PREDICTING FATIGUE CRACK INITIATION LIFE OF AN ALUMINIUM ALLOY AT LOW TEMPERATURES

Abstract— A simple approach to predict the fatigue crack initiation (FCI) life of notches at low temperatures is developed. The stress cycle to initiate a 0.25 mm crack at a notch tip is presented as a function of an equivalent stress amplitude. The results of the study indicate that the FCI life of an aluminium alloy increases with decrease in temperature and the effect of temperature on the FCI resistance can be predict in the form of an FCI coefficient C and the FCI threshold. The coefficient C is the parameter controlling FCI resistance in the low cycle fatigue region and it can be calculated from the elasticity modulus and the strain hardening exponent. The threshold is the parameter governing FCI resistance in the high cycle fatigue region and its value depends mainly upon the endurance limit. The temperature- dependence of the endurance limit can be predicted by a thermal activation model. By means of this approach, the fatigue crack initiation life at low temperatures can be predicted from the material tensile properties without any additional low temperature fatigue tests and without any empirical modification so long as the endurance limit of the metal at room temperature is predetermined. The results suggest that this approach is applicable to other aluminium alloys.     

DETERMINATION OF FATIGUE CRACK INITIATION LIFE

Abstract— A reanalysis has been carried out on the results of Zachariah. An elastic-plastic analysis based on S-N data indicates that the mechanism of growth of very small cracks is similar to that expressed by linear elastic fracture mechanics, i.e. crack growth in mild steel is given by where Δγ_p is the plastic shear strain range and a is the crack length. Crack initiation occurs within a single grain and crack propagation is given by the above equation for cracks which can be smaller than a few microns. The size of an initiated crack is a function of stress level varying from 0·1–1·0 μm in the high strain fatigue regime to 2·3 μm close to the fatigue limit. The period of crack initiation is negligible in the HSF regime whilst the initiation period can dominate lifetime at low stress levels.     

FATIGUE LIFE AND SURFACE CRACK PENETRATION BEHAVIOUR OF AN ALUMINIUM ALLOY

Fatigue life and crack retardation behaviour after penetration were examined experimentally using CT specimens and surface pre-cracked specimens of aluminium alloy 5083-0. The fatigue crack shape before penetration is almost semicircular, and the measured aspect ratio is larger than the value obtained by calculation using K values proposed by Newman-Raju. It was found that crack growth behaviour on the back side after penetration is unique, and can be divided into three stages. The Wheeler model retardation parameter was used successfully to predict crack growth behaviour after penetration. By using a crack propagation rule, the change in crack shape after penetration can be evaluated quantitatively.     

ON CRACK INITIATION LIFE DURING LOW CYCLE FATIGUE

Abstract— A new method of investigating life to crack initiation during low cycle fatigue, which combines hour-glass shape specimen testing with scanning electron-microscopy observations, was introduced in the paper. The effect of grain size on low cycle fatigue crack initiation life of 37CrNi3MoV steel and the propagation of cracks in this multi-phase steel was studied. Results show that refining the grain size can increase fatigue initiation lifetime.     

LY12CZ 铝合金超塑性孔洞长大及其对断裂的影响~*

供应状态 LY12CZ 铝合金具有超塑性,平均晶粒尺寸为15.3μm,在490℃,(?)_0=1.67×10~(-4)s~(-1)时,延伸率为346%,m 值为0.52—0.6。该材料为孔洞敏感材料,孔洞长大规律可用本文提出的二阶段孔洞模型描述。同时考虑材料的应变速率敏感性(m)和孔洞长大效应,可从理论上预测该材料的延伸率。     

冷胀孔裂纹寿命增长效果估算模型

本文用含孔边穿透裂纹的冷胀孔、未胀孔剩余寿命之比来评价孔冷胀强化工艺延长裂纹扩展寿命的效果。本文提出把理论计算方法与实验测试结果相结合来确定残余应力场:根据实验测量结果确定冷胀孔塑性区半径:把塑性区半径代入残余应力场的理论计算式中求出残余应力场初形;根据最大残余应力值与材料屈服应力之间的规律关系(由冷胀孔残余应力测试结果得出的)修正已计算出的残余应力场。本文用冷胀孔单边穿透裂纹在等幅循环载荷作用下的裂纹扩展寿命试验结果检验了所提出的模型,此估算模型可较保守而又较充分反映孔冷胀强化工艺对孔边裂纹的增寿作用。     

AN EXPERIMENTAL AND STATISTICAL INVESTIGATION OF SURFACE FATIGUE CRACK INITIATION AND GROWTH

Surface fatigue crack studies were carried out and statistically analysed from rotating bend fatigue tests in the high cycle region for three metals, copper, stainless steel and mild steel with four ferrite grain sizes. Quantitative observations of the initiation and growth behavior, including coalescence of closely spaced cracks, are discussed and a limiting condition for coalescence is proposed. Statistical properties of initiation, propagation and propagation rate of surface cracks are examined and the effect of different metals and grain sizes is discussed.     

NOTCHED MEMBER FATIGUE LIFE PREDICTIONS COMBINING CRACK INITIATION AND PROPAGATION

Abstract Fatigue lives of notched members are considered to be divided into crack initiation and propagation phases. Apparent size effects caused by crack propagation through the strain gradient of the notch are accounted for if initiation is defined as a crack size within the local notch field. The extent of this field may be estimated from fracture mechanics analysis, with its size being of the order of one tenth of the notch radius. Plasticity effects must be properly handled in predicting crack initiation, but linear elastic analysis is generally satisfactory for handling the propagation phase.     

柔度法测试车轮轮箍的疲劳裂纹萌生寿命

借助MTS TESTSTAR材料试验机的Fatigue Crack Growth Test应用软件，建立了材料的疲劳裂纹萌生寿命测试方法——柔度法。用该方法测试了HDSA车轮和LG61轮箍的疲劳裂纹萌生寿命，并与其它六种车轮的有关数据进行了对比。结果表明，HDSA车轮和LG61轮箍的疲劳裂纹萌生寿命分别比915D车轮提高了33．4％和35．5％。     

FATIGUE LIFE PREDICTION OF HEAT-TREATED CARBON STEELS AND LOW ALLOY STEELS BASED ON A SMALL CRACK GROWTH LAW

Abstract— Since heat-treated high strength steels are often used as materials for machines and structures that operate under severe service conditions, it is important to evaluate their fatigue life. Hence the growth law of a small fatigue crack must be known in order to estimate the fatigue life of machines and structures since the life of such members is controlled mainly by the behaviour of a small crack. The growth rate of a small crack can not be predicted usually by linear elastic fracture mechanics, but can be determined uniquely by the term σⁿ_a l , where σ_a is stress amplitude, l is crack length and n is a material constant. In this paper, the small-crack growth law of heat-treated carbon steels and low alloy steels was studied. An effective and convenient method based on a small-crack growth law, d l /d N = C ₃(σ_a/σ_a)ⁿ l is proposed, where σ_u is the ultimate tensile strength, for predicting the small crack propagation life of heat- treated steels with different tensile strength levels, together with a method for determining the fatigue life of plain members.     

EFFECTS OF CRACK CLOSURE AND MEAN STRESS ON THE THRESHOLD STRESS INTENSITY FACTOR FOR FATIGUE OF AN ALUMINIUM CASTING ALLOY,

Abstract— Observations have been made of the threshold fatigue properties of an Al-Mg-Si casting alloy. First, it has been shown that there exists a critical value of the stress ratio, R , below which the threshold stress intensity factor decreases with increasing R but above which it is constant. Second, measurements of the cyclic crack opening displacement have been used to examine crack closure effects and to deduce the effective cyclic stress intensity factor. The two sets of data are compared with existing models for threshold phenomena.     

MICROSTRUCTURAL EFFECTS ON SMALL FATIGUE CRACK INITIATION AND GROWTH IN Ti6A14V ALLOYS

Abstract— The nucleation and growth of small naturally initiated cracks have been investigated on Ti 6 Al 4V alloys, with bimodal or globular microstructures. Tests have been performed in air at a stress amplitude near 0.75 of the yield stress. The influence of microstructure on fatigue damage is described and the differences in fatigue life of some titanium alloys are explained. The effect of microstructure on fatigue resistance is mainly related to the early stages of damage including initiation and small crack growth. Coalescence processes favoured by a high density of initiated surface microcracks in fine α grain material, or rapid initiation of large cracks in coarse α colonies, explains low fatigue resistance or lifetime scattering in globular alloys. Small crack growth retardation due to α/β barriers associated with a low surface crack density, limiting coalescence processes, explains the highest resistance of bimodal structures.     

EFFECTS OF AIR AND INERT ENVIRONMENTS ON THE NEAR THRESHOLD FATIGUE CRACK GROWTH BEHAVIOR OF ALLOY 718

The near threshold fatigue crack growth behavior of alloy 718 was studied in air and helium environments at room temperature and at 538°C. Tests were performed at 100 Hz and at load ratios of 0.1 and 0.5. At room temperature and at 538°C, the ΔK_th values in helium were lower than in air. The ΔK_th values in air decreased with increasing load ratio. These results can be explained with a model that involves the accumulation of oxide in the crack which enhances crack closure. In the air tests, the oxide build-up on the fatigue fracture surfaces at ΔK_th was of the order of magnitude as the crack tip opening displacement. In the helium tests, no significant build-up of oxide on the fracture surface at threshold was found.     

THE EFFECT OF HYDROGEN ON SHORT FATIGUE CRACK GROWTH IN AN Al-Li ALLOY

Abstract— Experimental results are presented to illustrate the degree of susceptibility to hydrogen embrittlement in an Al-Li 8090 alloy. The ductility of the alloy (as recorded in slow strain rate tests) is reduced by hydrogen charging which induces microcrack formation on the surface of the hydrogen treated specimens. Results of fatigue tests show that small fatigue cracks propagate 1.5 to 10 times faster in specimens charged with hydrogen and fractographic evidence shows that short crack growth in hydrogen precharged specimens is transgranular, along persistent slip bands. The effect of hydrogen is reversible, the embrittlement effect being eliminated by holding the specimens for 24 hr at 470°C.     

THE EFFECTS OF MOISTURE ON THE FATIGUE CRACK GROWTH BEHAVIOUR OF A LOW ALLOY STEEL NEAR THRESHOLD

Abstract— The influence of moisture on the fatigue crack growth behaviour near threshold of a 2NiCrMoV rotor steel has been investigated. At a high stress ratio ( R = 0.6), moisture enhances fatigue crack growth rates by approximately 60% compared with the growth rate in dry air. The effect would appear to be due to the influence of hydrogen which is confined to a volume of material at the crack tip considerably smaller than the plastic zone. At a low stress ratio ( R = 0.14), the growth rates in moist air can be very much lower than in dry air. This difference is closely associated with the formation of oxides on the fracture surface—moisture modifying the type and extent of oxidation which is observed. Observations of transient crack growth following environmental changes, suggest that fracture surface oxides within approximately 0.3 mm of the crack tip exert a strong retarding influence on crack growth although oxides up to at least 3 mm from the tip may also have some retarding effect.     

CRACK INITIATION AND SMALL FATIGUE CRACK GROWTH BEHAVIOUR OF SQUEEZE-CAST Al-Si ALUMINIUM ALLOYS

Abstract— Fatigue strength, crack initiation and small crack growth behaviour in two kinds of squeeze-cast aluminium alloys, AC8A-T6 and AC4C-T6 were investigated using smooth specimens subjected to rotatary-bending fatigue at room temperature. Fatigue resistance of these alloys was almost the same as that of the wrought aluminium alloys because of their fine microstructure and of the decrease in defect size due to squeeze-casting. Fatigue crack initiation sites were at the eutectic silicon particles on the surface of specimens or at internal microporosity in the specimens. Crack initiation life, defined as a crack length of 50 μm on the specimen surface, was successfully estimated from an evaluation of initiation sites using fracture mechanics and the statistics of extrema. Small fatigue crack growth in the two kinds of alloys obeys the relation proposed by Nisitani et al. , namely that d(2c)/d N = C (σ_a/σ_B)ⁿ· (2 c ), where C is a constant and σ_B is the ultimate tensile strength. It is pointed out that an improvement in fatigue strength of cast aluminium alloys can be expected by refining the eutectic silicon rather than by an increase in static strength.     

THE EFFECT OF GRAIN SIZE ON FATIGUE CRACK GROWTH IN AN ALUMINIUM MAGNESIUM ALLOY

Abstract Fully reversed uniaxial fatigue tests were performed on aluminium magnesium alloy Al 5754 with four different grain sizes in order that the effect of grain size on fatigue crack growth could be examined. Surface cracks were monitored by a plastic replication technique. Fatigue strength was shown to improve with a decrease in grain size. The endurance stress is a function of the inverse square root of the grain size and is described empiricdty by a Hall-Petch type relation. The effect of grain size on fatigue crack growth is most significant when the crack length is of the order of the microstructure. Fluctuations in the growth rate of microstructurally short cracks are most marked in a fine grained microstructure and may be related to the need to transfer slip to adjacent grains. Crack path deviation is greatest in the coarsest grained microstructure and SEM fractography reveals a more pronounced crack surface roughness in the coarser grained alloy than in the finer grained alloy.     

残余应力与胶粘剂对ARALL层板疲劳裂纹扩展特性的影响

研究了粘剂性质、含量及残余应力状态对纤维－铝合金胶接层板（ＡＲＡＬＬ）疲劳裂纹扩展特性的影响，分析了裂纹扩展过程中的分层状态的变化，结果表明，ＡＲＡＬＬ层板内富胶层的剪切形变和伴随裂纹扩展的分层区越大，即这两方面耗散能量越多，则疲劳裂纺扩展速率越低；胶粘剂含量的影响不明显，给层板施加预应力极大降低了层板的疲劳裂纹扩展速率，其本质在于裂尖在同样的疲劳载荷下实际所受到的有效应力降低。