Peak stress intensity dictates fatigue crack propagation in UHMWPE

The majority of total joint replacements employs ultra-high molecular weight polyethylene (UHMWPE) for one of the bearing components. These bearings may fail due to the stresses generated in the joint during use, and fatigue failure of the device may occur due to extended or repeated loading of the implant. One method of analysis for fatigue failure is the application of fracture mechanics to predict the growth of cracks in the component. Traditional analyses use the linear elastic stress intensity factor K to describe the stresses near a loaded crack. For many materials, such as metals, it is the range of stress intensity, ΔK, that determines the rate of crack propagation for fatigue analysis. This work shows that crack propagation in UHMWPE correlates to the maximum stress intensity, K_max, experienced during cyclic loading. This K_max dependence is expected due to the viscoelastic nature of the material and the absence of crazing or other cyclic load dependent crack tip phenomena. Such a dependence on a non-cyclic component of the stress allows cracks to propagate under load with little or no fluctuating stresses. Consequently, traditional fatigue analyses, which depend on the range of the stress to predict failure, are not always accurate for this material. For example, significant static stresses that develop near stress concentrations in the component locking mechanisms of orthopedic implants make such locations likely candidates for premature failure due the inherent underestimate of crack growth obtained from conventional fatigue analyses.     

Growth of fatigue cracks in polycarbonate

The rapid increase in the rate of application of thermoplastics in engineering design problems and the interest in the structural use of these materials have resulted in the requirement of comprehensive information about the behaviour of thermoplastics when subjected to cyclic loading conditions. In addition to the “total fatigue life” data already available for many materials, attempts have been made to analyse the crack initiation and steady crack growth processes and determine the effects of parameters such as mean load, frequency and crack geometry on the rate of crack propagation. The results of an investigation of these aspects of fatigue crack growth in a brittle thermoplastic, polymethylmethacrylate (PMMA), have already been reported. In this paper, the results of a test program devised to study the behaviour, at room temperature and in air, of a polycarbonate, (PC), under similar loading conditions, are presented. Fracture Mechanics concepts have been used to analyse the results. It was found that a relationship of the form ?_N = β λⁿ already shown to predict the cyclic fatigue crack propagation rate in PMMA, is also applicable to polycarbonate. However, when the effects of frequency and loading rate were studied, it was found that after the magnitude of parameter K?( = ΔK/half the periodic time) exceeded 4000 lbf in. ^?3/2 s^?1, the influence of the mean level of stress intensity factor, K_m, became negligible in comparison to the effect of ΔK.     

Fatigue and fracture characteristics of a fine-grained (Mg,Y)–PSZ zirconia ceramic

The fatigue and fracture characteristics of a partially-stabilized fine-grained zirconia with spinel additions, (Mg,Y)–PSZ, were studied. Fracture toughness, crack growth resistance curves and fatigue crack growth (FCG) behavior, under both sustained and cyclic loading, were evaluated. Mechanical fatigue effects were clearly evidenced by (1) remarkable crack growth rate differences under cyclic and static loading and (2) significant loading ratio effects. Comparing the cyclic and the static FCG behavior allows to deduce a higher cyclic fatigue sensitivity of the fine-grained (Mg,Y)–PSZ with respect to a commercial peak-aged Mg–PSZ used as a reference material. By in situ observation of crack extension under cyclic loading, the fatigue mechanisms could be resolved. Mechanical degradation of bridging ligaments, as already known for coarse-grained Mg–PSZ, is one source of cyclic fatigue. An additional source attributed to the particle dispersed microstructure of the (Mg,Y)–PSZ is the interaction between crack faces and hard spinel particles. The sensitivity of (Mg,Y)–PSZ and Mg–PSZ to cyclic fatigue is discussed in terms of the respective microstructures, prevalence and operativity of distinct mechanical fatigue mechanisms.     

Static and Cyclic Fatigue Behavior of a Sintered Silicon Nitride at Room Temperature

The static and cyclic fatigue behavior of sintered silicon nitride was investigated at room temperature. Flexure specimens, with an indentation-induced flaw at the center, were tested under a static or cyclic load applied by four-point bending. Sintered silicon nitride was shown to be susceptible to static and cyclic fatigue failure. Comparing the static and cyclic fatigue lifetimes at frequencies from 0.01 to 10 H z , it was shown that minimum time to failure was almost the same, in spite of differences in loading mode or frequency. However, cyclic stress decreased the scatter in lifetime by reducing the upper limit. Moreover, the cyclic fatigue limit was significantly lower than the static fatigue limit. High-magnification fractography revealed a fatigue failure dominated by intergranular cracking with partial transgranular failure at perpendicularly elongated crystals. This suggests that the intergranular fatigue crack can be arrested at grain-boundary triplets, and also can be reactivated by subsequent cyclic loading. The crack growth rate, calculated from the fatigue lifetime, showed three characteristic regions having a plateau at 70% to 90% of the fracture toughness, which suggests a possible intergranular stress corrosion cracking mechanism resembling that in glass or alumina.     

Fatigue crack propagation behavior of polyether ether ketone under biaxial loading

Polyether ether ketone (PEEK) has become a promising material in total joint replacement. However, it still faces the risk of fatigue fracture during service. In this paper, the effects of biaxial stress ratio λ, cyclic stress ratio R, and load phase difference θ on fatigue crack propagation (FCG) behavior of PEEK are investigated. In the case of vertical cracks, results show that the FCG rate of PEEK increases with the R value, while decreases with the increase of λ value. Furthermore, the effective stress intensity factor range ΔK_eff can uniformly describe the biaxial FCG behavior at different cyclic stress ratios. In the case of 45° slant cracks, compared with mode-I intensity factor range ΔK_I, the energy release rate range ΔG is more accurate for describing the FCG behavior under various load phase differences. In addition, the investigation on the 45° crack propagation path shows that a bifurcated Y-shaped crack appears under 180° load phase difference, while no bifurcated crack appears under 90° load phase difference and uniaxial loading. Three different methods are used to predict the crack propagation path. The comparison results show that the maximum circumferential stress (MTS) criterion can well predict the crack propagation path under out-of-phase biaxial loading and uniaxial loading.     

Cyclic contact fatigue behavior of baria-silicate glass-ceramics as a function of crystal aspect ratio

Ceramic materials are potentially useful for dental applications because of their esthetic potential and biocompatibility. However, evidence of contact fatigue damage in ceramics raises considerable concern regarding its effect on the survival probability predicted for dental prostheses. To simulate intraoral conditions, Hertzian indentation loading with steel indenters was applied in this study to characterize the fatigue failure mechanisms of ceramic materials. Baria silicate glasses and glass-ceramics with different aspect ratios of crystals were selected because the glass and crystal phases have similar density, elastic modulus, and thermal expansion coefficients. Therefore, this system is a model ceramic for studying the effect of crystal geometry on contact cyclic fatigue failure. The subsequent flexural strength results show that the failure of materials with a low fracture toughness such as baria-silicate glass (0.7 MPa m^1/2) and glass-ceramic with an aspect ratio of 3.6/1 (1.3 MPa m^1/2) initiated from cone cracks developed during cyclic loading for 10³ to 10⁵ cycles. The mean strengths of baria-silicate glass and glass-ceramics with an aspect ratio of 3.6/1 decreased significantly as a result of the presence of a cone crack. Failures of baria-silicate glass-ceramics with an aspect ratio of 8.1/1 (K_c = 2.1 MPa m^1/2) were initiated from surface flaws caused by either grinding or cyclic loading. The gradual decrease of fracture stress was observed in specimens with an aspect ratio of 8.1/1 after loading in air for 10³ to 10⁵ cycles. A reduction of approximately 50 % in fracture stress levels was found for specimens with an aspect ratio of 8.1/1 after loading for 10⁵ cycles in deionized water. Thus, even though this glass-ceramic with an 8.1/1 crystal aspect ratio material is tougher than that with a 3.6/1 crystal aspect ratio, the fatigue damage induced by a large number of cycles is comparable. The mechanisms for cyclic fatigue crack propagation in baria-silicate glass-ceramics are similar to those observed under quasi-static loading conditions. An intergranular fracture path was observed in glass-ceramics with an aspect ratio of 3.6/1. For an aspect ratio of 8.1/1, a transgranular fracture mode was dominant.     

The effects of water and frequency on fatigue crack growth rate in modified and unmodified polyvinyl chloride

A study of the influence of water environments on the cyclic fatigue crack behavior of polyvinyl chloride (PVC), with (PVC‐M) and without (PVC‐U) chlorinated polyethylene (CPE) impact modifier was undertaken and compared with corresponding results in air. Two frequencies of 1 and 7 Hz were applied to assess the influence of frequency on the fatigue behavior; a higher fatigue resistance and threshold were obtained with increasing frequency. This trend is more significant in water. However, in this environment, the fatigue resistance deteriorated under conditions of higher stress intensity factor amplitude (ΔK) and frequency. The fatigue properties of PVC‐U are the most affected by the presence of water, particularly at low frequency and higher ΔK. Examination of the fracture surface showed the interaction of water molecules and the PVC matrix with the formation of (1) a nodular structure, close to the fatigue threshold and (2) plasticized structures at high ΔK, which are associated with a greater threshold value and fatigue resistance. The absorption of the water retarded the fibrillation of craze and caused crack blunting effects. Water functions as a plasticizer, particularly at high ΔK, through the formation of the plasticized structures. Results are compared with those observed from an in‐service failure. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

A crack layer approach to fatigue crack propagation in high density polyethylene

Fatigue crack propagation (FCP) in high density polyethylene (HDPE) is observed to occur with an accompanying layer of damage ahead of the crack tip. The crack layer theory, which accounts for the presence of both the damage and the main crack, is applied to the problem. It is observed that the kinetic behavior of HDPE under fatigue consists of three regions: initial acceleration, constant crack speed (“deceleration”), and reacceleration to failure. Within the first two regions, crack propagation appears “brittle,” while in the third region “ductile” behavior is manifested. Ultimate failure occurs via massive yielding of the unbroken ligament. Two damage mechanisms are found to be responsible for HDPE failure: formation of fibrillated voids and yielding. Both mechanisms are present throughout the entire lifetime of the crack, but the former dominates the “brittle” crack propagation region, while the latter is more prominent in the “ductile.” Throughout the analysis the resistance moment R_t is approximated as the total volume of transformed material associated with crack advance. Crack layer analysis produces a satisfactory fit of the experimental data and yields a specific enthalpy of damage, γ^*, value in the 1–2 cal/g range.     

Fatigue crack growth behavior and mechanism of closed‐cell PVC foam

The applicability of linear‐elastic fracture mechanics parameters (ΔK and K_max), elastic–plastic fracture mechanics parameter (ΔJ), and time‐dependent fracture mechanics parameter (C*) to characterize fatigue crack growth (FCG) rate of closed‐cell polyvinyl chloride foam was investigated in the present work. The effect of stress ratios (R = 0.1 and 0.4) on FCGs was observed when the ΔK, K_max and ΔJ were used as fracture mechanics parameters. As a fracture mechanics parameter that combines ΔK and K_max, the K* successfully characterized FCGs (da/dN) at R = 0.1 and 0.4. While, a time‐dependent fracture mechanics parameter (C*) successfully correlated da/dt of creep crack growth (CCG) test, but it failed to correlate da/dt of FCG tests. The FCGs at both R = 0.1 and 0.4 were cyclic dependent, while the CCG was time dependent. For cyclic‐dependent crack growth, the interaction between polymer‐chain scission and small scale crack‐tip blunting was the main mechanism, whereas the interaction between polymer‐chain pullout and large scale crack‐tip blunting dominated fracture process for time‐dependent crack growth. POLYM. ENG. SCI., 2013. © 2012 Society of Plastics Engineers     

Origin of the Static Fatigue Limit in Oxide Glasses

Oxide glasses exhibit slow crack growth under stress intensities below the fracture toughness in the presence of water vapor or liquid water. The log of crack velocity decreases linearly with decreasing stress intensity factor in Region I. For some glasses, at a lower stress intensity, K_o, log v asymptotically diminishes where there is no measurable crack growth. The same glasses exhibit static fatigue, or a decreasing strength for increasing static loading times, as cracks grow and stress intensity eventually reaches the fracture toughness. In this case, some glasses exhibit a low stress below which no fatigue/failure is observed. The absence of slow crack growth under a low stress intensity factor is called the fatigue limit. Currently, no satisfactory explanation exists for the origin of the fatigue limit. We show that the surface stress relaxation mechanism, which is promoted by molecular water diffusion near the glass surface, may be the origin of the fatigue limit. First, we hypothesize that the slowing down of slow crack growth takes place due to surface stress relaxation during slow crack growth near the static fatigue limit. The applied stress intensity becomes diminished by a shielding stress intensity due to relaxation of crack tip stresses, thus resulting in a reduced crack velocity. This diminishing stress intensity factor should result in a crack growth rate near the static fatigue limit that decreases in time. By performing Double Cantilever Beam crack growth measurements of a soda‐lime silicate glass, a decreasing crack growth rate was measured. These experimental observations indicate that surface stress relaxation is causing crack velocities to asymptotically become immeasurably small at the static fatigue limit. Since the surface stress relaxation was shown to take place for various oxide glasses, the mechanism for fatigue limit explained here should be applicable to various oxide glasses.     

Effect of Adhesive Ductility on Cyclic Debond Mechanism in Composite-to-Composite Bonded Joints

An investigation of an adhesively bonded composite joint with a brittle adhesive was conducted to characterize both the static and fatigue debond growth mechanism under mode I and mixed mode I-II loadings. The bonded system consisted of graphite/epoxy adherends bonded with FM-400 adhesive. Two specimen types were tested: (1) a double-cantilever-beam specimen for mode I loading and (2) a cracked-lap-shear specimen for mixed mode I-II loading. In all specimens tested, failure occurred in the form of debond growth either in a cohesive or adhesive manner. The total strain-energy-release rate is not the criterion for cohesive debond growth under static and fatigue loading in the birttle adhesive as observed in previous studies with the ductile adhesives. Furthermore, the relative fatigue resistance and threshold value of cyclic debond growth in terms of its static fracture strength is higher in the brittle adhesive than its counterpart in the ductile adhesive.     

Fatigue Crack Propagation Evaluation of Several Commercial Grade Propylene Polymers

ABSTRACT

Results of an experimental evaluation of commercial propylene polymers' performance under cyclic loading are reported. Experiments were conducted on one extrusion grade homopolymer and one impact block copolymer. The influence of thermal annealing was taken into account on the homopolymer. A laboratory-made mechanical fatigue unit capable of applying sinusoidal displacement was used to conduct fatigue tests on precracked specimens in three points bending at room temperature. Materials exhibit different crack propagation modes. The neat homopolymer displays discontinuous-catastrophic crack propagation. Both copolymer and annealed homopolymer show longer fatigue lifetime but faster propagation rates than the neat homopolymer. The annealed homopolymer also propagates in a step-like way whereas the block copolymer displays a continuous crack propagation mode in which the crack advances regularly as cycling proceeds. A noticeable crack front damage (identified as stress whitening) is developed at the crack root, which seems to control the crack propagation rate     

Synergistic effects of carbon nanotubes and carbon black on the fracture and fatigue resistance of natural rubber composites

The quasi‐static fracture and dynamic fatigue behaviors of natural rubber composites reinforced with hybrid carbon nanotube bundles (CNTBs) and carbon black (CB) at similar hardness values were investigated on the basis of fracture mechanical methods. Mechanical measurement and J‐integral tests were carried out to characterize the quasi‐static fracture resistance. Dynamic fatigue tests were performed under cyclic constant strain conditions with single‐edged notched test pieces. The results indicate that synergistic effects between CNTBs and CB on the mechanical properties, fracture, and fatigue resistance were obtained. The composite reinforced with 3‐phr CNTBs displayed the strongest fatigue resistance. The synergistic mechanisms and dominating factors of quasi‐static and dynamic failure, such as the dispersion state of nanotubes, hybrid filler network structure, strain‐induced crystallization, tearing energy input, and viscoelastic hysteresis loss, were examined. The weakest fatigue resistance of the composite filled with 5‐phr CNTBs was ascribed to its strikingly high hysteresis, which resulted in marked heat generation under dynamic fatigue conditions. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42075.     

Influence of the dynamic stress intensity factor on cyclic crack propagation in polymers

A relationship of the form developed for the evaluation of cyclic crack propagation in tensile/tensile fatigue was used to investigate the effects of frequency on fatigue crack growth. In order to establish the correlation between stress intensity K and dK/dt at 21°C, dynamic fracture toughness tests were performed on a range of polymers. It was shown that, in general, fracture toughness increased with the strain rate applied. Consequently, a decreasing trend in the crack growth rate was observed in the fatigue tests performed at higher frequencies. The occurrence of other localized peaks of fracture toughness recorded at various temperatures and strain rates is described. The fractography of fatigue surfaces is also discussed.     

Monotonic and Cyclic Fatigue Behavior of High-Performance Ceramic Fibers

Monotonic and cyclic fatigue behavior of single fibers or fiber fabrics are of significant interest, since fiber assemblies or fiber-reinforced composite materials in structural applications are often subjected to cyclic loading. Studying the cyclic fatigue behavior of fibers is particularly difficult because of their small diameter (∼10 μm) and high aspect ratio. In this paper, we report results of monotonic tension and tension–tension fatigue behavior of two sol–gel-derived ceramic fibers: Al₂O₃–SiO₂–B₂O₃ (Nextel 312) and Al₂O₃ (Nextel 610). Nextel 312 exhibited a great deal of variability in tensile strength, reflected by a Weibull modulus of 4.6, versus Nextel 610, which had a Weibull modulus of 10.5. Our experiments showed clearly that cyclic loading was more damaging than static loading and, thus, resulted in a lower cyclic fatigue life compared with static loading. The fracture behavior under fatigue loading was distinctly different from that under monotonic loading. It is believed that processing-induced flaws acted as crack initiation sites, and that the cyclic loading induced subcritical cracking, followed by coalescence of cracks immediately prior to failure.     

On the measurement of fracture toughness of soft biogel

In this study, the rate dependent energy dissipation process and the fracture toughness of physical gels were investigated using agarose as a sample material. Both the J‐integral and Essential work of Fracture (EWF) methods were examined. To assess the quasi‐static fracture toughness of gels, linear regression was performed on critical J (J_c) values at different loading rates resulting in a quasi‐static J_c value of 6.5 J/m². This is close to the quasi‐static EWF value of 5.3 J/m² obtained by performing EWF tests at a quasi‐static loading rate (crosshead speed of less than 2 mm/min). Nearly constant crack propagation rates at low loading rates, regardless of crack length, suggest viscoplastic chain pull‐out is the fracture mechanism. At high loading rates failure was highly brittle, which is attributed to sufficient elastic energy accumulation to precipitate failure by chain scission. We conclude that in physical gels quasi‐static fracture toughness can be evaluated by both the J‐integral and EWF methods provided the effects of loading rate are investigated and accounted for. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers     

In situ observation of stable crack growth in freestanding diamond film samples under low cycle fatigue loading

Laser notched and pre-cracked freestanding diamond film samples were tested under cyclic loading in three point bending using a fatigue machine incorporated with the SEM(550)-SERVO scanning electron microscope. Stable crack growth was observed in situ. Crack growth was found to be discontinuous; there was generally a break after each growth. It was found that the minimum cyclic load at the first stable crack growth was approximately 60% of the fracture load for the notched sample under static loading. The minimum cyclic load for the ultimate brittle fracture was about 74% of the fracture load for the notched sample. Mechanisms for the observed stable crack growth in freestanding diamond film samples under cyclic loading are discussed. The columnar grain feature of the freestanding diamond films and the grain boundary may be responsible for the stable crack growth under cyclic loading.     

Fatigue crack propagation behavior of cellulose esters

The effect of plasticizer concentration on fatigue crack propagation (FCP) rate in cellulose acetate-propionate (CAP) was determined. Compact tension specimens were machined from 6.2 mm-thick injection molded plaques and tested on an MTS servohydraulic testing machine using a sinusoidal waveform with a frequency of 1 Hz. Two FCP mechanisms were identified: a crazing mechanism, which dominated at low values of stress intensity factor range, ΔK, and a shear yielding mechanism, which dominated at high values of ΔK. The value of ΔK at the onset of the transition from the crazing mechanism to the shear yielding mechanism was a function of plasticizer concentration, and therefore yield strength of the CAP. The transition in crack propagation mechanism created a V-shaped feature on the fracture surface, which could be used to weight the contributions from the two crack propagation mechanisms to the overall FCP rate.     

Fatigue Behavior of Alumina–Zirconia Multilayered Ceramics

The influence of sustained and cyclic loading on the crack growth behavior of a multilayered alumina–zirconia composite exhibiting high internal compressive stresses is investigated. The study was conducted on precracked notched samples and focused on evaluating the static and cyclic fatigue resistance to crack extension beyond the first arresting interface (threshold) as well as the mechanisms involved during stable crack growth through the layered structure for each loading condition studied. Although it is found that the layered composite is prone to subcritical crack growth, the effectiveness of operative toughening mechanisms, i.e., compressive residual stresses as well as crack bifurcation and delamination at interfaces, is observed to be independent of the loading conditions. As a consequence, fatigue degradation of the multilayered ceramics studied is restricted to the intrinsic environmental-assisted cracking of the individual layers, pointing them out as toughened composites practically immune to variable stresses and much less static and cyclic fatigue sensitive than other structural ceramics.     

Static and Cyclic Fatigue of Alumina at High Temperatures: II, Failure Analysis

Failure mechanisms of an alumina, tested at 1200°C under static and various cyclic loading conditions, were examined. Slow crack growth of a single crack is the dominant mechanism for the failure in specimens under cyclic loading with a short duration of maximum stress at all applied stress levels, as well as at high applied loads for static loading and cyclic loading with a longer hold time at maximum stress. At low stress levels, failure of static loading and cyclic loading with a longer hold time at maximum stress might occur by formation and/or growth of multiple macrocracks. More importantly, for all the given loading conditions. The viscous glassy phase behind the crack tip could have a bridging effect on the crack surfaces. A simplified model for calculating effective stress intensity factor at the crack tip under static and various cyclic loading demonstrated a trend consistent with the stress–life data.