Determination of threshold stress intensities: fatigue of low alloy steel BS4360-50D

An experimental method for obtaining the effective stress intensities necessary for cyclic crack growth prediction is described. Also, it is shown that the critical threshold value, ΔK_{c, th}, can be estimated using simple energetic considerations, leading to an equation:

$\text{Δ}\text{K}{}_{\mathrm{c,th}}\text{=}\text{4π}\text{E}\text{λ}{}_{\mathrm{s}}\text{2?}\text{(θ}{}_{\mathrm{uts}}\text{?}{}_{\mathrm{f}}\text{)}\text{((1+}\text{n}\text{)θ}{}_{\mathrm{yc}}\text{)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}$

The threshold values obtained compare well with the experimentally observed values for a structural steel BS 4360-50D and for other steels.     

Prediction of threshold and ultra-low fatigue crack growth rates

A model was derived to predict the true threshold value for fatigue crack growth in the absence of crack closure. The model, based only on the tensile and cyclic properties of the material, was successfully verified against a set of experimental data on medium and high strength steels and one aluminium alloy. Good agreement with experimental results was also obtained for Region I of the $\text{d}\text{a/}\text{d}\text{N vs ΔK}$ curve using a fatigue crack growth rate equation based on the same model.Fatigue crack growth data obtained from the medium strength steel CK45 in the normalized state and two heat-treated conditions were analysed. Good data correlation was shown using a previously developed normalizing parameter, $\text{φ = (ΔK}{}^2\text{?ΔK}{}^2{}_{\mathrm{<mtext>th</mtext>}}\text{)/(K}{}^2{}_{\mathrm{<mtext>c</mtext>}}\text{?K}{}^2{}_{\mathrm{<mtext>max</mtext>}}\text{)}$, in the entire range of fatigue crack growth rates and for stress ratios ranging from 0.1 to 0.8.     

Some formulas for the crack opening stress level

Crack growth data for 2024-T3 sheet material were analysed with different formulas for $\text{ΔK}{}_{\mathrm{eff}}$ as a function fo the stress ratio $\text{R}$. The data covered $\text{R}$ values from ?1.0 to 0.54. A good correlation was obtained for $\text{ΔK}{}_{\mathrm{eff}}$/$\text{ΔK}$ = 0.55 + 0.33$\text{R}$ + 0.12$\text{R}{}^2$ The relation between log $\text{d}\text{a/}\text{d}\text{n}$ and log $\text{ΔK}{}_{\mathrm{eff}}$ was non-linear for high crack rates (> 1 μm/c).     

Fracture mechanics approach to fatigue crack initiation from deep notches

Fracture mechanics approach is applied to fatigue crack initiation at the tips of deep, blunt notches including those with very small notch-tip radius. The theoretical relations between the stress intensity range ΔK_ρ and the notch-tip radius ρ for a fixed life for crack initiation were derived based on the models of dislocation-dipole accumulation and blocked slip-band. Those are approximated by a simpler equation: $\text{ΔK}{}_{\mathrm{\rho }}\text{ΔK}{}_{\mathrm{o}}\text{= (1 + ρ/ρ0)}\text{1}\text{2}$ where ΔK₀ and ρ0 are material constants which are related to the fatigue strength of smooth specimens Δρ0 as $\text{Δρ0 =}\text{2ΔK}{}_0\text{(πρ0)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}$. The results of experiments done with bluntly notched compact tension specimens of a structural low-carbon steel agree with the above relation between $\text{ΔK}{}_{\mathrm{gr}}\text{ΔK}{}_{\mathrm{o}}$ and ρ/ρ_o. The method to predict ΔK_o, ρ_o and Δρ_o from the fatigue data of cracked and smooth specimens is proposed.     

Fatigue crack propagation from a crack inclined to the cyclic tensile axis

Cyclic stresses with stress ratio R = 0.65 were applied to sheet specimens of aluminium which have an initial crack inclined to the tensile axis at angles of 30°, 45°, 72° or 90°. The threshold condition for the non-propagation of the initial crack was found to be given by a quadratic form of the ranges of the stress intensity factors of modes I and II. The direction of fatigue crack extension from the inclined crack was roughly perpendicular to the tensile axis at stress ranges just above the threshold value for non-propagation. On the other hand, at stress ranges 1.6 times higher than the threshold values the crack grew in the direction of the initial crack. The rate of crack growth in the initial crack direction was found to be expressed by the following function of stress intensity factor ranges of mode I, K₁, and mode II, K₂: $\text{dc}\text{dN}\text{= C(K}{}_{\mathrm{eff}}\text{)sum}$, where $\text{K}{}_{\mathrm{eff}}\text{= [K}{}_1{}^4\text{+ 8K}{}_2{}^4\text{]}{}^{\mathrm{<mtext>1</mtext><mtext>4</mtext>}}$. This law was derived on the basis of the fatigue crack propagation model proposed by Weertman.     

Cyclic analysis of a propagating crack and its correlation with fatigue crack growth

Stress and strain field of a propagating fatigue crack and the resulting crack opening and closing behavior were analysed. It was found that a propagating fatigue crack was closed at tensile external loads due to the cyclically induced residual stresses. Strain range value $\text{Δ?}{}_{\mathrm{y}}$ in the vicinity of the crack tip was found to be closely related with the effective stress intensity factor range $\text{ΔK}{}_{\mathrm{eff}}$ which was determined on the basts of the analytical crack opening and closing behavior at its tip. Application of this analysis to the non-propagating fatigue crack problem and the fatigue crack propagation problems under variable stress amplitude conditions revealed that both $\text{Δ?}{}_{\mathrm{y}}$ and $\text{ΔK}{}_{\mathrm{eff}}$ were essential parameters governing fatigue crack growth rate.     

A cumulative model of fatigue crack growth and the crack closure effect

A model of fatigue crack growth based on an analysis of elastic/plastic stress and strain at the crack tip is presented. It is shown that the fatigue crack growth rate can be calculated using the local stress/strain at the crack tip by assuming that a small highly strained area $\text{x}{}^1$, existing at the crack tip, is responsible for the fatigue crack growth, and that the fatigue crack growth may be regarded as the cumulation of successive crack re-initiations over a distance $\text{x}{}^1$. It is shown that crack closure can be modelled using the effective contact zone g behind the crack tip. The model allows the fatigue crack growth rate over the near threshold and linear ranges of the general da/dN versus ΔK curve to be calculated. The fatigue crack growth retardation due to overload and fatigue crack arrest can also be analysed in terms of g and $\text{x}{}^1$.Calculated fatigue crack growth rates are compared with experimental ones for low and high strength steel.     

Crack tip closure and environmental crack propagation

Crack propagation rate, da/dN, and crack tip closure stress, σ_cc, in part-through crack fatigue specimens of aluminum alloys are drastically affected by gaseous environments. The present studies indicate that the crack closure reflects the influence of the environment on the plastic deformation at the crack tip, and, therefore, on the crack propagation rates. Postulating that da/dN is mainly determined by $\text{ΔK}{}_{\mathrm{eff}}\text{∝ (σ}{}_{\max }\text{?σ}{}_{\mathrm{cc}}\text{)}$ (instead of $\text{ΔK ∝ (σ}{}_{\max }\text{?σ}{}_{\min }\text{)}$, as is done traditionally) leads to the relationship $\text{da/dN = A(ΔK}{}_{\mathrm{eff}}\text{)}{}^{\mathrm{n}}$ in which $\text{A}$ and $\text{n}$ are virtually independent of the gaseous environment. The exponents are $\text{n ≈ 3.3}$ for Al 7075 T651 and $\text{n ≈ 3.1}$ for Al 2024 T351, respectively.     

Prior-to-failure extension of flaws under monotonic and pulsating loadings

An equation governing the prior to failure crack propagation is proposed. For a rate-sensitive solid containing two-dimensional crack and subject to the tensile mode of fracture the differential equations are integrated numerically for the loads increasing monotonically in time. The resulting integral curves gs = σ(l) and l= l(t), i.e. load vs crack length and length vs time, indicate that the growth of cracks in the subcritical range is strongly rate dependent.The fatigue growth, viewed as a sequence of slow growth periods, is simulated on EAI 380 analogue computer. The fourth power law proposed by Paris is confirmed only within certain range of high-cycle fatigue propagation and for a rate-insensitive solid. Otherwise, that is for a more pronounced rate dependency induced by viscosity of a solid and/or in the proximity of the final instability point the growth is markedly enhanced. For sufficiently small ratios of the applied stress intensity range ΔK to the toughness K_c, the suggested fatigue growth law consists of two terms, i.e.

$\text{d}\text{l}\text{d}\text{n}\text{=}\text{l}{}_1\text{12}\text{4}\text{ΔK}\text{K}{}_{\mathrm{c}}{}^4\text{+Cf}{}^{\mathrm{?1}}\text{ΔK}\text{K}{}_{\mathrm{c}}{}^2\text{, l}{}_1\text{=}\text{πK}{}^2{}_{\mathrm{c}}\text{8Y}{}^2$

First term is the familiar Paris expression while the second one accounts for the rate-dependent contribution; f denotes frequency and Y is the yield strength. Rate-sensitivity C is defined by eq. (1.13).     

A cumulative model of fatigue crack growth

A model of fatigue crack growth based on an analysis of elastic/plastic stress and strain at the crack tip is presented. It is shown that the fatigue crack growth rate can be calculated by means of the local stress/strain at the crack tip. The local stress and strain calculations are based on the general solutions given by Hutchinson, Rice and Rosengren. It is assumed that a small highly strained area existing at the crack tip is responsible for the fatigue crack growth. It is also assumed that the fatigue crack growth rate depends mainly on the width, x¹, of the highly strained zone and on the strain range, $\text{Δ?}{}^1$, within the zone. A relationship between stress intensity factor K and the local strain and stress has been developed. It is possible to calculate the local strain for a variety of crack problems. Then, the number of cycles N¹ required for material failure inside the highly strained zone is calculated. The fatigue crack growth rate is calculated as the ratio $\text{x}{}^1\text{N}{}^1$.The calculated fatigue crack growth rates were compared to the experimental ones. Two alloys steels and two aluminium alloys were analyzed. Good agreement between experimental and theoretical results is obtained.     

Fatigue crack propagation behaviour of rotor and wheel materials used in steam turbines

The fatigue crack propagation characteristics of several rotor and wheel materials that are commonly used in rotating components of steam turbines were investigated. Particular emphasis was placed on the behaviour at near-threshold growth rates, ie below 10^?5 mm/cycle, approaching the fatigue-crack propagation threshold, $\text{ΔK}{}_{\mathrm{<mtext>th</mtext>}}$. The lifetimes of the cracks of interest lie mostly in this region, and it is also the region where few data are available.The effects of load ratio on the fatigue crack growth rates were examined, as well as the tensile, Charpy V-notch and fracture toughness properties of the rotor and wheel materials. The relationship between fatigue crack propagation behaviour and fractographic features was examined. Fatigue crack growth rate data, $\text{da/d}\text{N}$ vs stress intesity range $\text{ΔK}$, were fitted with a four parameter Weibull survivorship function. This curve fitting can be used for life estimation and establishment of $\text{ΔK}{}_{\mathrm{<mtext>th</mtext>}}$. The results show that load ratio and microstructure play a role in determining the fatigue crack threshold and fatigue crack growth behaviour.     

Studies on crack growth rate under high temperature creep,fatigue and creep-fatigue interaction—II: On the role of fracture mechanics parameter aeffσg

For high temperature creep, fatigue and creep-fatigue interaction, several authors have recently attempted to express crack growth rate in terms of stress intensity factor $\text{K}{}_{\mathrm{I}}\text{= α}\text{aσ}{}_{\mathrm{g}}$, where a is the equivalent crack length as the sum of the initial notch length a₀ and the actual crack length $\text{a}{}^1$, that is, $\text{a = a}{}_0\text{+ a}{}^1$. On the other hand, it has been shown by Yokobori and Konosu that under the large scale yielding condition, the local stress distribution near the notch tip is given by the fracture mechanics parameter of $\text{aσ}{}_{\mathrm{g}}\text{?(σ}{}_{\mathrm{g}}$), where a is the cycloidal notch length, σ_g is the gross section stress and $\text{?(σ}{}_{\mathrm{g}}$) is a function of σ_g. Furthermore, when the crack growth from the initial notch is concerned, it is more reasonable to use the effective crack length a_eff taking into account of the effect of the initial notch instead of the equivalent crack length a. Thus we believe mathematical formula for the crack growth rate under high temperature creep, fatigue and creep-fatigue interaction conditions may be expressed at least in principle as function of $\text{a}{}_{\mathrm{eff}}\text{σ}{}_{\mathrm{g}}\text{, σ}{}_{\mathrm{g}}$ and temperature.In the present paper, the geometrical change of notch shape from the instant of load application was continuously observed during the tests without interruption under high temperature creep, fatigue and creep-fatigue interaction conditions. Also, the effective crack length a_eff was calculated by the finite element method for the accurate estimation of local stress distribution near the tip of the crack initiated from the initial notch root. Furthermore, experimental data on crack growth rates previously obtained are analysed in terms of the parameter of $\text{a}{}_{\mathrm{eff}}\text{σ}{}_{\mathrm{g}}$ with gross section stresses and temperatures as parameters, respectively.     

Nucleation mechanism of stress corrosion cracking from notches

Crack nucleation mechanism of hydrogen assisted cracking at notched cracks in aqueous solutions is investigated, using the compact type specimens with various notch radius in low-tempered 4340 steel. A detached crack initiates at some distance ahead of the notch root. The crack nucleation at the notched root is determined by the electrical potential method. When the crack initiates, the voltage difference starts to increase. The crack nucleation site is examined by SEM. The time for crack nucleation increases with the notch root radius, ρ, and decreases with the apparent stress intensity factor K_ρ. A linear relationship between the crack nucleation time, t_n, and the parameter ${}^2\text{K}{}_{\mathrm{\rho }}\text{/(πρ)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}\text{-(2K}{}_{\mathrm{\rho }}\text{/(πρ)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}\text{)}{}_{\mathrm{th}}\text{}}$ is seen in semi-log diagram, where $\text{(2K}{}_{\mathrm{\rho }}\text{/(πρ)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}\text{)}{}_{\mathrm{th}}$ is almost equal to the yield shear strength.In order to explain these experimental results, a new model of micromechanics is proposed on the basis of stress induced diffusion of hydrogen in the high stress region ahead of the notch root. This model suggests that the detached crack initiates at the elasto-plastic boundary where the hydrogen concentration is from 2 to 5 times higher than that of the notch root surface. The theory agrees with experiments with respect to $\text{{2K}{}_{\mathrm{\rho }}\text{/(πρ)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}\text{-(2K}{}_{\mathrm{\rho }}\text{/(πρ)}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}\text{)}{}_{\mathrm{th}}\text{}}$ vs t_n and t_n vs ρ.The empirical equation holds under constant t_n, K_ρ = K_o(ρ/ρ_eff)^m where K₀ is the stress intensity factor with ρ ≈ 0 under the present environment, ρeff is the effective notch radius and m is constant. The value of m is 0.25 for the crack nucleation time (t_n)_th corresponding to the threshold stress intensity factor (K_ρ)_th, 0.5 for t_n < (t_n)_th and 0 for ρ ≦ ρ_eff. The above equation agrees with the theoretical equation proposed by Tanaka and Mura for any t_n and ρ_eff.     

Effect of loading history on stress corrosion cracking in high strength steel

The effect of preloading on crack nucleation time was examined with compact tension specimens having various notch radius in 0.1N-H²SO⁴ aqueous solution for 200°C tempered AISI 4340 steel. Crack nucleation time t_n increases by preloading for a given apparent stress intensity factor K_p2. The curve K_?2 vs. t_n deviates upward from the curve for the non preloading case. A linear relationship between the crack nucleation time and parameter is seen in semi-log diagram, where is taken as the value at t_n=α due to preloading. The apparent threshold stress intensity factor increases with K_?2 which is the apparent stress intensity factor of preloading. A detached crack is nucleated at some distance from the notch root and extends in a form of circle. This distance increases with increasing K_?2. The effect of load reduction during crack growth was examined. When the K-value was reduced from K₁ to K₂, an incubation time was observed before the crack started growing under the K₂-value. The incubation time t_m tends to increase with increasing ΔK = K₁-K₂. The threshold stress intensity factor was also found to increase for high load reduction.In order to explain these experimental results, a new dislocation model is proposed on the basis of stress induced diffusion of hydrogen in high stress region ahead of the notch root or a crack. This model suggests that the change in the crack nucleation time and the increase of the incubation time due to preloading or load reduction are caused by reducing the hydrostatic pressure and by spreading the hydrogen saturated region which requires more time for the hydrogen accumulation due to preloading or load reduction. The theory predicts the experimentally observed relations between and t_n and between log t_in and ΔK.     

Effect of mechanical properties of material on rate of fatigue crack propagation

Many experimental and analytical equations on a rate of a fatigue crack propagation have been proposed. However, it seems that they can not fully express its complex behavior. There are still many problems remaining to be solved in order to clarify its mechanism. One of them is to clarify the relation between the rate of the crack propagation and the mechanical properties of material. In this paper, the rate of the crack propagation is analysed to clarify this problem. This analysis is based on the observation results of the fatigue crack propagation behavior previously by the authors. The analytical result is compared with the experimental one to make sure that they agree with each other. The conclusion obtained is; the rate of fatigue crack propagation is expressed by using the stress intensity factors as

$\text{dl}\text{dN}\text{= {}\text{c}\text{[Y}{}^2\text{F}{}^{\mathrm{a}}\text{E}{}^{\mathrm{a(1?n)}}\text{]}\text{} (K}{}_{\max }\text{)}{}^2\text{(K}{}_{\mathrm{a}}\text{)}{}^{\mathrm{a(2?n)}}$

. where C is a constant; E, Young's modulus; F, plastic coefficient; Y, yield stress; K_max and K_a, maximum and amplitude of the stress intensity factor, and α and n, exponents of the Manson-Coffin's law and work-hardening.     

Fracture toughness and fatigue crack propagation in high strength steel from room temperature to −180°c

Fracture toughness under tensile test and fatigue test on high strength steel at temperature ranging from room temperature to ?180°C were experimentally studied. The value of fracture toughness under fatigue test is considerably tower than that obtained under tensile test.Within the range from room temperature to ?100°C the following results were obtained: the power coefficient δ of the fatigue crack propagation rate $\text{[(dc)/(dN)] = AΔK}{}^5$ is related with [(1)/($\text{T}$)] as: $\text{δ = b}{}_1\text{+ [(a}{}_1\text{)/(kT)]}$. $\text{[(dc)/(dN)]}$ shows Arrhenius type, and, however, different equation from usual stress dependent rate process equation. The trend is in good agreement with the dislocation dynamics theory of fatigue crack propagation.     

Fracture of thin sections containing surface cracks

Surface-cracked specimens of several thicknesses of 7075-T651 and 7075-T6 aluminum were tested in uniaxial tension. For thicknesses t less than 0.25 in., the gross fracture stress σ_f of 7075-T651 Al was empirically related to flaw size by the following expression:

$\text{δ}{}_{\mathrm{f}}\text{σ}{}_{\mathrm{ult}}\text{= 1 + S(}\text{a}\text{φ}{}^2\text{.t}{}^{\mathrm{<mtext>?1</mtext><mtext>2</mtext>}}$

where σ_ult is the ultimate strength, a the crack depth, φ a function of crack shape, and S a proportionality constant equal to ?1.7 in.^{$\text{?1}\text{2}$}. For 0.25-in. thick 7075-T651 aluminum, σ_f was found to obey this relationship only when $\text{a}\text{φ}{}^2$ is less than 0.065 in.; for larger flaws, such that $\text{0.065 <}\text{a}\text{φ}{}^2\text{< 0.11, σ}{}_{\mathrm{f}}$ is better predicted by Irwin's surface-crack equation with an apparent K_IC value of $\text{32.2}\text{ksi-in.}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}$.Fracture data for thin sections of 2014-T6 and 2014-T651 Al tested at ?423°F are analyzed in terms of the empirical relationship above and are found to be in good agreement. For these alloys, S has a value of ?2.6 in.^{$\text{?1}\text{2}$}.Applicability of the empirical relationship and Irwin's surface-crack analysis to the fracture of thin sections is discussed in terms of crack size, section thickness, and plastic zone size.     

Fatigue crack propagation in steels

From previous investigations of the mechanisms of both fracture and fatigue crack propagation, the static fracture model proposed by Lal and Weiss may be thought as reasonable for describing fatigue crack propagation in metals at both low and intermediate stress intensity factor ranges $\text{ΔK}$. Recent progress in fatigue crack propagation indicates that it is not only possible, but also necessary, to modify this static fracture model. Based on the modified static fracture model, the effective stress intensity factor range $\text{ΔK}{}_{\mathrm{eff}}$, which is defined as the difference between $\text{ΔK}$ and the fatigue crack propagation threshold value $\text{Δ}{}_{\mathrm{th}}$, is taken as the governing parameter for fatigue crack propagation. Utilising the estimates of the theoretical strengths of metals employed in industry, a new expression for fatigue crack propagation, which may be predicted from the tensile properties of the metals, has been derived. The correlation between the fatigue crack propagation rate and the tensile properties is thus revealed. The new expression fits the test results of fatigue crack propagation of steels below 10^?3 mm/cycle and indicates well the effect of stress ratio on the fatigue crack propagation rate.     

The effect of temperature and R ratio on fatigue crack growth in A612 grade B steel

Fatigue-crack propagation rates in ASTM$\text{A612}$ Grade B steel were investigated at room temperature and ?100°F (?73°C) with $\text{R}\text{ratio}\text{= ?0.1}\text{and}\text{+0.67}$. The data were evaluated in terms of the crack propagation rates ($\text{d}\text{a/}\text{d}\text{N}$) as a function of the alternating stress intensition ($\text{ΔK}$), according to $\text{d}\text{a/}\text{d}\text{N = e+(v ? e)(? 1}\text{n}\text{(1 ?}\text{Δ}\text{K/K}{}_{\mathrm{b}}\text{))}{}^{\mathrm{t/k}}$. It was found that crack growth rates were increased due to increasing $\text{R}$ ratio. Also the dependence of crack growth rates on $\text{R}$ ratio is strongest at the lowest crack growth rates where a $\text{ΔK}$ fatigue threshold is established. Crack growth rates were decreased due to decreasing test temperature in the slow crack growth region. However, it was found that crack growth rates were increased due to decreasing test temperature in the fast crack growth region near the upper instability asymptote. Decreased test temperature and increased $\text{R}$ ratio interact synergistically to increase crack growth rates for the entire range of $\text{ΔK}$.