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.     

Microscopic and Macroscopic Growth Rates of Fatigue Cracks in Steels and Alloys under the Influence of Crack Closure

On the basis of the experimental data, we show that the difference between the macroscopic and microscopic fatigue crack growth rates in the second section of the kinetic diagram of fatigue fracture is caused by the effect of crack closure within the limits of its existence. We establish the relationships between the macroscopic and microscopic fatigue crack growth rates and the structure of the material in the second section of the diagram for various values of the load ratio with regard for the effect of crack closure and propose a procedure of examination of the fracture processes in structural materials based on the analysis of microscopic and macroscopic fatigue crack growth rates.     

Effects of solidification structure on fatigue crack initiation and fatigue strength in Al−Si−Mg cast alloys

Rotating-bending uniaxial fatigue tests and micro-fatigue crack initiation tests were carried out using a permanent mold cast (PMC) and semi-solid die cast (SDC) with Al−7%Si−0.35%Mg composition in order to examine the relationship between solidification structures and fatigue behaviors. The crack length was measured using a replication method. Fatigue strength was improved in SDC, which was almost consistent with the predicted fatigue strength using the size of Si particle cluster. Resistance to fatigue crack initiation and fatigue strength were improved in SDC owing to the finer Si cluster and to higher ultimate tensile strength. Fatigue crack in PMC was preferentially initiated at pores. For SDC, the fatigue crack was initiated at the Si particle/matrix interface, and then sucessively grew along eutectic cell boundaries.     

Threshold and growth mechanism of fatigue cracks under mode II and III loadings

ABSTRACT The fatigue crack growth behaviour of 0.47% carbon steel was studied under mode II and III loadings. Mode II fatigue crack growth tests were carried out using specially designed double cantilever (DC) type specimens in order to measure the mode II threshold stress intensity factor range, ΔK_IIth. The relationship ΔK_IIth > ΔK_Ith caused crack branching from mode II to I after a crack reached the mode II threshold. Torsion fatigue tests on circumferentially cracked specimens were carried out to study the mechanisms of both mode III crack growth and of the formation of the factory‐roof crack surface morphology. A change in microstructure occurred at a crack tip during crack growth in both mode II and mode III shear cracks. It is presumed that the crack growth mechanisms in mode II and in mode III are essentially the same. Detailed fractographic investigation showed that factory‐roofs were formed by crack branching into mode I. Crack branching started from small semi‐elliptical cracks nucleated by shear at the tip of the original circumferential crack.     

Low-cycle fatigue properties of eutectic solders at high temperatures

This paper details the deformation mechanism and low‐cycle fatigue life of eutectic solder alloys at high temperature (around 0.8T_m). Grain boundary sliding generally nucleates a wedge‐type cavity that reduces the low‐cycle fatigue life of metals. In this study, grain boundary sliding has promoted intergranular failure contributing to the reduction in fatigue life of Sn–Ag–Cu alloy. However, grain boundary sliding has exerted no deleterious effects on fatigue resistance of eutectic Pb–Sn and Bi–Sn alloys. The phase boundary sliding with very fine microstructure induces exceptional ductility in these alloys leading to superior low‐cycle fatigue endurance for theses eutectic Pb–Sn and Bi–Sn alloys.     

Off-axis fatigue cracking behaviour in notched fibre metal laminates

The off‐axis fatigue cracking behaviour of notched fibre metal laminates under constant amplitude loading conditions was investigated experimentally and numerically. It was found that the off‐axis fatigue crack initiation life decreased as the off‐axis angles increased. This indicated that the off‐axis laminates raised the applied stress level in the aluminium (Al) layer and subsequently resulted in earlier cracking in the Al layer. The off‐axis fatigue crack initiation lives of notched fibre metal laminates were predicted using lamination theory and an energy‐based critical plane fatigue damage analysis from the literature. After a crack initiated in the Al layer, it was observed that the crack path angles of the off‐axis specimens were neither perpendicular to the fibre nor to the loading direction. A finite‐element model was established for predicting the crack path angles.     

Crack closure in fibre metal laminates

GLARE is a fibre metal laminate (FML) built up of alternating layers of S2-glass/FM94 prepreg and aluminium 2024-T3. The excellent fatigue behaviour of GLARE can be described with a recently published analytical prediction model. This model is based on linear elastic fracture mechanics and the assumption that a similar stress state in the aluminium layers of GLARE and monolithic aluminium result in the same crack growth behaviour. It therefore describes the crack growth with an effective stress intensity factor (SIF) range at the crack tip in the aluminium layers, including the effect of internal residual stress as result of curing and the stiffness differences between the individual layers. In that model, an empirical relation is used to calculate the effective SIF range, which had been determined without sufficiently investigating the effect of crack closure. This paper presents the research performed on crack closure in GLARE. It is assumed that crack closure in FMLs is determined by the actual stress cycles in the metal layers and that it can be described with the available relations for monolithic aluminium published in the literature. Fatigue crack growth experiments have been performed on GLARE specimens in which crack growth rates and crack opening stresses have been recorded. The prediction model incorporating the crack closure relation for aluminium 2024-T3 obtained from the literature has been validated with the test results. It is concluded that crack growth in GLARE can be correlated with the effective SIF range at the crack tip in the aluminium layers, if it is determined with the crack closure relation for aluminium 2024-T3 based on actual stresses in the aluminium layers.     

S-N-P curves in 7075 T7351 and 2024 T3 aluminium alloys subjected to surface treatments

The S-N-P (stress, number of cycles, failure probability) curves for 2024 T3 and 7075 T7351 aluminium alloys were obtained. Previously, surface treatments of degreasing and different types of anodizing were applied to samples, evaluating the influence of these treatments on the fatigue life of the alloys. The determination of the S-N-P curves was done using Maennig's method. Rotary fatigue was used because this technique produces greater stress on the sample surfaces, the zone in which it is important to evaluate fatigue resistance. Both the transition range and the finite life range were evaluated, calculating the 1, 50 and 99% fracture probability. SEM was performed in order to characterize the fracture micromechanism. The conclusions were that Maennig's method is useful to evaluate fatigue life of these materials in a fast and efficient manner. Moreover, surface treatments produce a decrease in the fatigue life of both alloys, associating this effect with the surface damage produced on each sample during the treatment.     

Finite-element analysis and experimental study on tensile fatigue behaviour of bitumen–stone adhesion

Tensile fatigue behaviours of bitumen–stone adhesion were investigated using a dynamic mechanics analyser under stress‐controlled mode at two temperatures of 5 and 25°C and various controlled‐stress levels. Failure characteristics including interfacial failure and cohesive failure were examined using image analysis of fracture surfaces. Finite‐element analysis on stress distributions was conducted under different temperatures, film thickness and interfacial bonding conditions. A Coulomb–Mohr like criterion in combination with shear and normal stresses is proposed to deal with the extreme thin adhesive layer, which can be further simplified into an adhesive zone without significant loss of accuracy for stress analysis.