A TECHNICAL NOTE. INFLUENCE OF MEAN STRESS ON FATIGUE IN SEVERAL ALUMINIUM ALLOYS UTILIZING Kcmax THRESHOLD PROCEDURES

Recent interest in the constant K_max (K^c_max) threshold testing procedure has resulted in a more in-depth study of the influence of K_max level on fatigue response and ΔK_th in aluminium alloys. Under R^c= 0.1 conditions, which cause large amounts of closure, ΔK^th levels were typically 2 to 4 Mpam. However, under K^c_max test procedures, associated with no measurable closure at threshold, ΔK_th was typically 1 Mpam. A slight K^c_max level effect on ΔK_th was observed at high K_max values for some of the alloys, and was deemed to be a pure mean stress effect, separate from closure arguments.     

Examination of fatigue crack driving force parameter

Most of the previous parameters that utilized as a crack driving force were established in modifying the parameter K_op in Elber's effective SIF range ΔK_eff(=K_max?K_op). However, the parameters that replaced the traditional parameter K_op were based on different measurements or theoretical calculations, so it is difficult to distinguish their differences. This paper focuses on the physical meaning of compliance changes caused by plastic deformation at the crack tip; the tests were carried out under different amplitude loading for structural steel. Based on these test results, differences of several parameter ΔK_eff in literature are analysed and an improved two‐parameter driving force ΔK_drive(=(K_max)ⁿ(ΔK^∧)^1‐n) has been proposed. Experimental data for several different types of materials taken from literature were used in the analyses. Presented results indicate that the ΔK_drive parameter was equally effective or better than ΔK(=K_max?K_min), ΔK_eff(=K_max?K_op) and ΔK*(= (K_max)^α(ΔK⁺)^1?α) in correlating and predicting the R‐ratio effects on fatigue crack growth rate.     

Experimentelle Bestimmung des ΔKeff für Ermüdungsrißfortschritt

Experimental Determination of ΔK_eff for Fatigue Crack Propagation The results of semi-empirical determinations of ΔK_eff, i.e. K_op, are compared with results obtained via COD and ?back face strain”? measurements. A basic discrepancy is noticed between both sets of results. Three experimental methods for determination of the partitioning point ?K_op”? are described. These methods rely solely on the crack propagation behaviour of fatigue crack and do not depend on any preexisting mechanical model concerning the causes for the partitioning point ?K_op”?. The results obtained with these new test methods are in good agreement with the results obtained semi-empirically. Additionally, Elber's hypothesis, that at high R-ratios ΔK_eff ΔK, was experimentally supported. Yet, the essential finding shows that closure mechanisms cannot be the causes for the existence of a partitioning point and therewith the causes for the existence of ΔK_eff.     

Schwellwert für Ermüdungsrißausbreitung: Bestimmungsmethoden,Kennwerte, Einflußgrößen

Threshold for Fatigue Crack Propagation: Experimental Procedure, Characterizing and Influencing Parameters For the determination of a fatigue crack propagation threshold there exists no “Standard” or other generally accepted experimental procedure. The threshold behaviour of “long” cracks can be characterized by threshold ΔK_th determination as a function of R as well as a function of K_max. The experimental determination of ΔK_th with constant K_max is simpler and a plot of the results versus K_max represents the threshold behaviour of a material more accurate. The whole threshold behaviour is characterized by three parameters. These three parameters can be obtained with relatively little experimental expenditure. The influence of certain conditions, i. e. material, microstructure, environment, ect., on the threshold ΔK_th are discussed. It seems that for a particular material and environment only two of these parameters can be considered as material properties. Test results show that with large change of amplitude ΔK fatigue cracks can grow still at ΔK smaller than ΔK_th. But after some growth, fatigue crack propagation ceases.     

NEAR THRESHOLD FATIGUE CRACK PROPAGATION BEHAVIOUR OF A HETEROGENEOUS MICROSTRUCTURE

The threshold regime of a heterogeneous, pearlitic-ferritic microstructure was investigated at R= 0.1. Not only did the ΔK_th values vary depending on the test procedure in that da/dN vs ΔK curves before and after ΔK_th determination were not identical but transition ΔK values also differed. The observations are correlated with inherent micro- structural features.     

On assumptions associated with ΔKeff and their implications on FCG predictions

In this paper, an assessment of commonly used assumptions associated with ΔK_eff and their implications on FCG predictions in light of existing experimental and numerical data is presented. In particular, the following assumptions are examined: (1). ΔK_eff fully describes cyclic stresses and strains at the crack-tip vicinity. (2). K_op can be determined experimentally or numerically with certain accuracy. (3). Overload alters K_op but not K_max and associated σ_max at the crack-tip ‘process zone’. (4). Contact of crack faces curtails the crack driving force in terms of ΔK_eff.The analysis indicates that there is insufficient support to justify the above assumptions. In contrary, the analysis demonstrates that a two-parameter fatigue crack driving force in terms of ΔK and K_max, which accounts for both applied and the internal stresses should be used in FCG analyses and predictions.     

Effect of welding residual stresses on fatigue crack growth thresholds

Fatigue crack growth thresholds ΔK_th were determined for friction stir welded butt joints made from aluminium alloys AA2024 and AA6013. Plotting the thresholds as a function of load ratio R showed distinctly higher amounts for welded joints as compared to those for parent material at small load ratios, but differences became smaller with increasing load ratio, until thresholds became finally identical for the highest R values. Applying Döker’s concept of two controlling parameters, namely ΔK and K_max [1], and plotting ΔK_th versus K_max, however, revealed that the effective threshold ΔK_th,eff determined at very high R ratios was nearly independent on the alloy and, simultaneously, was identical for parent material and respective welded joints. Thus, differences in threshold behaviour were only caused by the second threshold K_max,th, which was significantly higher for welded joints as compared to parent material. Differences in K_max,th coincided with compressive residual stresses determined by cut-compliance measurements in terms of stress intensity factors K_rs acting at the crack tip. Based on the analytical approach described by Döker [1], only one characteristic K_rs value was needed to calculate all thresholds of welded joints for 0 ⩽ R ⩽ 1 provided a base material master curve is available.     

FATIGUE THERESHOLD IN A 2618A ALUMINIUM ALLOY

Abstract— This work is concerned with the determination of the fatigue threshold ΔK_th for an aluminium alloy. No dependency of ΔK_th with grain size was observed. Crack closure concepts were applied in order to explain the effect of mean stress and environment. The opening load P_op was determined by the compliance method. Results show no significant variation of P_op with environment (air or vacuum) but partially explain the influence of mean stress on crack growth rates. Fractographic analysis (SEM) of fracture surfaces and evolution of compliance diagrams suggest that a change of mechanism in crack propagation occurs when stage I changes to stage II growth.     

PASSIVATION EFFECTS ON CRACK CLOSURE IN THE FATIGUE CRACK PROPAGATION OF A PEAK-AGED Al-Li-Zr ALLOY IN NaCl AND Na2SO4 SOLUTIONS

Abstract Fatigue cracking of a peak-aged Al-Li-Zr alloy was investigated by measuring crack closure as a function of applied anodic potential in 0.6 M NaCl and 0.5 M Na₂SO₄ solutions with an unloading elastic compliance technique, and by comparison with crack closure in dry air. The present work involves complementary anodic behaviour of the Al-Li-Zr alloy in both solutions by potentiodynamic polarization and potentiostatic current transient experiments. From the repassivation rates in the passivation potential range in both solutions, it is indicated that a more stable passive film is formed at lower applied anodic potential than at higher applied anodic potential. The intrinsic fatigue crack propagation (FCP) rates under unstable passivation potential in both solutions were significantly larger than those obtained in dry air. Under stable passivation potential in both solutions, however, the intrinsic FCP rates in the low ΔK_eff range were slightly lower than those obtained in dry air. The crack closure in the low ΔK_eff range increased under stable passivation potential, in dry air and under unstable passivation potential. The high crack closures appearing in the low ΔK_eff range were characterized by a tortuous fracture surface in dry air, and the occurrence of various crack paths such as rolling plane delamination under unstable passivation potential. The difference between environmental crack closures under stable and unstable passivation conditions is discussed in terms of environment-assisted crack-tip damage processes.     

TOUGHNESS GIVEN BY ACCUMULATED WORK IN LEFM: POSSIBLE IMPLICATIONS FOR ELASTOPLASTIC JR"RESISTANCE CURVES"

Abstract J _R vs. Δa curves are often determined from the accumulated work U_acc operated on by an η/Bb factor, and rising J_R curves are said to indicate increased resistance to fracture. It seems to have been overlooked, however, that Krafft G_R resistance curves in lefm are not obtained in this way from U_acc. Indeed the concept of accumulated work during propagation does not appear in the lefm literature. This paper investigates U_acc in lefm and derives relations for ηU_acc/Bb vs. Δa/b for the compact tension and 3-point notched bend testpieces. For fracture at constant G_c a series of quasi-linear plots is predicted: all have G_c as their ordinate intercept with slopes which are multiples of G_c, individual values depending on the starting (a/W). Note that ηU_acc/Bb does not indicate current toughness directly during globally-elastic crack propagation; the ordinate values not coinciding with the known toughness G_c (or R, K_c etc) even in cases where there is “real”G_R behaviour in the Irwin-Krafft sense.     

THE EFFECTS OF MICROSTRUCTURE AND FRACTURE SURFACE ROUGHNESS ON NEAR THRESHOLD FATIGUE CRACK PROPAGATION CHARACTERISTICS OF A TWO-PHASE CAST STAINLESS STEEL

In this study, the effects of stress ratio, microstructure and fracture surface roughness on the fatigue properties of a two-phase cast stainless steel were investigated. This behaviour was examined by means of the fracture mechanics approach and fractography. The fatigue crack growth rate decreased with decreasing stress ratio. The stress ratio markedly influenced the fatigue crack growth rate as ΔK approached the ΔK_th value. The roughness of the fracture surface was greater in the as-cast material than in the heat-treated material. Analysis of the crack growth data using ΔK_eff showed that the effect of R ratio could be explained but that the effect of microstructure on crack growth rate could not.     

THE INFLUENCE OF AGE-HARDENING ON FATIGUE CRACK PROPAGATION BEHAVIOUR IN 7075 ALUMINIUM ALLOY IN VACUUM

Abstract— The influence of age-hardening on the middle and low crack growth rates of a 7075 Al alloy is studied in vacuum. A transition in fracture surfaces morphology and crack growth curves is observed with the T 651 and T 7351 treatments in the near-threshold regime. Measurements of crack closure show its dependance on surfaces roughness and explain the lack of dependance of ΔK_th with load ratio, except for the T 7351 alloy. An equation of crack growth rate to the fourth power of ΔK_eff is in good agreement only with the crack propagation curves obtained for microstructure with an homogeneous deformation mode.     

Crack closure under high load-ratio conditions for Inconel-718 near threshold behavior

Fatigue-crack-growth (FCG) rate tests were conducted on compact specimens made of an Inconel-718 alloy to study the behavior over a wide range in load ratios (0.1 ? R ? 0.95) and a constant K_max test condition. Previous research had indicated that high R (>0.7) and constant K_max test conditions near threshold conditions were suspected to be crack-closure-free and that any differences were attributed to K_max effects. During a test at a load ratio of 0.7, strain gages were placed near and ahead of the crack tip to measure crack-opening loads from local load-strain records during crack growth. In addition, a back-face strain (BFS) gage was also used to monitor crack lengths and to measure crack-opening loads from remote load-strain records during the same test. The BFS gage indicated that the crack was fully open (no crack closure), but the local load-strain records indicated significant amounts of crack closure. The crack-opening loads were increasing as the crack approached threshold conditions at R = 0.7. Based on these measurements, crack-closure-free FCG data (ΔK_eff against rate) were calculated. The ΔK_eff-rate data fell at lower ΔK values and higher rates than the constant K_max test results. In addition, constant R tests at extremely high R (0.9 and 0.95) were also performed and compared with the constant K_max test results. The constant R test results at 0.95 agreed well with the ΔK_eff-rate data, while the R = 0.9 data agreed well with constant K_max test data in the low-rate regime. These results imply that the R = 0.7 test had a significant amount of crack closure as the threshold was approached, while the R = 0.9 and K_max test results may have had a small amount of crack closure, and may not be closure free, as originally suspected. Under the high load-ratio conditions (R ? 0.7), it is suspected that the crack surfaces are developing debris-induced crack closure from contacting surfaces, which corresponded to darkening of the fatigue surfaces in the near-threshold regime. Tests at low R also showed darkening of the fatigue surfaces only in the near-threshold regime. These results suggest that the ΔK_eff against rate relation may be nearly a unique function over a wide range of R in the threshold regime.     

Microstructure variation effects on room temperature fatigue threshold and crack propagation in Udimet 720Li Ni-base superalloy

An assessment of the effects of microstructure on room temperature fatigue threshold and crack propagation behaviour has been carried out on microstructural variants of U720Li, i.e. as‐received U720Li, U720Li‐LG (large grain variant) and U720Li‐LP (large intragranular coherent γ′ variant). Fatigue tests were carried out at room temperature using a 20 Hz sinusoidal cycling waveform at an R‐ratio = 0.1 on 12.5 mm × 12.5 mm square cross‐section SENB specimens with a 60° starter notch. U720Li‐LG showed the highest threshold ΔK (ΔK_th), whilst U720Li‐LP showed the lowest ΔK_th value. U720Li‐LP also showed higher crack growth rates in the near‐threshold regime and at high ΔK (although at higher ΔK levels the difference was less marked). Crack growth rates of U720Li and U720Li‐LG were relatively similar both in the near‐threshold regime and at high ΔK. The materials showed crystallographic stage I type crack growth in the near‐threshold regime, with U720Li showing distinct crystallographic facets on the fracture surface, while U720Li‐LG and U720Li‐LP showed mostly microfacets and a lower proportion of large facets. At high ΔK, crack growth in the materials becomes flat and featureless indicative of stage II type crack growth. The observed fatigue behaviour, which is an effect of the combined contributions of intrinsic and extrinsic crack growth resistances, is rationalized in terms of the microstructural characteristics of the materials. Enhanced room temperature fatigue threshold and near‐threshold long crack growth resistance are seen for materials with larger grain size and higher degree of planar slip which may be related to increased extrinsic crack growth resistance contributions from crack tip shielding and roughness‐induced crack closure. Differences in the deformation behaviour, either homogeneous or heterogeneous due to microstructural variation in this set of materials may provide approximately equivalent intrinsic crack growth resistance contributions at room temperature.     

Crack-closure behavior of 2324-T39 aluminum alloy near-threshold conditions for high load ratio and constant Kmax tests

Fatigue-crack-growth rate tests were conducted on compact specimens made of 2324-T39 aluminum alloy to study the behavior over a wide range in load ratios (0.1  R  0.95) and a constant K_max test condition. Previous research had indicated that high R (> 0.7) and constant K_max test conditions near threshold were suspected to be crack-closure free and that any differences were attributed to K_max effects. During the tests, strain gages were placed near and ahead of the crack tip to measure crack-opening loads from local strain records on all tests, except R = 0.95. In addition, a back-face strain gage was used to monitor crack lengths and also to measure crack-opening loads from remote strain records. From local gages, significant amounts of crack closure were measured at the high-R conditions and crack-opening loads were increasing as the threshold condition was approached. Crack-closure-free data, ΔK_eff (= U ΔK) against rate, were calculated. These results suggest that the ΔK_eff against rate relation may be nearly a unique function over a wide range of R even in the threshold regime, if crack-opening loads were measured from local strain gages and not from remote gages. At low R, all three major shielding mechanisms (plasticity, roughness, and fretting debris) are suspected to cause crack closure. But at high R and K_max tests, roughness and fretting debris are suspected to cause crack closure above the minimum load.     

On R ratio dependence of threshold stress intensity factor range for fatigue crack growth in type 316(N) stainless steel weld

Abstract

The influence of R ratio in the range 0·05–0·4 on the ambient temperature fatigue crack growth behaviour of an austenitic stainless steel weld, SS 316(N), has been studied. Results indicate that the cyclic threshold stress intensity factor ΔK_th increases with decreasing R ratio. The data are compared with those for SS 316, SS 316L and SS 316L(N) base materials from the literature, and various approaches dealing with the R ratio effects are examined. Zhang’s model considering the contribution of the crack tip plasticity to the fundamental fatigue crack propagation process does provide a consistent interpretation for the data.     

Crack closure and fatigue crack growth near threshold of a metastable austenitic stainless steel

In this paper R-ratio effects on fatigue crack growth near threshold region of a metastable austenitic stainless steel (MASS) in two different conditions, i.e. annealed and cold rolled, is investigated. The authors present two approaches to correlate FCGR data for R = 0.1, 0.3, 0.5, 0.7 and K_max = 23 MPa√m using a two-parameters approach (ΔK, K_max and α in Kujawski’s model) and crack closure model (using Elber’s K_op and in Donald’s ACRn2 approaches). The K_op and ACRn2 were experimentally measured on a single edge tension specimens. The K_op measurements were performed using a modified method and based on ASTM standards. While the two driving force approaches correlate data well in the Paris region, they fail to correlate them in the threshold region. However, this correlation can be improved in the threshold region when a different α value from the Paris region is used. The authors indicated that two different mechanisms operate; one in the Paris region and another in the near threshold. Hence, they proposed to combine the two-parameter and crack closure approaches where ΔK is replaced by ΔK_eff (estimated by a new method proposed in this paper), which is shown to correlate the FCGR data for different stress ratios for annealed steel. The correlation for cold rolled condition shows improvement with the new approach but is not as good as for the annealed one. The author further suggests to modify K_max in the two-parameter approach.     

IN SITU SEM MEASUREMENTS OF CRACK CLOSURE FOR SMALL FATIGUE CRACKS IN ALUMINIUM 2024-T351

Abstract Crack closure has been measured for a range of small, self-initiated fatigue cracks using in situ SEM loading. Cracks were grown at positive R ratios in the aluminium alloy 2024-T351 and at nominal ΔK levels that extend substantially below the corresponding long crack threshold. The crack closure stress of the small cracks decreased and the K_cl level increased with increasing crack size until the long crack value near threshold was reached. For cracks of depth larger than about one grain size, a good correlation was obtained between small and long crack growth rate data in terms of ΔK_eff     

Very high cycle fatigue properties of high‐strength spring steel 60SiCrV7

The very high cycle fatigue properties of spring steel 60SiCrV7 for automotive suspension system with different hydrogen contents were studied by using ultrasonic fatigue testing and fatigue crack growth testing. The results show that the S–N curves exhibit continuous drop of fatigue lives and no obvious horizontal line exists. Similar fracture surface features were observed for all the specimens that failed mainly from internal inclusions with surrounding granular bright facet (GBF). Fatigue strength decreases remarkably with increasing hydrogen content. The applied stress intensity factor range at the periphery of GBF ΔK_GBF is approximately proportional to 1/3 power of the square of GBF area. The average values of ΔK_GBF for uncharged specimens are close to crack growth threshold ΔK_th, which indicates that ΔK_GBF could be regarded as the threshold value governing the beginning of stable fatigue crack propagation. The increase of hydrogen content tends to reduce ΔK_GBF.