力速率区σ_ｆ－σ在双对数坐标下为负斜率直线，直线斜率为（ｍ为阻力曲线ＫＲ＝ｋ（△ａ）~ｍ的指数），断裂主要由材料阻力行为控制；低应力速率区，σ_ｆ－σ在双对数坐标下为正斜率直线，直线斜率为　（ｎ为应力腐蚀指数），断裂主要由材料应力腐蚀行为控制。建立了测定材料阻力特性的一种新方法，分别用这种方法及压痕／弯曲方法对一种可切削玻璃－陶瓷的阻力特性进行了实验测定，两种方法所得结果有很好的一致性。     

On the corrosion fatigue crack initiation model and expression of metallic notched elements

In the present study, attempts are made to extend the application of the mechanical model for the fatigue crack initiation (FCI) and the FCI life formula of metallic notched elements in laboratory air to those in the corrosive environment. The test results and analysis of the corrosion FCI (CFCI) life of aluminum alloys and Ti---6A1---4V show that the expression of the CFCI life obtained by modifying the FCI life formula in laboratory air can give a good fit to the test results of the CFCI life. The salt water (3.5% NaCl) environment has no effects on the CFCI resistant coefficient compared with the FCI resistant coefficient in laboratory air. However, 3.5% NaCl environment greatly decreases the CFCI threshold of aluminum alloy, but has little effect on the CFCI threshold of Ti---6A1---4V. The loading frequency ranging from 1 Hz to 10 Hz has no appreciable effect on the CFCI life, and thus, the CFCI threshold of aluminum alloys investigated. Hence, the expression for the CFCI life of metallic notched elements proposed in this study is a better one, which reveals a correlation between the CFCI life and the governing parameters, such as, the geometry of the notched elements, the nominal stress range, the stress ratio, the tensile properties and the CFCI threshold. However, this new expression of the CFCI life needs to be verified by more test results.     

氧化铝陶瓷缺口件循环疲劳及断裂机理

用实验方法研究了Ａｌ＿２Ｏ＿３陶瓷缺口试件在循环载荷作用下的疲劳寿命。结果表明，缺口导致的应力集中效应显著降低了循环疲劳寿命；若用缺口根部最大应力为应力水平，则不同缺口半径陶瓷试件具有相同疲劳断裂规律，说明陶瓷材料的疲劳集中系数和理论应力集中系数相同。本文还分析讨论了陶瓷材料的循环疲劳寿命表达式和循环疲劳断裂机理。     

Grain Boundary Sliding in Fatigue of Pure Aluminum

The distributions of plastic strain near grain boundaries induced by fatigue loading were investigatedby the fiducial grid method in pure aluminum specimens, and the resulted grain boundary sliding(GBS) was systematically analysed. The results show that the strain field near a grain boundary isnonuniform. GBS is restricted by the junction of grain boundaries and causes discontinuities of bothdisplacement and strain. A peak value of shear strain was created in short-range area across the grainboundary. GBS plays an important role in cyclic softening and secondary hardening. The control fac-tor of GBS is the relative orientation between two grains and the macro orientation of the grainboundary rather than the ∑ value of the boundary.     

A new monitoring system for piping systems in fossil fired power plants

A CEC-funded project has been performed to tackle the problem of producing an advanced Life Monitoring System (LMS) which would calculate the creep and fatigue damage experienced by high temperature pipework components. Four areas were identified where existing Life Monitoring System technology could be improved:

1. 1. the inclusion of creep relaxation

2. 2. the inclusion of external loads on components

3. 3. a more accurate method of calculating thermal stresses due to temperature transients

4. 4. the inclusion of high cycle fatigue terms.

The creep relaxation problem was solved using stress reduction factors in an analytical in-elastic stress calculation. The stress reduction factors were produced for a number of common geometries and materials by means of non-linear finite element analysis. External loads were catered for by producing influence coefficients from in-elastic analysis of the particular piping system and using them to calculate bending moments at critical positions on the pipework from load and displacement measurements made at the convenient points at the pipework. The thermal stress problem was solved by producing a completely new solution based on Green's Function and Fast Fourier transforms. This allowed the thermal stress in a complex component to be calculated from simple non-intrusive thermocouple measurements made on the outside of the component. The high-cycle fatigue problem was dealt with precalculating the fatigue damage associated with standard transients and adding this damage to cumulative total when a transient occurred.

The site testing provided good practical experience and showed up problems which would not otherwise have been detected.     

工艺因素对金属封装外引线弯曲疲劳的影响

考察了金属封装外壳制造工艺对外引线弯曲疲劳的影响,发现电镀镍是导致外引线弯曲次数明显减少的最主要工艺步骤,且随镀镍层厚度的增加,弯曲次数减少。此外还讨论了外引线的氢含量和晶粒度对引线抗疲劳能力的影响。     

重载齿轮齿面疲劳损坏及预防

点蚀和剥落是重载齿轮齿面疲劳损坏最普遍的形式.根据齿轮失效分析实例,对齿面初始点蚀、破坏性点蚀和齿面剥落等三种主要疲劳损坏的特征、发生部位及破损危害程度进行了分析研究,较系统地论述了齿轮接触疲劳破坏机理,影响因素及其产生原因,并对有关的齿面破坏提出了相应的预防措施.     

X60管线钢疲劳特性的研究

利用2、4和14mm的X60钢紧凑拉伸试样进行同样应力水平、固定应力比（R＝0．1）的疲劳裂纹扩展试验，揭示出高韧性管道钢的疲劳裂纹扩展存在显著的厚度效应。由于应力水平低，相应的离面应力也低，不足以导致分层开裂，因此，裂纹端部的三维应力约束随厚度增加而增大。4mm试样的疲劳裂纹速率远高于2mm试样，但厚度再增大，裂纹扩展速率不再有显著变化。进一步对表面裂纹试样进行疲劳裂纹扩展试验，并用勾线法纪录裂纹扩展情况，利用穿透裂纹的da/dN-ΔK曲线预测表面裂纹扩展，用2mm厚试样的数据控制裂纹表面长度的扩展，用14mm厚试样的数据控制裂纹底部沿厚度方面的扩展，得到了与表面裂纹扩展实验吻合很好的预测结果。     

The effect of a solid additive on rolling fatigue life

Behaviour of a series of lubricant oils and the effect of a non stoichiometric inorganic compound, as solid extreme pressure additive, on rolling fatigue life are studied using the rolling four-ball accelerated service simulation test proposed by Barwell and Scott. The results show, in all tested cases, the remarkable efficacy of this type of additive. The Total Acidity Number (tan) was found to increase with performance time for the case of the base lubricant, while for the oils with additives, it remained at its constant low value. This led to a proposal of a possible mechanism of the additive performance in the rolling process.