Fatigue behaviour of a box-welded joint under biaxial cyclic loads

Multiaxial fatigue behaviour of box-welded (wrap-around) joints in a JIS SM400B steel (12-mm-thick plate) was examined using a biaxial fatigue test facility. For the specimen, two stiffeners were attached to a main plate by a CO₂ semi-automatic welding procedure. Residual stress measurements and finite element (FE) analyses were also performed. Fatigue tests were performed under both uniaxial and biaxial (mainly out-of-phase) cyclic loads, and both results were compared and examined. It was found that fatigue cracks in the biaxial fatigue test specimens were initiated at the boxing-weld toes and propagated almost in the direction of the lateral loads. This is considered to be due to the dominant direction of tensile residual stresses from welding and the stress concentration in the vicinity of the boxing-weld toe. From the relation between the strain range near a weld toe, Δε₅ , and the fatigue lives, it was found that crack initiation life, N_c , was almost equivalent in the biaxial and uniaxial fatigue tests, while the failure life, N_f , was slightly longer in the biaxial tests. However, when the fatigue lives are put in order using the stress range near a weld toe, Δσ₅ , the crack initiation life, N_c , in the out-of-phase biaxial tests (phase difference of π) is ~30% lower than in the in-phase biaxial and uniaxial tests, while the failure life, N_f , was almost equivalent in the biaxial and uniaxial tests. From these results, it is concluded that an increase in Δσ₅ (lowering of the minimum value of σ₅ ), induced by the out-of-phase lateral loads, leads to an increase in fatigue damage where the high tensile welding residual stresses exist in the vicinity of the boxing-weld toe. Finally, a simple life estimation for the biaxial fatigue tests was made using FE analyses and the results of the uniaxial fatigue tests, proving that the effects of the lateral loads should be taken into consideration.     

Prediction of thermal fatigue life of ceramics

On the assumption that the thermal fatigue life of ceramics is determined mainly by the duration over which a crack reaches a small critical length, a prediction of the life was made by application of fracture mechanics to ceramics based on subcritical crack growth. Approximated formulae, such asN/N(T _N /T _N ) ⁿ , were derived, whereN andN are the lives for temperature differences of T _N and T _N , respectively, andn is a material constant. Experimental examination showed that the formulae proved to be valid for glass, sintered mullite under moderate shock severity, and zirconia. Data given by other authors also prove their validity. The deviation of the life from the formulae for sintered mullite under a thermal shock of extremely low severity, suggests that a certain mechanism, for example strengthening, is needed to understand the life of the sintered mullite. Moreover,n determined from the thermal shock experiments is comparable with that given in data determined by a mechanical method.     

CRACK NUCLEATION AND PROPAGATION IN BLADE STEEL MATERIAL

Stress corrosion cracking and corrosion fatigue of 12 Cr steel in sodium chloride solution has been investigated. Tests have been performed in air at room temperature and in aqueous solution with 22% NaCl at 80°C. The influence of corrosion pits on crack nucleation has been investigated. On fracture surfaces tested in environment (22% NaCl solution), crack initiation was observed in correspondence with corrosion pits; in this case fatigue life can be described using a fracture mechanics approach. The ΔK value for crack nucleation from a pit in rotating bending fatigue tests is very low in air (about 3 MPa√m). The results of slow strain rate tests on smooth specimens show that there is a threshold stress intensity, K_ISCC, of about 15 MPa√m and a plateau in stress corrosion crack growth rate of about 10^-5mm/s.     

FRACTURE MECHANICS ANALYSIS OF FATIGUE RESISTANCE OF SPOT WELDED COACH-PEEL JOINTS

Resistance spot welding is the most widely used joining method in automobile manufacture. The number, location, and quality of welds are some of the factors that influence the performance of welded subassemblies, and body panel structures. Therefore, design optimization requires knowledge of not only sheet metal behavior, but also weld behavior under service loadings. A linear elastic fracture mechanics approach was employed in this study to estimate the fatigue lives of spot welds subjected to tearing loads in a coach-peel specimen. Using a finite element method (FEM), the initial J-integral values for five coach-peel joints, each with different geometries, were calculated. Fatigue tests conducted on the same weld geometries provided life data. The experimental data were used to derive a relationship between the initial elastic J-integral values (ΔJ_e) and the fatigue life. It was found that the total fatigue life (N_f) of a weld at one applied stress range is related to its range of J-integral value such that a ΔJ_e vs N_f log-log plot gives a straight line relationship. This relationship can be used to evaluate the effects of geometrical variables on the fatigue life of coach-peel joints. The results show that, within the dimension range studied here, the effects of geometrical variables on the fatigue resistance can be ranked in the following decreasing order: weld eccentricity, sheet thickness and weld nugget diameter.     

A SINGLE EXPRESSION FORMULA FOR INVERTING STRAIN-LIFE AND STRESS-STRAIN RELATIONSHIPS

Starting with the basic fatigue life formula Δε/Δε_T= (N_f/N_T)^b+ (N_f/N_T)^c an inversion formula is derived in the form N _f/N_T= [(Δε/Δε_T)^z/b+ (Δε/Δε_T)^z/c]^1/z where z is a function of strain range and the ratio c/b. The inversion formula is valid over the entire life range of engineering interest for all materials examined. Conformity between the two equations is extremely close, suitable for all engineering problems. The approach used to invert the life relation is also suitable for the inversion of other formulas involving the sum of two power-law terms.     

Characterization of fatigue damage for paving asphaltic materials*

This study investigates the fatigue characteristics of typical bituminous materials used in road applications. Fatigue testing was performed in a four‐point bending beam test apparatus under controlled strain and stress conditions. Fatigue life was defined using the classical approach as the number of cycles, N_f, to 50% reduction in the initial stiffness modulus. It has also been defined in terms of macro‐crack initiation, N₁. A different approach, based on the linear reduction in stiffness during a particular stage of a fatigue test, was introduced to define a damage parameter, and the evolution of this damage parameter with number of cycles was used to characterize fatigue life. Furthermore, refinements to the linear damage model were introduced to take into account the difference in the evolution of dissipated energy between controlled strain and stress testing modes. These modifications have enabled the identification of a unique fatigue damage rate for both controlled strain and stress test modes.     

Fretting fatigue limit as a short crack problem at the edge of contact

This paper proposes a local stress concept to evaluate the fretting fatigue limit for contact edge cracks. A unique S–N curve based on the local stress could be obtained for a contact edge crack irrespective of mechanical factors such as contact pressure, relative slip, contact length, specimen size and loading type. The analytical background for the local stress concept was studied using FEM analysis. It was shown that the local stress uniquely determined the ΔK change due to crack growth as well as the stress distribution near the contact edge. The condition that determined the fretting fatigue limit was predicted by combining the ΔK change due to crack growth and the ΔK_th for a short crack. The formation of a non‐propagating crack at the fatigue limit was predicted by the model and it was experimentally confirmed by a long‐life fretting fatigue test.     

Fracture toughness and thermal shock of tool and turbine ceramics

The behaviour of some commercial tool carbides and turbine ceramics has been investigated in regard to resistance to crack initiation, crack propagation and retained strength after thermal shock. New data are provided, particularly measurements of the fracture toughness of these materials at actual operating temperatures (up to 1200° C). Many of the materials did not follow the generally accepted Hasselman theory for thermal shock in ceramics, and instead of showing a discontinuity in retained strength at some critical quenching temperature difference, their residual strengths fell gradually at temperatures lower than their supposed critical quenching temperature. This behaviour is explicable when high temperature toughnesses, strengths and moduli are used in the damage resistance parameter (ER/gs _f ² ). It seems that materials not following the Hasselman model suffer cumulative damage with increasing number of shocks. Sub-critical crack growth occurs even if (K _IC/gs _f)² values are constant, and such damage, which reduces the room temperature retained strength, is enhanced by (K _IC/gs _f)² decreasing at temperatures below ΔT _c. In contrast, materials obeying Hasselman's model appear to have a constant (K _IC/gs _f)² below ΔT_c and for some temperature range above. Only then are “one-shock“ characterizations of materials possible, otherwise, the retained strength depends upon the number of prior shocks. Experiments are also reported which describe the effects of rate of testing on the unshocked and shocked mechanical properties of ceramics. Oxidation is shown to influence the results in a manner not obvious from single shock tests.     

Effect of impact modification on slow crack growth in poly(vinyl chloride)

The effect of impact modification on slow crack growth in a poly(vinyl chloride) (PVC) compound was examined in order to test a methodology for predicting long-term creep fracture from short-term tension-tension fatigue tests. In all cases the crack propagated in a stepwise manner through a crack tip craze zone. Step length was analyzed in terms of the Dugdale model for a crack tip plastic zone. The overall crack growth rate in fatigue and creep followed the conventional Paris power law with the same power 2.7, da/dt = A _f K _I ^2.7 and da/dt = BK _I ^2.7,respectively. The effects of frequency, temperature, and R-ratio (the ratio of the minimum to maximum stress intensity factor in the fatigue loading cycle) on the Paris prefactor were determined. Crack growth rate was modeled as the product of a creep contribution that depended only on the maximum stress intensity factor and a fatigue contribution that depended on strain rate da/dt = B _f K _I,max ^2.7 (1 + C , where C is a coefficient defining the strain rate sensitivity. A linear correlation allowed for extrapolation of the creep prefactor B _f from fatigue data. Impact modification decreased B _f but had no effect on C.     

Crack growth process in GBF area of SUJ2 bearing steel in very high cycle fatigue regime

Abstract

The crack growth process in GBF of high strength bearing steel JIS SUJ2 is qualitatively investigated by low–high two-step variable amplitude loading (TSAL) tests. It is demonstrated that the GBF size reduces with the increase in applied stress amplitude, and that the GBF size at a given stress amplitude is a constant which is independent of inclusion size at the crack origin. The fatigue life at a given stress amplitude, which is proportional to ?8 power of the inclusion size, reduces with increasing inclusion size. It was shown by TSAL tests that GBF was formed at the earlier stage (approximate 10⁵ cycles corresponding to less than 1% total fatigue life in the regime N_f≧10⁷ cycles) and propagated hardly until near to the final life (more than 90% total fatigue life). After that the GBF crack will propagate rapidly to the ultimate size in a short time.     

FATIGUE LIFE PREDICTION IN BENDING FROM AXIAL FATIGUE INFORMATION

Bending fatigue in the low cyclic life range differs from axial fatigue due to the plastic flow which alters the linear stress-strain relation normally used to determine the nominal stresses. An approach is presented in this report to take into account the plastic flow in calculating nominal bending stress S_bending based on true surface stress. For a given surface strain ε_S, hence the surface life (N_S), an equation is derived to express S_bending in terms of axial fatigue stress (S_axial), involving material constants c, b, N_T which are obtained from axial fatigue information and f₁ and f₂ which are functions of strain hardening exponent and depend on the geometry of cross-section. These functions are derived in closed form for rectangular and circular cross-sections. The nominal bending stress and the axial fatigue stress are plotted as a function of life (N_S) and these curves are shown for some materials of engineering interest.     

Fatigue behaviour of friction stir welded AA2024‐T3 alloy: longitudinal and transverse crack growth

The fatigue crack growth properties of friction stir welded joints of 2024‐T3 aluminium alloy have been studied under constant load amplitude (increasing‐ΔK), with special emphasis on the residual stress (inverse weight function) effects on longitudinal and transverse crack growth rate predictions (Glinka's method). In general, welded joints were more resistant to longitudinally growing fatigue cracks than the parent material at threshold ΔK values, when beneficial thermal residual stresses decelerated crack growth rate, while the opposite behaviour was observed next to K_C instability, basically due to monotonic fracture modes intercepting fatigue crack growth in weld microstructures. As a result, fatigue crack growth rate (FCGR) predictions were conservative at lower propagation rates and non‐conservative for faster cracks. Regarding transverse cracks, intense compressive residual stresses rendered welded plates more fatigue resistant than neat parent plate. However, once the crack tip entered the more brittle weld region substantial acceleration of FCGR occurred due to operative monotonic tensile modes of fracture, leading to non‐conservative crack growth rate predictions next to K_C instability. At threshold ΔK values non‐conservative predictions values resulted from residual stress relaxation. Improvements on predicted FCGR values were strongly dependent on how the progressive plastic relaxation of the residual stress field was considered.     

超声载荷下TC4钛合金的疲劳寿命分析

通过计算裂纹尖端应力强度因子及疲劳裂纹扩展速率da/d N,由C.Paris模型推导出安全寿命Nf,由Bathias公式计算"哑铃"状钛合金试样的裂纹扩展寿命。通过理论计算和有限元分析超声疲劳"哑铃"状试样,得出应力最大位置。利用有限元仿真和实验数据分析TC4钛合金疲劳寿命。在20 k Hz的超声疲劳试验中,试样的断口位置表明:TC4钛合金材料内部缺陷是试样萌生裂纹使断裂位置偏离最大应力处的主要原因。并得出疲劳裂纹萌生阶段寿命决定"哑铃"状试样的疲劳寿命。     

FATIGUE CRACK GROWTH UNDER MIXED MODES I AND II

Fatigue crack growth behaviour under mixed modes I and II was studied by applying in-phase alternating tensile and torsional loading to a thin-walled hollow cylindrical specimen with an initial crack. In the linear region of a log-log plot where da/dN=A(ΔK)^m, da/dN at first decreases with increasing ΔK₁₁₀ component and then approaches a minimum close to the value of ΔK₁₁₀/ΔK₁₀～ 0.58; here ΔK₁₁₀/ΔK₁₀ is the ratio of the initial ΔK_II to the initial ΔK₁., When ΔK₁₁₀/ΔK₁₀ increases further, da/dN increases. Under shear mode, da/dN becomes higher than that under mode I. The ΔK₁, and ΔK₁₁ components during fatigue crack growth under mixed mode loading increase and decrease, respectively, with an increase in da/dN In the low crack growth rate region the fatigue crack growth rates accelerate with an increase of the initial ΔK₁₁ component, ΔK₁₁₀. Fatigue life increases with increase of ΔK₁₁₀/ΔK₁₀ under the test condition of equivalent stress range being kept constant and the pre-crack length being the same.     

Thermal shock behaviour of a kaolinte refractory prepared using a natural organic binder

The thermal shock resistance of a kaolinite-based refractory prepared with a binder derived from a plant (corchorus olitorius) was investigated. Thermal shock tests employing water-quenching technique were performed at quench temperature differences of between 80 and 580 °C and then the damage parameter, and thermal shock parameters (R, R′, and R′′′) evaluated using measured strength and modulus values. The results showed that R and R′ parameters increased with increasing binder concentrations, an indication that the damage due to crack initiation was progressively impaired with increased binder concentrations. The R′′′ parameter on the other hand decreased with increasing binder concentrations indicating poor resistance of the material to crack propagation. These observations were also matched with thermal shock results which showed that samples plasticized with higher binder concentration had relatively very high strengths before thermal shock, compared to those plasticized with plain water, but they experienced rather large strength losses (over 60% of their initial values) at quench temperature difference (ΔT) exceeding 325 °C. The critical temperature difference (ΔT _C) for the samples tested was in the range 250–325 °C. Scanning electron microscope (SEM) micrographs of samples quenched at temperature difference of 580 °C showed that samples plasticized with high binder concentration (0.68) experienced severe cracking of the matrix compared to their counterparts plasticized with plain water, whose microstructures showed an inhibited crack propagation.     

Comparison of fatigue failure criterion in flexural fatigue test

This study compares traditional stiffness and energy based fatigue failure criteria with the fatigue failure criterion based on the viscoelastic continuum damage (VECD) approach. In traditional approach, fatigue failure is defined as the number of cycles at which the stiffness of a material reduces by 50% (N_f50). In energy based approach, fatigue failure is defined by the number of cycles at the maximum energy ratio or Rowe’s maximum stiffness defined by stiffness multiplied by the corresponding number of the cycle (E * N). In VECD approach, fatigue failure is defined by the number of loading cycles at the inflection point of the normalized pseudostiffness (C) versus damage variable (S) curve. It is shown that a correlation exits between traditional criteria and VECD criteria. It is shown that maximum energy ratio or Rowe’s maximum stiffness based fatigue life is higher than the traditional fatigue life (N_f50). This indicates the traditional approach is conservative. A strong correlation of fatigue was observed between the VECD fatigue criterion and energy ratio based fatigue criteria. However, the fatigue life by VECD approach is always less than the fatigue life by energy ratio or Rowe’s maximum stiffness.     

FATIGUE CRACK PROPAGATION CHARACTERISTICS OF GLASS FIBRE REINFORCED POLYCARBONATE IN HOT DISTILLED WATER

The fatigue crack propagation behaviour of polycarbonate and glass fibre reinforced polycarbonate was studied in hot distilled water. The effects of temperature, distilled water and glass fibre content on fatigue crack growth rate were determined. In distilled water at 333 K, the fatigue crack growth rate decreased with increasing glass fibre content. A melting was observed of the adhesive bond between the glass fibres and the matrix. It was evident that the fracture morphology closely relates to the fatigue crack growth rate which depends on the ΔK parameter rather than the K_max parameter when the materials are tested in hot distilled water.     

Macromechanics study of stable fatigue crack growth in Al–Cu–Li–Mg–Ag alloy

This study was made on a fresh variety of Al–Li base alloy to investigate the role of ageing precipitates and microstructure dimensions in the fatigue crack growth resistance. The fatigue crack growth rate was measured in three different states of the material (i.e. base metal in T8 condition, friction stir weld and laser beam weld in full‐aged condition). Metallurgical analysis showed that the base metal in T8 temper is precipitation hardened by an equivalent amount of δ′ (AL₃Li), T₁ (AI₂CuLi) and θ′ (AI₂Cu) precipitates. The friction stir weld retained the morphology of strengthening precipitate; however, coarsening of Cu containing precipitates has occurred. On the other hand, laser beam weld showed a different type of CuAl phase morphology, which is characteristic of cast metal. The results of fatigue tests confirmed that fatigue crack growth resistance largely depends on microstructural features, specifically the strengthening phases. The fatigue crack resistance was in the order of base metal > laser beam weldment > friction stir weldment. The CuAl phase played a vital role in the crack closure of the laser beam weldment, thus enhancing the fatigue life as compared with the friction stir weldment, which was evident from the plot between log of da/dN (crack growth in each cycle) and log of ΔK (stress intensity range).     

The effect of thermal ageing on carbon fibre-reinforced polyetheretherketone (PEEK)

The static and dynamic mechanical properties of carbon fibre-reinforced PEEK (APC-2) laminates subjected to long-term thermal ageing and cycling treatments have been studied using three-point bend flexure tests. Results are discussed with respect to morphological changes and degradation analysis. S/N curves were modelled using fatigue modulus degradation data. Ageing laminates at high temperatures, for long time periods, between the glass transition temperature, T _g, and the melting temperature, T _m, caused a significant reduction in mechanical properties. However, for short ageing periods, a crystal-perfection process occurs which enhanced the low stress level fatigue resistance of both laminate geometries.