FATIGUE CRACK PROPAGATION BEHAVIOUR OF SHORT CRACKS; THE EFFECT OF MICROSTRUCTURE

–Fatigue cracks shorter than some critical length tend to propagate anomalously quickly. This paper examines the concept of a ‘critical length’, identifying three regimes of behaviour for different crack lengths. Some published work is examined, covering a wide range of different materials. It is concluded that there is an approximate correlation between the critical length for short crack behaviour and the scale of the microstructure. LEFM is difficult, if not impossible, to apply to cracks shorter than this critical length because the material surrounding a crack cannot be assumed to approximate to a homogeneous continuum. Suggestions are made for a fatigue design philosophy which incorporates short crack behaviour.     

THE INITIATION AND PROPAGATION BEHAVIOUR OF SHORT FATIGUE CRACKS IN WASPALOY SUBJECTED TO BENDING

The fatigue crack growth behaviour of a nickel base superalloy, Waspaloy, has been studied using four point bending specimens in laboratory air. Two groups of tests, for which the span/width ratios were 1 and 2.5, were conducted and the results compared. Surface crack lengths were measured from plastic replicas of the surface. Equations which describe both short and long cracks have been derived and used to predict the fatigue life for the Waspaloy specimens. From plastic replication studies and scanning electron microscope examinations, a physical understanding of the relationship between crack growth and microstructural features was enhanced.     

INITIATION AND PROPAGATION OF SHORT FATIGUE CRACKS IN A WELD METAL

Abstract— Fatigue tests were performed using a purpose designed triangular shaped specimen to investigate the initiation and propagation of short fatigue cracks in a weld metal. It was observed that short fatigue cracks evolved from slip bands and were predominantly within ferrite grains. As the test progressed, the short crack density increased with minor changes in crack length. The growth of short cracks, in the early stage resulted mainly from coalescence with other existing cracks. The mechanism of short crack behaviour is discussed.     

SHORT CRACK FATIGUE BEHAVIOUR IN A MEDIUM CARBON STEEL

The initiation stage and short crack behaviour in torsional fatigue of a 0.4% C steel was investigated by a replication technique. The fatigue cracks initiated and propagated in the ferrite phase which is located at the prior austenite grain boundaries in the form of long allotriomorphs. At this stage of crack development it is proposed that crack growth rate depends on the extent and intensity of plasticity at the tip of the crack. Crack growth per cycle is correspondingly proportional to the strength of the slip band. The ferrite-pearlite boundaries are strong barriers to crack propagation, which is manifested by a deceleration of growth and possible arrest. On raising the stress level the previously non-propagating cracks may continue to grow by branching or joining with other cracks in the ferrite phase. This process is repeated until the stress fields of one or more dominant cracks attain a critical value to sustain continued growth that leads to failure.     

PROPAGATION AND NON-PROPAGATION OF SHORT FATIGUE CRACKS AT A SHARP NOTCH

Abstract— Sharply notched specimens of a structural low-carbon steel were fatigued under several ratios of the maximum to minimum loads. The growth behavior of a short fatigue crack near the notch tip was analyzed based on crack closure measurements. A fatigue crack first decelerates with increasing crack length, and then accelerates or becomes non-propagating depending on the applied stress. A similar deceleration is seen when the rate is correlated to the stress intensity range. The effective stress intensity range is a unique parameter in correlating the growth rate of a short crack for all the stress levels examined, and the relation is identical to that obtained for a long crack. By considering the increase in crack closure with crack length, a quantitative method is proposed for predicting the non-propagating crack length and the fatigue limit of notched specimens as a function of the applied stress and the notch geometry.     

EFFECT OF BIAXIAL MEAN STRESS ON CYCLIC STRESS-STRAIN RESPONSE AND BEHAVIOUR OF SHORT FATIGUE CRACKS IN A HIGH STRENGTH SPRING STEEL

Abstract— Biaxial fatigue tests were conducted on a high strength spring steel using hour-glass shaped smooth specimens. Four types of loading system were employed, i.e. (a) fully reversed cyclic torsion, (b) uniaxial push—pull, (c) fully reversed torsion with a superimposed axial static tension or compression stress, and (d) uniaxial push—pull with a superimposed static torque, to evaluate the effects of mean stress on the cyclic stress—strain response and short fatigue crack growth behaviour. Experimental results indicate that a biaxial mean stress has no apparent influence on the stress—strain response in torsion, however a superimposed tensile mean stress was detrimental to torsional fatigue strength. Similarly a superimposed static shear stress reduced the push—pull fatigue lifetime. A compressive mean stress was seen to be beneficial to torsion fatigue life. The role of mean stress on fatigue lifetime, under mixed mode loading, was investigated through experimental observations and theoretical analyses of short crack initiation and propagation. Using a plastic replication technique the effects of biaxial mean stress on both Stage I (mode II) and Stage II (mode I) short cracks were evaluated and analysed in detail. A two stage biaxial short fatigue crack growth model incorporating the influence of mean stress was subsequently developed and applied to correlate data of crack growth rate and fatigue life.     

HIGH TEMPERATURE SHORT FATIGUE CRACK BEHAVIOUR IN A STAINLESS STEEL

Abstract— Continuous low cycle fatigue (LCF) tests with-and without-hold time in push-pull and torsion loading modes and sequential LCF tests in push-pull mode were carried out at 650°C in air on thin tubular specimens of 316 stainless steel; the sequential tests involving pure fatigue (PF) and creep-fatigue (CF) loadings. The growth of short fatigue cracks was studied by taking several replicas from the specimen surface which were subsequently observed under a scanning electron microscope. An analysis was done with respect to both crack density and the orientation of microcracks and macrocrack(s) which led to failure.
Crack density was higher on the surface of a CF tested specimen than that of a PF tested specimen. Mainly short cracks oriented at 45° to the specimen axis were observed on a torsion fatigue tested specimen surface. For push-pull specimens the microcracks propagated perpendicular to the specimen axis to form macrocracks that propagated in the same direction. On the other hand, for torsion specimens the microcracks which initially propagated at 45° to the specimen axis linked to form macrocracks oriented parallel and perpendicular to the specimen axis. However, the macrocrack responsible for the final fracture was always oriented parallel to the specimen axis.
Cumulative damage was dependent on the type of loading (PF or CF) in the first part of sequential tests. In particular microcracks initiated during an initial damage phase observed under sequential LCF tests in PF were found to be healed by oxide formation during the hold times applied in the subsequent CF loading and this produced a total damage summation significantly larger than one.     

CRACK INITIATION AND PROPAGATION BEHAVIOUR OF A HEAT-TREATED CARBON STEEL IN CORROSION FATIGUE

Abstract— When estimating fatigue damage quantitatively it is important to clarify its physical basis. In this study, rotating bending fatigue tests of a heat-treated 0.45% carbon steel were carried out in 3% NaCl solution, in order to clarify the physical basis of corrosion fatigue damage from successive observations of plastic replicas. The results show that corrosion pits are generated during the early stages of cycling, then most of them grow with further cycling until a crack is initiated from each corrosion pit. The initiation of corrosion pits from slip bands is observed only in the case when the stress range is relatively large, and in the range of stress for which slip bands are produced in air. After initiation of a crack, the crack propagates by frequent interactions and coalescence with other cracks. The growth rate of an especially small crack in NaCl solution is larger than that in air. However, the growth rate of a comparatively large crack is smaller in NaCl solution than in air.     

A SIMULATION OF THE BEHAVIOUR OF MULTI-SURFACE FATIGUE CRACKS IN TYPE 304 STAINLESS STEEL PLATE

Abstract— Fatigue tests were carried out to study the growth and coalescence behaviour of multi-surface cracks which were initiated at semi-circular surface notches, and an existing crack growth simulation program was developed to predict and compare with the experimental results. Additional comparisons with ASME and BSI conditions were also carried out to enhance the reliance and integrity of structures and machine elements. The results presented in this paper show that the simulation procedure has utility for fatigue life prediction.     

PROPAGATION AND CLOSURE OF SHORT FATIGUE CRACKS AT NOTCHES UNDER COMPRESSIVE MEAN STRESSES

Abstract— Single-edge-notched specimens of a low-carbon steel were fatigued under cyclic in-plane bending with compressive mean stresses. The development of crack closure with crack growth was studied both experimentally and theoretically. The relation between the crack opening stress and the crack length was a function of the minimum (compressive) applied stress, irrespective of the maximum stress. The effective stress intensity range was a unique parameter in correlating the crack growth rate, even if the crack was embedded in the compressive plastic zone. Under a constant minimum stress, the length of nonpropagating cracks became longer with increasing maximum applied stress. A theoretical model was proposed for predicting the crack opening stress on the basis of the compressive stress distribution at the minimum applied stress. The predicted value agreed fairly well with the experimental result. The model gave upper bounds of the crack growth rate and the length of nonpropagating fatigue cracks within the plastic zone.     

SHORT FATIGUE CRACK GROWTH BEHAVIOUR OF A LOW CARBON STEEL UNDER CORROSION FATIGUE CONDITIONS

The effect of an aqueous chloride environment upon the development and growth of short fatigue cracks from smooth specimen surfaces has been studied under fully reversed torsional fatigue loading conditions. Crack initiation and growth has been monitored using a plastic replication technique enabling a full history of cracking characteristics to be recorded. Corrosion fatigue conditions were achieved by complete immersion in a 0.6 M NaCl solution, of nominal pH value 6.0, with specimens corroding at the free corrosion potential. Variations to these conditions were obtained by the addition of concentrated hydrochloric acid enabling test solution pH values to be altered, typically pH values of 3.5 and 2.0 were obtained. Further information regarding the effects of the environment on the early stages of crack development were obtained by conducting two stage alternate immersion type testing conditions. Evaluation of these effects through previously established Elastic-Plastic Fracture Mechanics models shows that the environment plays a major role during the early stages of microstructure-dominated crack growth particularly as cracks approach major barriers to propagation and at decreasing levels of applied shear stress.     

THE PROPAGATION OF NON-COPLANAR SEMI-ELLIPTICAL FATIGUE CRACKS

Abstract— The results of fatigue tests on specimens containing parallel offset and parallel collinear configurations of multiple non-coplanar cracks are presented. The fatigue growth of parallel collinear cracks is shown to be significantly affected by crack-tip shielding and parallel offset cracks are shown to grow almost independently before their adjacent tips overlap. Subsequent growth in the region of overlap results in coalescence which begins when the deviating crack tips come into contact below the surfaces of the specimens. Simplified predictions of the propagation of offset non-coplanar semi-elliptical cracks are also presented and their implications for the prediction of fatigue lives in structures containing offset coplanar cracks are assessed.     

PROPAGATION OF FATIGUE CRACKS UNDER POLYMODAL LOADING

Abstract— The influence of steady mode III on mode I fatigue growth behavior is investigated in four materials–a plain carbon steel, a Ni–Cr–Mo–V rotor steel, and titanium alloys, TA6V and TA5E ELI. It is shown that these loading conditions give rise to two main effects: (i) a strong reduction in propagation rate and (ii) a modification in crack path, the fatigue crack adopting a characteristic "factory-roof' aspect. In 2024 Al alloy, it is shown that the superimposition of steady mode II to cyclic mode I leads to crack bifurcation, the angle θ being a function of K _a/ K _tmax. These observations are discussed in the light of a new criterion which is introduced. This criterion is based on two main assumptions: (i) Fatigue cracking is assumed to occur only under the effect of local mode I opening. (ii) It is postulated that a fatigue crack grows in a direction where the crack propagation rate is maximum. A number of limitations of this approach, associated with crack closure phenomenon, are discussed.     

FATIGUE CRACK PROPAGATION BEHAVIOUR UNDER VARIABLE AMPLITUDE LOADING IN THE NEAR-THRESHOLD REGION OF A HIGH-STRENGTH LOW-ALLOY STEEL

The near-threshold behaviour of a high-strength low-alloy steel used in helicopter rotors under variable amplitude loading is investigated in ambient air and in vacuum. Strong sequence effects occur, in particular a high decrease in crack growth rates after overloads of 40% on maximum load while keeping the amplitude constant. A detailed study of the retardation phenomenon due to the overloads provides an explanation for the different behaviour observed in air and in vacuum and has laid the basis for a method of predicting crack propagation under helicopter loading spectra.