Rißausbreitung bei Leichtbauwerkstoffen

Fatigue Crack Propagation of High Strength Alloys Investigations of the crack propagation behaviour under variable amplitude loading conditions show a strong influence of sequence effects. The fatigue crack propagation as a consequence of changes in the loading conditions is not linear. New continuum mechanical analyses enable an interpretation of the influence of sequence effects on fatigue crack propagation by considering the plastic deformations and displacements around the crack tip and their correlation to the crack closure behaviour. In order to enable a direct investigation of the crack propagation and crack closure behaviour in the scanning electron microscope a special loading equipment was designed. The investigations led to the following results:

• there existed only a weak correlation between the crack propagation rates and mechanisms at the side surfaces and on the fracture surfaces of the specimens,
• the crack propagation behaviour was significantly influenced by the microstructural constitution of the alloy,
• the continuum mechanical analyses could be corroborated in the tests.

For the tests the high strength aluminum alloys 2024-T3 and X-7075 were applied.     

Fatigue crack growth in heat-treated aluminium alloys

Fatigue crack propagation tests have been performed in several heat-treated aluminium alloys under constant amplitude loading. All experiments were performed, in load control, in a servo-hydraulic closed-loop mechanical test machine. The tests were carried out using middle tension, M(T), specimens. The influence of stress ratio and thickness were analysed. Crack closure was monitored in all tests by the compliance technique using a pin microgauge. A strong stress ratio and material dependence effects on the fatigue crack growth were observed. These effects are discussed in terms of the different dominant closure mechanism. The crack growth behaviour of heat-treated aluminium alloys depends mainly on whether the dominant closure mechanism is plasticity-induced or roughness-induced. The enhancement of roughness-induced closure promotes higher crack growth resistance in these alloys. Roughness-induced closure dominates crack closure in aluminium alloys age hardened by naturally ageing and also artificially aged alloys with higher contents of Mn and Cr elements. In alloys aged hardened by artificially ageing and simultaneously with a lower content of these alloying elements plasticity-induced closure is dominant.     

Effects of alloy additions on the fatigue properties of cast Co-Cr-Mo alloy used for surgical implants

As the second part of the present study, the effects of modifying the composition of the Co-Cr-Mo alloy with additions of nickel and some trace elements aluminium, titanium and boron, have been investigated. A great improvement in the fatigue crack growth resistance of the cast alloy is obtained by nickel additions to the base alloy, mainly because of a significant increase in the alloy's stacking fault energy. In addition, the fatigue fracture ductility is observed to be improved strikingly with the nickel additions. Much smaller facets and better ductility with a mixed fatigue crack propagation mode, as compared to the base alloy, are observed in the alloys with low nickel content level, and in the alloys with high nickel content level, localized ductile fatigue striations are observed. It is also indicated that minor additions of such elements as aluminium, titanium and boron can be used to improve further the fatigue crack growth resistance resulting from the elimination of some microstructural casting defects.     

Microstructural influences on fatigue and fracture resistance in high strength structural materials

A concise review is given of microstructural influences on fatigue strength, fatigue crack propagation, fracture toughness, and stress corrosion in high strength aluminium alloys, titanium alloys, and steels.     

Messung und Modellierung der Lebensdauer der Legierung AlCuMg2 unter zweistufiger Schwingbeanspruchung

Fatigue lifetime investigations on Aluminium 2024 under two stage cyclic loading by means of experiments and three microstructural models The aim of this work is to achieve information about the development of fatigue failure in the aluminium alloy 2024. The attention was focused on short fatigue cracks under cyclic loading and the occurring load sequence effects on lifetime under two‐level cyclic loading. Following the experiments, a revision of three different microstructural crack growth models, which were found in the literature, was made. Based on the data of constant‐level cyclic loading, predictions of two‐level cyclic loading behaviour were made and compared with the experimentally measured crack propagation rates and reached lifetimes.     

Fatigue crack propagation under in‐phase and out‐of‐phase biaxial loading

Fatigue damage characteristics of aluminium alloy under complex biaxial loads such as in‐phase and out‐of‐phase loading conditions and different biaxiality ratios have been investigated. The effects of microscale phenomena on macroscale crack growth were studied to develop an in‐depth understanding of crack nucleation and growth. Material characterization was conducted to study the microstructure variability. Scanning electron microscopy was used to identify the second phase particles, and energy dispersive X‐ray spectroscopy was performed to analyse their phases and elements. Extensive quasi‐static and fatigue tests were conducted on Al7075‐T651 cruciform specimens over a wide range of load ratios and phases. Detailed fractography analysis was conducted to understand the crack growth behaviour observed during the fatigue tests. Significant differences in crack initiation and propagation behaviour were observed when a phase difference was applied. Primarily, crack retardation and splitting were observed because of the constantly varying mode mixity caused by phase difference. The crack growth behaviour and fatigue lives under out‐of‐phase loading were compared with those under in‐phase loading to understand the effect of mixed‐mode fracture.     

Environmentally-assisted fatigue crack growth mechanisms in advanced materials for aerospace applications

This paper addresses the issue of environmentally-assisted fatigue crack propagation in metallic and intermetallic alloys, which is essential to predict the durability of aerospace components. A review of the current understanding of the mechanisms accounting for the detrimental effect of air on fatigue crack growth resistance of conventional alloys is first presented. The adequacy of the two sequential processes identified, namely water vapour adsorption on crack tip surfaces and hydrogen embrittlement of cyclically deformed material within the plastic zone, to account for environmentally-assisted fatigue crack propagation in alloys based on intermetallic compounds is then examined. The last section is devoted to the analysis of environmental effects during creep–fatigue crack growth in an age-hardened aluminium alloy for supersonic aircraft. In particular the influence of environment on the intergranular cavitation damage process is analysed.     

Fatigue behaviour of friction stir welds without neither welding flash nor flaw in several aluminium alloys

Fully reversed axial fatigue tests have been performed in order to investigate the fatigue behaviour in the friction stir welds of 1050-O, 5083-O, 6061-T6 and 7075-T6 aluminium alloys. In all alloys, the comparative studies on the fatigue behaviour between parent materials and welds have been done. The fatigue behaviour of the welds was sensitive to the microstructures such as stir zone, thermo-mechanically affected zone and heat affected zone. The fatigue strengths of the welds are comparative to or lower than those of the parent materials. The observed fatigue strengths were discussed based on the microstructure and crack initiation behaviour.     

SHORT FATIGUE CRACK GROWTH BEHAVIOUR IN WASPALOY AT ROOM AND ELEVATED TEMPERATURES

Short fatigue crack growth tests have been carried out at room and elevated temperatures using the nickel-based superalloy known as Waspaloy. A fully automated computer controlled system has been developed and employed for controlling the testing and monitoring of the growth of freely initiated surface short cracks on smooth specimens. Surface cracks as small as 10 um in length have been detected and recorded at temperatures up to 700°C. Anomalous short crack propagation behaviour was observed when comparisons were made with the corresponding long crack behaviour. Some aspects of mechanical, microstructural and environmental effects on the short fatigue crack growth behaviour of the material are discussed.     

The effect of silicon content on long crack fatigue behaviour of aluminium–silicon piston alloys at elevated temperature

The microstructure of aluminium piston alloys comprises primary and eutectic silicon together with numerous intermetallics. Previous research has shown that primary silicon strongly influences both fatigue crack initiation and subsequent propagation behaviour, however, the detailed effects of varying silicon volume fraction and morphology have not been fully addressed. Therefore, the fatigue properties of a number of candidate piston alloys with varying volume fractions of silicon have been studied. Long crack fatigue tests have been performed at room and elevated temperature typical of the gudgeon pin boss (200 °C) using a test frequency of 15 Hz (a typical engine frequency at engine idle condition).Microstructural characterisation using image analysis approaches combined with optical profilometry has been used to assess the fracture surfaces of test samples. The role of primary Si in enhancing crack growth rates at high ΔK levels, whilst affording improvements in crack growth rates at lower ΔK levels due to local crack deflections and shielding, has been confirmed. In the absence of primary Si (lower Si content alloys) the low ΔK level crack growth behaviour is dominated by matrix properties (intra-dendritic crack growth pre-dominates) whilst the high ΔK level crack growth behaviour is inter-dendritic and occurs along the weak path of the eutectic Si and/or intermetallic network.     

FATIGUE BEHAVIOUR OF FIBRE ALUMINIUM LAMINATES WITH DIFFERENT RESIDUAL STRESSES

In this study two kinds of fibre aluminium laminates (aramid aluminium laminates, ARALL and glass aluminium laminates, GLARE) with different residual stresses in the aluminium layers were prepared. Fatigue crack propagation tests were performed. It is found that the residual stress condition plays an important role in the fatigue behaviour of fibre aluminium laminates. With a decrease of the tensile residual stress in the aluminium layers, the fatigue crack growth rate of the laminates is greatly reduced, and the shape of the curves of fatigue crack propagation rate as a function of the stress intensity factor changed. Compared to GLARE, the ARALL is more sensitive to the residual stress condition. The fatigue properties of non-prestressed GLARE are better than those of ARALL. The influence of the residual stress is discussed in detail.     

FRACTURE BEHAVIOUR OF Al12wt.%Si0.35wt.%Mg(0–0.02)wt.%Sr CASTING ALLOYS UNDER FATIGUE TESTING

Abstract— A systematic study of the fatigue crack growth characteristics and mechanisms in Al–Si–Mg and A356 casting alloys was carried out. Compact tension specimens, prepared from modified and unmodified alloys were tested at different stress ratios and stress intensity factor range values, and a study of the mechanistic role of the silicon particles in influencing the fracture behaviour during fatigue crack propagation was made, employing both optical and scanning electron microscopy. The results indicated that the fatigue crack growth behaviour of the alloys is affected by the stress ratio, stress intensity level and the size, shape and distribution of the eutectic silicon particles. The particle characteristics also determine the fracture mode of the alloy. Fracture Characteristics observed include decohesion of the silicon particles from the aluminum matrix; silicon particle cleavage/cracking; and striations in the aluminum phase, particularly at high stress ratios.     

A modification of UniGrow 2‐parameter driving force model for short fatigue crack growth

In this paper, a modification of the UniGrow model is proposed to predict total fatigue life with the presence of a short fatigue crack by incorporating short crack propagation into the UniGrow crack growth model. The UniGrow model is modified by 2 different methods, namely the “short crack stress intensity correction method” and the “short crack data‐fitting method” to estimate the total fatigue life including both short and long fatigue crack propagations. Predicted fatigue lives obtained from these 2 methods were compared with experimental data sets of 2024‐T3, 7075‐T56 aluminium alloys, and Ti‐6Al‐4V titanium alloy. Two proposed methods have shown good fatigue life predictions at relatively high maximum stresses; however, they provide conservative fatigue life predictions at lower stresses corresponding high cycle fatigue lives where short crack behaviour dominates total fatigue life at lower stress levels.     

The significance of stress corrosion cracking in corrosion fatigue crack growth studies

A model is proposed to account for interactions between fatigue and stress corrosion crack propagation mechanisms in appropriate corrosion fatigue conditions. Tests on an alloy steel, and both wrought and cast aluminium alloys, are reported. Despite the use of very simple coefficients in the equations derived, encouraging results are obtained.     

MICROSTRUCTURE AND FATIGUE PROPERTIES OF A WELDED DUPLEX STAINLESS STEEL

Abstract— In response to the increasing structural applications in duplex steels for welded structures, fatigue behaviour of a SAF 2304 grade duplex stainless steel was investigated, considering both the base metal and GTAW welded joints. Fatigue curves and fatigue limits under rotary bending fatigue were obtained. The study focused attention on the microstructural features of fatigue crack propagation of the two series of experiments, thereby permitting an evaluation of the tortuous crack path of welded joints and the mechanisms related to threshold microstructural barriers.     

Relationships between microstructure and fatigue crack propagation paths in Al–Si–Mg cast alloys

Fatigue crack propagation of long and small cracks was investigated for hypoeutectic and eutectic Al–Si–Mg cast alloys. Crack propagation behavior in the near-threshold regime and Regions II and III was related to microstructural constituents namely primary α-Al dendrites and volume fraction and morphology of eutectic Si. Long crack thresholds reflect combined closure effects of global residual stress and microstructure/roughness. The small crack threshold behavior is explained through closure independent mechanisms, specifically through the barrier effects of characteristic microstructural features specific to each alloy. In Regions II and III changes in fracture surface roughness are associated with different crack propagation mechanisms at the microstructure scale. The extent of the plastic zone ahead of the crack tip was successfully used to explain the observed changes in crack propagation mechanisms.     

Microstructure dependent fatigue crack growth in aged hardened aluminium alloys

Fatigue crack propagation tests in constant amplitude loading, as well as with single peak overloads, have been performed in AlMgSi1-T6 aluminium alloys with different Mn and Cr contents. Crack closure was monitored in all tests by the compliance technique using a pin microgauge. A moderate stress ratio and a strong material dependence effects on the fatigue crack growth were observed. These effects are discussed in terms of the different dominant closure mechanism (plasticity-induced closure or roughness-induced closure). Roughness-induced closure dominates crack closure in the alloys with higher contents of Mn and Cr elements. In the alloy with a lower content of these elements, plasticity-induced closure is dominant. When roughness-induced closure is the prime pre-overload closure mechanism, the retardation effect is decreased in comparison to when plasticity-induced closure is dominant.