FATIGUE CRACK GROWTH BEHAVIOUR OF METALLIC BIOMATERIALS IN A PHYSIOLOGICAL ENVIRONMENT

Fatigue crack propagation (FCP) in Ringer's solution has been studied on four metallic biomaterials, i.e. pure titanium (TP35H), stainless steel (SUS304), dual-phase stainless steel (SUS329J4L), and titanium alloy (Ti–6Al–4V). For TP35H and SUS329J4L, the crack growth characteristics in Ringer's solution were almost the same as those in room air in the entire ΔK region examined, and thus the effect of Ringer's solution was not observed. The crack growth rates of SUS304 were enhanced in Ringer's solution in the region of ΔK ≥ 25  MPa m as compared to room air, while below this ΔK level they were similar in both environments. Also in Ti–6Al–4V, similar crack growth behaviour in Ringer's solution was found. From the comparison among the da/dN–ΔK relationships of the four materials in Ringer's solution, TP35H exhibited the fastest growth rates and then Ti–6Al–4V, SUS304, SUS329J4L in the order of decreasing growth rate. On the contrary, if the data were plotted in terms of ΔK_eff /E, Ti–6Al–4V and TP35H showed superior crack growth resistance to the stainless steels.     

CREEP-FATIGUE CRACK GROWTH AND FRACTOGRAPHY OF METALLIC MATERIALS IN AIR AND VACUUM AT ELEVATED TEMPERATURES

Creep-fatigue crack growth behaviour of a Type 304 stainless steel, a quenched 21/4Cr-1Mo steel, Hastelloy X, a Ti-6242 alloy, and a low carbon steel under different reversed loading patterns (P-P, C-P and C-C) were investigated in air and a vacuum environment. The results are discussed in the light of fracture mechanics and fractography. Crack growth rates for all of the materials tested were successfully correlated in terms of the cyclic J integral range (Δ J ) irrespective of the loading patterns. In the low growth rate region, where fatigue fracture was predominant, crack growth rates of all the materials were about the same for the same value of Δ J. On the other hand, growth rates were somewhat different, depending on the creep ductility of the material in the region of high growth rate, where creep fracture was predominant. Materials with lower ductility exhibited higher growth rates for the same Δ J values. Differences were insignificant between the crack growth rates in air and vacuum and were consistent with the small differences observed in the fracture surface morphology in the two environments.     

SLOW FATIGUE CRACK GROWTH AND THRESHOLD BEHAVIOUR IN AIR AND VACUUM OF COMMERCIAL ALUMINIUM ALLOYS

Abstract— Fatigue crack growth and threshold behaviour have been examined in three commercial aluminium alloys in both air and vacuum environments. It was observed that, in air, the threshold stress intensity range Δ K _t, varied linearly with the Δ K _t ratio. In contrast Δ K , in vacuum was found to be independent of R. Over the whole growth rate range examined fatigue crack growth in vacuum was Δ K controlled and failure occurred by a dimple and ductile striation mechanism. This also applied to failure in the intermediate growth rate ranges in air. However, at slow growth rates in air, fatigue crack growth was structure sensitive and crystallographic facets were formed during the crack propagation process.     

MECHANISMS OF CYCLIC FATIGUE-CRACK PROPAGATION IN A FINE-GRAINED ALUMINA CERAMIC: THE ROLE OF CRACK CLOSURE

Abstract— Cyclic fatigue-crack growth and resistance-curve behavior have been studied in a fine-grained (∼ 1 μm), high-purity alumina. Specific emphasis is given to the mechanisms associated with crack growth that are controlled by the maximum ( K _max) and the alternating (Δ K ), stress intensities and to the role of crack-face interference (crack closure), which is known to be an important crack-tip shielding mechanism in metal fatigue. Significant levels of subcritical crack growth were detected above a threshold stress intensity of ∼60% of the fracture toughness ( K _c) in the alumina, with growth rates displaying a far larger dependence on K _max compared to Δ K. The role of crack closure was examined using constant- K _max experiments, where the minimum stress intensity ( K _min) was maintained either above or below the stress intensity for crack closure ( K _cl). Where K _min< K _cl, growth rates were found to exhibit a lower dependence on Δ K , which was rationalized in terms of the frictional wear model for crack growth in grain-bridging ceramics. It is concluded that crack closure, as conventionally defined, has little relevance as a crack-tip shielding mechanism during fatigue-crack growth in grain-bridging ceramics, due to the low dependence of growth rates on Δ K compared to K _max.     

THE EFFECT OF STRESS RATIO AND FREQUENCY ON FATIGUE CRACK GROWTH

Abstract The influence of stress ratio and the loading frequency on fatigue crack growth rates in BS 4360–50C steel was investigated in laboratory air.
Fatigue crack growth tests were performed on compact tension specimens (CTS) made in two thicknesses 12 and 24 mm. Tests were conducted at two frequencies of 0·25 and 30 Hz, applying a stress ratio R varying from – 0·7 to 0·7. The results were analysed using the linear elastic fracture mechanics approach. They showed that the increase in both positive and negative R caused increased fatigue crack growth rates. Also an empirical effective stress intensity factor range, Δ K _eff, was found more appropriate to correlate the fatigue crack growth data than the Δ K factor frequently used in crack growth studies.
The loading frequency had only a little influence on crack growth rates at low R . However, at high R , growth rates were significantly higher at lower frequencies. It is suggested that this frequency influence may be associated with environmental effects, due to the embrittlement caused by hydrogen from the moist air, while the crack was fully open.     

EFFECTS OF TEMPERATURE, CYCLIC FREQUENCY AND ENVIRONMENT ON FIBRE DEGRADATION AND FATIGUE CRACK GROWTH RESISTANCE IN A FIBRE-REINFORCED TITANIUM METAL-MATRIX COMPOSITE UNDER DISPLACEMENT-RANGE LOADING

The fatigue crack growth resistance of a [0/90°]_2s cross-ply SCS6 fibre-reinforced Ti–6Al–4V alloy metal-matrix composite has been assessed under displacement range control (i.e. under load shedding conditions with crack extension) to investigate potential fibre degradation and the process of crack extension at room temperature, and at 450°C, in air and in vacuum. Attention is focused on initial conditions that will promote crack arrest at room temperature. Under the test conditions employed here, regions of crack growth can occur where the applied nominal stress intensity factor range (ΔK) is relatively constant. This 'constant'ΔK range is the result of a fortuitous balance between the particular test-piece geometry, loading conditions utilized, matrix crack growth and the rate of fibre fracture. It allows the influence of environment, cyclic frequency and temperature on fatigue crack growth resistance to be analysed more easily than for tests carried out under load control.
The crack growth rate remained almost constant but with some steep local retardations in growth rate in the constant ΔK region at a temperature of 450°C, while crack arrest occurred at room temperature for the same initial ΔK. The average crack propagation rate in this 'constant ΔK region' at a temperature of 450°C in air was much greater than that at a temperature of 450°C in vacuum. This indicates that environment plays an important role in the process of fibre degradation. The effect of cyclic frequency is saturated at a frequency of less than 1  Hz. The process of crack growth at various frequencies is also discussed.     

AN EVALUATION OF FATIGUE AND FRACTURE MECHANICS PROPERTIES OF ULTRA-HIGH STRENGTH 7XXX SERIES Al-ALLOYS

Abstract— The fatigue and fracture mechanics properties of rapidly solidified ultra-high strength 7XXX series Al-alloys have been studied. With respect to conventional high-strength Al-alloys, these materials exhibited a better fatigue-endurance on both plain and notched specimens at low stress amplitude in constant amplitude fatigue tests, whereas the opposite occurred at high stress amplitudes. Fatigue crack growth tests indicated lower crack growth rates at low Δ K -levels, but at intermediate and high Δ K -values these materials were particularly prone to additional components of "static" crack propagation, which led to steeply inclined d a/ d N vs Δ K curves. Moreover, the increase in tensile strength was linked with some loss of ductility and fracture toughness. Overload regions were characterized by a large amount of intergranular decohesion, possibly facilitated by the presence of incoherent particles at grain boundary regions and by the large strength differential between the matrix and precipitate free zone. The best results in terms of elongation to rupture and toughness were obtained by reducing the amount of Cr/Mn incoherent dispersoid-forming elements, in order to lessen the tendency towards matrix-dispersoid interface decohesion at grain boundaries.     

FATIGUE CRACK GROWTH IN NICKEL-BASED SUPERALLOYS AT 500-700°C. II: DIRECT-AGED ALLOY 718

Abstract— The effects of cyclic frequency, hold time, and stress-intensity factor range (Δ K ) on rates of fatigue crack growth in air at 500°C and 700°C have been studied for the direct-aged version of the nickel-based superalloy 718. The main effects were similar to those observed for Waspaloy (Part I), namely: (i) small effects of cyclic frequency and hold time at 500°C, (ii) higher rates of crack growth at lower cyclic frequencies at high Δ K at 700°C, and (iii) lower rates of crack growth at low Δ K (and higher Δ K thresholds) for longer hold times at 700°C. For DA 718, there was no increase in crack growth rates with increasing hold times (0–60 s) at high Δ K at 700°C (unlike the large increases reported for standard processed Alloy 718). Metallographic and fractographic observations showed that crack growth was predominantly transgranular at 500°C, and predominantly intergranular at 700°C except at 2 Hz at high Δ K. The precise intergranular crack path, extent of branching, and fracture-surface appearance depended on Δ K , wave-form and cycle-period. The mechanisms responsible for the observed effects, and possible explanations for the different behaviour of DA 718 and standard processed Alloy 718, are discussed.     

PREDICTION OF THE FATIGUE THRESHOLD FOR A CRACKED BODY USING SHAKEDOWN THEORY

Abstract— In this paper, the fatigue threshold Δ K _th of a cracked body is studied. Unlike other approaches given in the literature, the shakedown theory is used for predicting Δ K _th. A crack is considered as a sharp notch, the radius of which, at the threshold stress level, is a material constant. The threshold of crack propagation is explained as being due to shakedown of the cracked body, and a simple but reasonable model is derived. The value of Δ K _th is found to be proportional to the yield stress multiplied by the square root of the effective crack tip radius. Using this model, Δ K _th is calculated for some materials. Comparison of the predicted fatigue thresholds with those obtained by experiments, or by using other approaches, indicates that our model provides satisfying results.     

RETARDATION AND ARREST OF FATIGUE CRACK GROWTH IN AISI 4340 STEEL BY INTRODUCING REST PERIODS AND OVERLOADS

Abstract— The aim of this study is to investigate the effects of an intermittent rest period at 300°C, an overload in tension, and the combination of an overload and a subsequent rest period, on fatigue crack growth in AISI 4340 steel. The intermittent rest period was found to stop fatigue crack growth completely near the threshold level of Δ K. The alleviation effect of a rest period on crack growth was more distinct at lower levels of Δ K. With overload, the higher overload ratio caused a greater effect on crack growth rate. The reduced stress intensity factor caused by crack branching and an enhanced roughness of crack surfaces probably contribute to the retardation and arrest of fatigue crack growth. The most distinct retardation of fatigue crack growth was found after the combined treatment of an overload and a subsequent rest period. Compressive residual stresses following an overload and strain-age hardening during the rest period at 300°C are suggested as assisting the arrest or retardation of fatigue crack propagation.     

THE GROWTH OF SMALL CORROSION FATIGUE CRACKS IN ALLOY 2024

Abstract— The corrosion fatigue crack growth characteristics of small surface and corner cracks in aluminium alloy 2024 is established. The damaging effect of salt water on the early stages of small crack growth is characterized by: (1) crack initiation at constituent particle pits, (2) intergranular microcracking for a≤100μm, and (3) transgranular small crack growth for a≥100μm. In aqueous 1% NaCl and at a constant anodic potential of −700 mV_SCE, small cracks exhibit a factor of three increase in fatigue crack growth rates compared to laboratory air. Small cracks exhibit accelerated corrosion fatigue crack growth rates at low levels of Δ K (< 1 MPa√m) below the long crack Δ K _th value. When exposed to Paris regime levels of crack tip stress intensity, small corrosion fatigue cracks exhibit growth rates similar to that observed for long cracks. Similar small and long crack growth behavior at various levels of R suggest that crack closure effects influence the corrosion fatigue crack growth rates of small cracks for a≥100 μm. Contrary to the corrosion fatigue characteristics of small cracks in high strength steels, no pronounced chemical crack length effect is observed for alloy 2024 exposed to salt water.     

EFFECT OF LASER BEAM RADIATION ON FATIGUE CRACK PROPAGATION IN AISI 4150 STEEL

The effect of laser beam radiation on fatigue crack growth in AISI 4150 steel was performed on compact-tension (CT) specimens, in which a composite region (CR) comprised of the hardened zones (HZs) on the top and bottom surfaces and the base metal (BM) in the interior, was aligned either along or normal to the crack growth direction. The microstructure of the HZs consisted of martensite, while lower bainite was present in the 300 °C preheated laser-hardened specimens. When the crack propagated along the laser tracks (LTs), the fatigue crack growth rates (FCGRs) of the laser-hardened specimen were lower than those of the base plate, particularly at low ΔK ranges. On the other hand, for a crack propagating normally to the LTs, decelerated FCGRs in the regions preceding the CR and accelerated FCGRs within the CR itself were found. However, enhanced FCGRs in the CR were not found in preheated specimens with a bainite structure in the HZs as the crack grew normal to the LTs. The enhancement of FCGRs in the CR, which became more accentuated at high ΔK values, was closely related to an embrittled microstructure (martensite) in the HZs.     

INITIATION AND GROWTH OF SMALL CRACKS IN DIRECTIONALLY SOLIDIFIED MAR-M247 UNDER CREEP-FATIGUE PART II: EFFECT OF ANGLE NETWEEN STRESS AXIS AND SOLIDIFICATION DIRECTION

This paper deals with the effect of anisotropy on fracture processes of a directionally solidified superalloy, Mar-M247, under a push–pull creep-fatigue condition at high-temperature. Three kinds of specimen were cut from a cast plate such that their axes possess angles of 0°, 45° and 90° with respect to the 〈001〉 orientation that is aligned parallel to the solidification direction (also to the grain boundaries and primary dendrite axis); these specimens being denoted the 0° specimen, the 45° specimen, and the 90° specimen, respectively. The tests were conducted at 1273  K (1000 °C) in air under equal magnitudes of the range of a Δ J -related parameter, Δ W _c , which represents the driving force for crack growth in creep-fatigue. Although the grain boundaries are macroscopically parallel to the solidification direction, they are wavy or serrated microscopically. Small cracks nucleate along parts of the grain boundaries perpendicular to the stress axis in all specimens. The 90° specimen has the shortest crack initiation life and the 0° specimen has the longest. In the 90° and 45° specimens, intergranular cracks continue to nucleate and a main crack is formed along the grain boundary due to the frequent coalescence of small cracks. In the 0° specimen, cracks grow into the grain, and transgranular cracks coalesce along the primary dendrite or grain boundary. The 0° specimen exhibits the slowest crack growth rate and the 90° specimen the fastest. These differences in the initiation and growth behaviour of small cracks cause the longest failure life in the 0° specimen and the shortest in the 90° specimen.     

A NEW METHOD FOR THE MEASUREMENT OF MODE II FATIGUE THRESHOLD STRESS INTENSITY FACTOR RANGE ΔKτth

Abstract— In order to evaluate the threshold value Δ K _τth for mode II fatigue crack growth, a new measurement method of mode II fatigue crack growth has been developed. This method uses a conventional closed-loop tension—compression fatigue testing machine without additional loading attachments. Mode II fatigue tests for structural steel and rail steel have been carried out. This method has proved successful and has reproduced mode II fatigue fracture surfaces similar to those found in the spalling of industrial steel-making rolls. The crack length during testing was measured by an AC potential method. The relationships between d a /d N and Δ K _τ and AK _τth for several materials have been obtained.     

Propagation of microcracks at stress amplitudes below the conventional fatigue limit in Ti–6Al–4V

Fatigue crack growth below the conventional fatigue limit was examined in Ti–6Al–4V in two different microstructural conditions, bi-modal and fully lamellar. Tests conducted at R = −1, at room temperature and in air showed that there is a stress dependency in the d a /d N –Δ K behaviour in both microstructures. The increasing crack front roughness associated with increasing crack size results in a decrease in the crack growth rate relative to the crack growth rate in a single grain. The d a /d N vs. Δ K lines were drawn for each crack size and a 'threshold'Δ K was determined using the intercept of the lines with d a /d N = 10⁻¹⁰ m cycle⁻¹. These values were used to construct modified Takahashi–Kitagawa diagrams to predict microcrack growth below the fatigue limit for each microstructure. A comparison of the two microstructures indicated differences in behaviour in microcrack and macrocrack growth that were explained by differences in crack front roughness at a given crack size.     

MECHANICALLY SHORT CRACK GROWTH FROM NOTCHES IN A MILD STEEL

Abstract— Two L-notched specimens made of mild steel (average grain size =30 μm) and having root radii of 0.1 mm and 3 mm, and also a smooth surface specimen were cyclically loaded at different stress levels at R =−1 and at R = 0. A technique based on miniature strain gauges was successfully used to monitor the depth and the opening level of mechanically short cracks of depths from 0.015 mm to 0.5 mm. Three dimensional FEM computations were made to obtain appropriate calibration curves for varying crack aspect ratios and gauge eccentricities as well as notch plastic strain distributions. The fracture of L-notched specimens having a root radius of 0.1 mm was characterized by an early and multiple crack initiation phase (defined by a crack depth of 30 μm), and the short crack growth rates showed a mechanical behaviour different from that of long cracks (large discrepancies at the same Δ K -value, crack deceleration at R =−1 even beyond the notch plastic zone). For smooth surface specimens both the initiation and the propagation of a single short crack represented important fractions of the total life; the short crack growth rates were high and continuously increasing. The notch influence was highly reduced when the stress singularity is truncated by a 3 mm radius. The cracking behaviour was, in several aspects, close to that at smooth surfaces. The evolutions of crack closure were analyzed in each condition (transient decrease and stabilized value of the closure ratio U =Δ K _eff/Δ K ) and were shown to have a strong influence on short crack growth. Most of the short crack growth rates obtained in the various geometry/loading conditions are well consolidated with LEFM long crack growth rates using the Δ K _eff parameter.     

THE SIZE OF PLASTIC ZONES AND FATIGUE CRACK GROWTH BEHAVIOUR OF THREE FORMS OF A Ti–6Al–2.5Mo–1.5Cr ALLOY

The effect of microstructure on the fatigue properties of Ti–6Al–2.5Mo–1.5Cr alloy was investigated. The experimental results for both the fatigue crack initiation and propagation behaviour, as well as the dynamic fracture toughness ( K _Id ) showed clearly that a lamellar microstructure is superior to two other structures. It was found that, as in the case of steels, the initiation and subsequent growth of cracks in the titanium specimens with a sharp notch may also occur on loading levels below the threshold values of the K factor (Δ K _th ) determined for long fatigue cracks. In addition, measurements by interferential-contrast of the plastic zone size on the surface of specimens revealed that the different rate of crack growth at identical values of Δ K in individual structural states can roughly be correlated with the size of the plastic zone. A general relationship between the fatigue crack growth rate and plastic zone size, the modulus of elasticity and the role of crack tip shielding is discussed.     

THE EFFECT OF REGULAR AND IRREGULAR SHEAR LIPS ON FATIGUE CRACK GROWTH IN Al 2024

Abstract— Multiple underloads and overloads with constant Δ K were carried out on centre-cracked tension specimens. It was found that when shear lips develop, underloads or overloads affect the crack growth rate d a /d N and the subsequent retardation. The appearance of the shear lip fracture surfaces depends on the frequency. At higher frequencies a greater number of rough shear lip fracture surfaces will develop, while at lower frequencies there is a tendency towards smooth shear lips. The amount of crack closure differs in each case. It was found that the type of shear lip, rough or smooth, can be related to the effect on d a /d N during and after underloads. The effect of rough and smooth shear lip growth was investigated in constant Δ K tests, performing these tests with and without crack closure.     

STUDY ON FATIGUE THRESHOLD BEHAVIOUR AND FATIGUE CRACK PROPAGATION IN A CAST Co-Cr-Mo ALLOY USED FOR SURGICAL IMPLANTS

Abstract— —Fatigue crack propagation rates (d a /d N ) and fatigue crack thresholds (Δ K _th) have been studied in a cast Co-Cr-Mo alloy used for surgical implants with various grain sizes. Results for materials with average grain sizes of about 400 and 60μm respectively are presented. Threshold values close to 10–15 MPam have been measured with decreasing values observed on increasing the grain size. Similar effects of grain size are found on the crack propagation behaviour at higher growth rates, where a coarse grain size material show a higher crack growth rate than a fine grain size material at the same Δ K levels. The effects of microstructure on fatigue properties of the cast Co-Cr-Mo alloy are caused not only by grain size variation but are also attributed to the microstructural differences: a coarse-grained material with a directionally grown dendritic structure vs a fine-grained material with an equiaxed grain structure.     

THE INFLUENCE OF TEST VARIABLES ON THE FATIGUE CRACK GROWTH THRESHOLD

Abstract— A microcomputer controlled fatigue crack growth and threshold testing system has been used to investigate the influence of test variables on the measured values of Δ K _th, the threshold for fatigue crack growth, using a C-Mn steel. The work has examined: (1) the influence of crack length and test management; (2) the basic material scatter from repeated testing; (3) the effect of unloading rate C where C = (1/Δ/ K )(d Δ K /d a ); (4) the effect of step unloading; (5) the influence of minimum stress intensity factor, K _min . Comparisons have been made between the results of this computer controlled work and those published previously but made using a manual load shedding technique. The results of Δ K _th and fatigue crack growth rates are in general agreement with previous data and confirm the K _min dependence of Δ K _th and d a /d n. The value of Δ K _th is shown to be generally independent of the other test variables for a wide range of conditions and is reproducible with a low degree of scatter.