Crack closure in 2219-T851 aluminum alloy

The effects of specimen thickness, stress ratio ($\text{R}$) and maximum stress intensity factor ($\text{K}{}_{\max }$) on crack closure (or opening) were studied using a 2219-T851 aluminum alloy. The crack length and the occurrence of crack closure were measured by an electrical potential method. The experimental work was carried out within the framework of linear-elastic fracture mechanics.The experimental results show that the onset of crack closure (or opening) dependes on $\text{R, K}{}_{\mathrm{<mtext>max</mtext>}}$), and specimen thickness. In terms of the “effective stress intensity range ratio” ($\text{U}$), as defined by Elber, the results show that $\text{U}$ tends to increase for increasing $\text{R}$, decrease for increasing $\text{K}{}_{\max }$, and decrease with increasing specimen thickness. From these trends, it is shown that the “effective stress intensity range” ($\text{ΔK}{}_{\mathrm{<mtext>eff</mtext>}}$) does not always increase with increasing stress intensity range ($\text{ΔK}$).The experimental results show that crack closure cannot fully account for the effects of stress ratio, specimen thickness and $\text{K}{}_{\max }$ on fatigue crack growth. The use of $\text{ΔK}{}_{\mathrm{<mtext>eff</mtext>}}$ as a parameter for characterizing the mechanical driving force for fatigue crack growth is questioned.     

Crack closure studies under constant amplitude loading

Crack closure experiments were performed on 6063-T6 Al-alloy using a COD-gauge for various load ranges and stress ratios. Experimental results show that for a given stress ratio, $\text{R}$, the crack closure load goes on decreasing as crack length increases (or $\text{K}{}_{\max }$ increases) and reaches even below minimum load level at higher values of stress ratios. On the basis of these experimental results, a model for effective stress intensity range ratio $\text{U}$, which is found to be a function of stress ratio $\text{R}$ and $\text{k}{}_{\max }$, is developed.     

On the influence of environment on the load ratio dependence of fatigue thresholds in pressure vessel steel

A study has been made of the influence of load ratio $\text{R}$ on fatigue crack propagation behavior and specifically on the value of the fatigue crack growth threshold, Δ$\text{K}{}_0$, in a bainitic 2.25 Cr-1Mo pressure vessel steel tested at 50 Hz in aqueous, and moist and dry gaseous environments. Data are obtained for crack growth in a distilled water environment and are compared to previously published results in air and hydrogen. It is found that in distilled water the dependence of thresholds Δ$\text{K}{}_0$ values on $\text{R}$ is far less marked than in moist air and dry hydrogen atmospheres where Δ$\text{K}{}_0$ values decrease sharply with increasing $\text{R}$. Furthermore, whereas in air and hydrogen, the threshold condition is characterized by a constant maximum stress intensity at low load ratios, and a constant alternating stress intensity at high load ratios, no such behavior is observed in water. Based on extensive measurements of crack face oxidation products using scanning Auger speetroscopy and on previous crack closure measurements using ultrasonics techniques, the role of load ratio in influencing near-threshold fatigue behavior is ascribed to mechanisms of crack closure specifically plasticity-induced closure and closure arising from crack face oxide debris. The implications of such plasticity-induced and oxide-induced closure to the load ratio-dependence of near-threshold fatigue behavior in various environments are discussed in detail.     

The influence of environment and stress ratio on fatigue crack growth at near threshold stress intensities in low-alloy steels

Fatigue crack propagation at low stress intensities has been studied in two low alloy steels in a variety of environments with particular emphasis being placed on the influence of stress ratio and strength level. It was found that fatigue crack growth rates are lower and threshold stress intensities ($\text{ΔK}{}_0$) are higher in vacuum than in humid, laboratory air but, in dry gaseous environments (argon, hydrogen and air) and at low stress ratio ($\text{R ~ 0.1}$), crack growth rates are faster and $\text{ΔK}{}_0$ values are lower than in laboratory air. However, the influence of stress ratio is considerably greater in laboratory air than in dry gaseous environments with the result that, at high stress ratio ($\text{R ~ 0.8}$) $\text{ΔK}{}_0$ values are similar in all environments examined. Increasing material strength level resulted in higher, near-threshold crack growth rates and a reduction in $\text{ΔK}{}_0$ in both dry and humid air environments. The results are discussed in terms of the influence of crack closure and environmental effects on fatigue crack growth behaviour. The importance of corrosion debris produced in fatigue cracks at low stress intensities is also discussed.     

On the cyclic behavior of cast and extruded aluminum alloys. Part A: Fatigue crack propagation

The fatigue crack propagation (FCP) response of a cast and extruded aluminum alloy was examined as a function of mean stress and specimen orientation. The extruded alloy was tested in both the longitudinal and transverse orientation and no difference in FCP response was noted. FCP tests were conducted at R ratios of 0.1, 0.5, 0.65 and 0.8. In the threshold regime, it was seen that as R ratio increased, $\text{Δ}\text{K}{}_{\mathrm{TH}}$ decreased. In addition, ΔK_TH values determined for the cast alloy were superior to those determined for the extruded alloy at all R ratios examined. The threshold regime was also shown to be K_MAX rather than $\text{Δ}\text{K}$ dependent. At intermediate ΔK levels, a mean stress effect was seen for both alloys at R ratios less than 0.5. Crack closure was monitored during testing so that ΔK_EFF values could be determined. $\text{Δ}\text{K}{}_{\mathrm{EFF}}$ was seen to explain mean stress effects at intermediate $\text{Δ}\text{K}$ levels.     

On the cyclic behavior of cast and extruded aluminum alloys. Part B: Fractography

In a prior study [1], the fatigue crack propagation (FCP) response of a cast and an extruded aluminum alloy was examined as a function of mean stress and specimen orientation while crack closure data were collected. In this work, extensive electron fractographic studies were conducted on the previously generated fatigue fracture surfaces using both scanning and transmission electron microscopy. The threshold micromorphology revealed crisp, cleavage-like facets. Striation spacing measurements at intermediate and high $\text{Δ}\text{K}$ levels were obtained to determine microscopic growth rates; these measurements were seen to vary with $\text{R}$ ratio and were best correlated with $\text{ΔK}{}_{\mathrm{EFF}}$ rather than $\text{Δ}\text{K}{}_{\mathrm{APP}}$. Slope changes in the $\text{da/da-}\text{Δ}\text{K}$ plots were identified and attempts made to establish correlations between the associated plastic zone sizes and microstructural dimensions. Of particular note, a stage IIa to IIb transition in the extruded material was found to correspond to a micromechanism change from faceted growth to striated growth when the reversed plastic zone size was similar to the subgrain dimension.     

The effects of load ratio on environmentally assisted fatigue crack growth

A modification to the model of Weir et al. for surface reaction and transport controlled fatigue crack growth has been developed to explicitly account for the effect of load ratio on environmentally assisted fatigue crack growth. Load ratio was found to affect principally gas transport to the crack tip, and therefore affected only transport controlled crack growth response. Experimental verification of the modified model was made by studying the room temperature fatigue crack growth responses at different load ratios for a 2219-T851 aluminum alloy exposed to water vapor.The results show that the effects of load ratio can be attributed to two different sources—one relating to its effect on local deformation at the crack tip and is reflected through the mechanical component, (d$\text{a}$/d$\text{N}$)₀ and the other on its role in modifying environmental effect and is manifested through the corrosion fatigue component, $\text{(da/dN)}{}_{\mathrm{cf}}$ Furthermore, the results show that the saturation value of corrosion fatigue component, $\text{(da/dN)}{}_{\mathrm{cf,s}}$, is essentially independent of $\text{R}$, and that the exposure needed to produce “saturation response” ($\text{P}{}_0\text{/2f)}{}_{\mathrm{s}}$, as a function of load ratio can be predicted from the modified model. The modified model, therefore, allows one to predict the corrosion fatigue crack growth response for any load ratio on the basis of measurements made at a single load ratio, provided that the values of ($\text{da/dN}$), are known.     

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.     

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).     

A simple model of stress intensity range threshold and crack closure stress

The cyclic stress intensity threshold (Δ$\text{K}{}_{\mathrm{TH}}$) below which cracks will not propagate varies with length for short cracks. A model is proposed which relates Δ$\text{K}{}_{\mathrm{TH}}$ to the crack closure stress arising from fracture surface roughness. This is used to predict a variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length for surface cracks in Ti 6Al-2Sn-4Zn-6Mo alloy, based upon measured values of crack opening displacement arising from roughness. The predicted variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length is found to be similar to that obtained from the empirical model of Δ$\text{K}{}_{\mathrm{TH}}$ proposed by El Haddad et al.[5]. The application of the new model to estimate the value of crack closure stress arising from crack tip plasticity for short surface cracks is also discussed.     

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.     

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.     

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.     

Effect of stress wave shape on the crack propagation velocity in cyclic delayed failure

Crack propagation velocity in delayed failure under superposed repeating load, ($\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{R}}$, was compared with that under static load, ($\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{S}}$Two peaks appear on the relation between decreasing rate of crack propagation velocity, $\text{1-β = 1 ? (}\text{d}\text{a/}\text{d}\text{t))}{}_{\mathrm{R}}\text{/(}\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{S}}$ and frequency, ?, both under sinusoidal and square load. By changing the ratio of holding time at maximum stress intensity factor to that at minimum stress intensity factor in square load, it was deduced that the existence of two peaks on the 1 ? β vs $\text{f}$ curve was caused by an asymmetric interaction between hydrogen atoms and cyclic moving of the position with triaxial tensile stress at crack tip. Moreover, the relation between 1 ? β and $\text{f}$ under the positive or negative saw tooth load could be well explained by the interaction model.     

G̃c and R-curve fracture toughness values for aluminum alloys under plane stress conditions

The effect of specimen geometry and subcritical crack growth on the nonlinear energy fracture toughness, $\text{G}\text{?}{}_{\mathrm{c}}$, has been examined for thin, center-cracked sheets of 2024-T3 and 7075-T6 aluminum alloys. The procedure followed was to independently vary the specimen length, L, width, w, andd crack length-to-specimen width ratio and to determine the toughness both at the onset of subcritical crack growth and at the initiation of unstable fracture. Comparisons were also made with the R-curve toughness, G_R, evaluated at unstable fracture from which it was found that both $\text{G}\text{?}{}_{\mathrm{c}}$ and G_R displayed the same trend of change with geometrical variables, with $\text{G}\text{?}{}_{\mathrm{c}}$ consistently higher than G_R. When the nonlinear energy fracture toughness was evaluated at the onset of subcritical crack growth, it was found that the geometry dependence essentially disappeared.Scanning electron microscopic examination of some typical fracture surfaces showed that stable crack growth was accompanied by a gradual change of fracture mode from plane strain to plane stress. An analysis of possible errors in the experimental procedure showed that the scatter observed in $\text{G}\text{?}{}_{\mathrm{c}}$ values was not due to experimental errors, but apparently due to inhomogeneities in the materials. Several techniques were also introduced for the purpose of more directly incorporating crack growth into the $\text{G}\text{?}{}_{\mathrm{c}}$ determination, but it was found that they did not cause significant variation in the toughness values.     

Studies on crack growth rate under high temperature creep,fatigue and creep-fatigue interaction—I: On the experimental studies on crack growth rate as affected by aσg,σg and temperature

Many experimental studies have been reported on the measurements of crack growth rate and the observation of crack growth behaviour under high temperature creep, fatigue and creep-fatigue interaction in literatures. However, many of them have been done in air atmosphere. Furthermore, in many of them the measurements of the crack growth rate have been carried out by interrupting intermittently the running of the testing machine. In such experiments the complex effects due to the atmosphere, the interruption period and the corresponding unloading operation for the crack length measurement might have been involved.In the present paper in order to eliminate such effects, series of experimental studies on the crack growth behaviour under creep, fatigue and creep-fatigue interaction conditions on 304 stainless steel have been carried out by using high temperature microscope and observing the crack length continuously during running the test without interruption in vacuum of 10^?5mm Hg.Among the results, it was found that crack growth rates on a time basis, $\text{da/dt}$, under high temperature creep and creep-fatigue interaction conditions can not be described in terms of solely elastic stress intensity factor $\text{k}{}_{\mathrm{i}}$ or only net section stress σ_net, both independent of gross section stress σ_g. The relation between crack growth rate and stress intensity factor under high temperature fatigue condition changes with some trend according to gross section stress at lower $\text{K}{}_{\mathrm{I}}$ level and it can be approximately described in terms of stress intensity factor $\text{K}{}_{\mathrm{I}}$ only, at higher $\text{K}{}_{\mathrm{I}}$ level. The threshold stress intensity factor and the threshold net section stress under high temperature creep, fatigue and creep-fatigue interaction conditions appears to be almost independent of temperature.     

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.     

On crack opening stress level in fatigue by Eddy current technique

Linear elastic fracture mechanics relates fatigue crack growth with the stress intensity factor at the crack tip. Presence of residual deformations at the tip of a fatigue crack reduces the crack tip stress intensification such that effective stress intensity range $\text{ΔK}{}_{\mathrm{e}}\text{= U · ΔK}$. In this paper use of eddy current technique is exhibited to find the values of test value of effective stress range factor $\text{U}{}_{\mathrm{test}}$. A reasonable comparison between computed and experimental results of $\text{U}{}_1$ and $\text{U}{}_{\mathrm{test}}$ on two Al alloys 6061-T6 and 6063-T6 has recommended the Eddy Current Technology for finding out the values of crack opening stress level under given loading conditions.     

The condition of fatigue crack growth in mixed mode condition

The condition of the initiation of fatigue crack growth in mixed mode conditions has been investigated by using precracked low carbon steel specimens.It is pointed out that, firstly, the critical condition of crack growth should be defined with regard to the modes of fatigue crack growth, i.e. shear mode and tensile mode. Secondly, it is proposed that the critical condition of fatigue crack growth is given by the local tensile stress and shearing stress at the notch tip determined by stress intensity factors $\text{K}{}_{\mathrm{I}}$ and $\text{K}{}_{\mathrm{II}}$, and that this criterion is generally applicable to in-plane-loading conditions, i.e. Mode $\text{I}$, Mode $\text{II}$ and Mixed Mode conditions.