Long crack growth behavior of implant material Ti–5Al–2.5Fe in air and simulated body environment related to microstructure

The fatigue crack propagation behavior of Ti–5Al–2.5Fe with various microstructures for biomedical applications was investigated in air and in a simulated body environment, Ringer's solution, in comparison with that of Ti–6Al–4V ELI and that of SUS 316L stainless steel. The crack propagation rate, da/dN, of Ti–5Al–2.5Fe in the case of each microstructure is greater than that of the Widmanstätten structure in Ti–6Al–4V ELI in air whereas da/dN of Ti–5Al–2.5Fe is nearly equal to that of the equiaxed structure in Ti–6Al–4V ELI in air when da/dN is plotted versus the nominal cyclic stress intensity factor range, ΔK. da/dN of the equiaxed structure and that of the Widmanstätten structure in Ti–5Al–2.5Fe are nearly the same in air when da/dN is plotted versus ΔK. da/dN of Ti–5Al–2.5Fe is nearly equal to that of SUS 316L stainless steel in the Paris Law region, whereas da/dN of Ti–5Al–2.5Fe is greater than that of SUS 316L stainless steel in the threshold region in air, when da/dN is plotted versus ΔK. da/dN of Ti–5Al–2.5Fe or Ti–6Al–4V ELI is nearly the same in air and in Ringer's solution when da/dN is plotted versus the effective cyclic stress intensity factor range, ΔK_eff, whereas da/dN of Ti–5Al–2.5Fe or Ti–6Al–4V ELI is greater in Ringer's solution than in air when da/dN is plotted versus ΔK.     

Evaluation of fatigue crack growth behavior of GLARE3 fiber/metal laminates using a compliance method

The objectives of this study were to investigate the effectiveness of a compliance method for analyzing the fatigue crack growth of GLARE3 fiber/metal laminates. The materials tested were GLARE3-5/4 (2.6 mm thick) and GLARE3-3/2 (1.4 mm thick). Centrally notched specimens with two kinds of notch length and two kinds of fiber orientation were fatigue tested under constant amplitude loading. The expression of the experimental stress intensity factor, K_exp, for the 2024-T3 aluminum-alloy layers of a GLARE3 is formulated and K_exp were obtained from the relationship between crack length and specimen compliance. The test results clarified the following: (1) da/dN–ΔK_exp relationships roughly show the linear relationship independent of the maximum stress level, specimen thickness, notch length, and fiber orientations, (2) the da/dN–ΔK_exp relationships approximately agree with the linear part and its extension of Paris–Erdogan’s law obtained for the da/dN–ΔK relationship of the 2024-T3 aluminum-alloy, (3) the compliance method is effective for analyzing fatigue crack growth in GLARE3 laminates.     

The effect of second principal stress on the fatigue propagation of mode I surface crack in Al2O3/Al alloy composites

Using a plate made of A2017-T6 metal matrix composites reinforced with 10 volume % and 20 volume % Al₂O₃ particles and Al alloy possesses the same composition as matrix alloy, the crack propagation rate da/dN of a mode I surface crack by the simultaneous action of plane bending and cyclic torsion are studied. And the effects of crack tip opening stress σ_top, crack opening displacement COD, biaxial stress ratio C (=second principal stress/first principal stress) and the surface roughness of crack section are examined. When stress intensity factor range ΔK is lower than the specific level, da/dN decreases with the increase of volume fraction of Al₂O₃ in C=0 and C=−0.55. But, da/dN of Al alloy becomes minimum in C=−1 and the effect of Al₂O₃ particles disappears. σ_top rises with the increase of volume fraction of Al₂O₃ particles and the decline of C. On the other hand, COD doesn’t always rise with the decline of C. These phenomena can be explained by the residual compressive stress formed at the surface layer of the specimen by the fatigue test and the surface roughness of crack section.     

On the calculation of closure-free fatigue crack propagation data in monolithic metal alloys

A computational method is described for the determination of ΔK_b, corresponding to a fatigue crack growth rate of b/cyc, where b is the Burgers vector for a monolithic metal alloy. ΔK_b is found to be numerically equal to E√b for the case of closure-free crack growth behavior. Given that the closure-free FCP rate of many monolithic metals varies with ΔK³, the growth rate of metal alloys at ΔK ΔK_b is given by da/dN = (ΔK/E)³(1/√b. Excellent agreement is found between experimental and computed FCP data for the case of monolithic metal alloys. The limits of these relations for metal-matrix composites and ceramics are discussed.     

Fatigue crack growth characteristics of rotor steels

Room temperature fatigue crack growth rate data were generated for Ni-Mo-V (ASTM A469, Cl-4), Cr-Mo-V (ASTM A470, Cl-8) and Ni-Cr-Mo-V (ASTM A471, Cl-4 and a 156,000 psi yield strength grade) rotor forging steels. Testing was conducted with WOL type compact toughness specimens and the results presented in terms of fracture mechanics parameters. Data show that the Ni-Cr-Mo-V steels exhibit slower fatigue crack growth rates at a given stress intensity range (ΔK) than do the Ni-Mo-V steels. In addition, the Cr-Mo-V steel was found to exhibit slower growth rates than the other alloys at ΔK levels below 40 ksi √in but somewhat foster rates at ΔK levels in excess of 45 ksi √in. The fatigue crack growth rate properties of the alloys studied conform to the generalized fracture mechanics crack growth rate law where da/dN = C₀ΔK^R. It was noted that the fatigue crack growth rate parameters n and C₀ tend to decrease and increase, respectively, with increasing material toughness, K_ic.     

The effects of overloads in fatigue crack growth

Several theories have been proposed to explain the transient fatigue crack growth decelerations and accelerations which follow overloads. The mechanisms that have been proposed to explain retardation after a tensile overload, for example, include residual stress, crack deflection, crack closure, strain hardening, and plastic blunting/resharpening. These mechanisms are reviewed in the light of recent experimental results, and implications with regard to their applicability are examined. It is suggested that no single mechanism can be expected to represent observed effects over the entire range of da/dN versus ΔK; eg, behaviour ranging from the near threshold region to the Paris region.     

Automatic near-threshold fatigue crack growth rate measurements at liquid helium temperature

The development of a fully automated test apparatus for near-threshold fatigue crack growth rate measurements in a liquid helium environment is described, and some initial results for AISI 300 series stainless steels are presented. The experimental apparatus consists of a servohydraulic test machine and a cryostat, complete with a minicomputer, a programmable arbituary waveform generator, a programmable digital oscilloscope and a fully automatic liquid helium refill system. The technique uses 6.4 mm thick compact specimens subjected to systematically decreasing loads, with 24 h operation at 40 Hz, the crack growth being continuously monitored by specimen compliance measurements. The results presented in this study include da/dN vs ΔK curves and threshold fatigue stress intensity factors, ΔK_th, at 4 K for AISI 304L, 304LN and 316 stainless steels. The near-threshold fatigue behaviours of these materials are similar, and the fatigue crack growth rate trends at intermediate ΔK levels nearly agree with published results.     

Contributions of internal hydrogen and room-temperature creep to the abnormal fatigue cracking of Ti6246 at high Kmax

This study aims at explaining the absence of a threshold for crack propagation in an /β titanium alloy during cyclic tests performed with constant K_max and increasing K_min, if K_max is higher than 60–70% of K_Ic. Tensile, creep as well as fatigue crack growth tests are performed on specimens with various hydrogen content. SIMS analyses of hydrogen content around the tip of a crack developed in the abnormal regime are made. Solute hydrogen is shown to segregate at the crack tip and to enhance room-temperature creep, strain localisation and decohesion along /β interfaces.     

Fatigue crack propagation rate at low ΔK of two aluminum sheet alloys, 2024-T3 and 7075-T6

For transport aircraft with long lifetimes, crack growth data to implement the durability life requirements in the low ΔK range are needed. This is the region comprising most of the lifetime for the cracks of interest, and it is also the region where there is little data available. Crack growth data in the form of da/dN vs ΔK vs R at constant amplitude for two primary aircraft aluminum sheet alloys, 2024-T3 and 7075-T6 (clad) were measured in laboratory air and 140°F in the low da/dN region 10⁻⁸ to 10⁻⁵ in./cycle. Crack growth rates were correlated with stress state and with fractographic features.     

An analysis of crack propagation velocity in delayed failure under repeating load using an internal friction model

Frequency and temperature dependency of crack propagation velocity in delayed failure under superposed repeating load was analyzed using an internal friction model which assumes the interaction between hydrogen atoms and the cyclic moving of the position with tri-axial tensile stress at crack tip.

The decrease of crack propagation velocity (da/dt)_R by the superposition of repeating load, the appearance of minimum value in (da/dt)_R at a certain frequency ƒ₀, and the shift of ƒ₀ by the change of temperature, are well explained by the internal friction model. Another reason for the decrease of (da/dt)_R by the superposition of repeating load appears to be the decrease of effective stress intensity at crack tip, though this cannot explain the appearance of minimum value of (da/dt)_R.     

Fatigue properties of ultrafine grained low carbon steel produced by equal channel angular pressing

Ultrafine grained low carbon (0.15 wt.% C) steel produced by equal channel angular pressing (ECAP) was tested for investigating fatigue properties, including cyclic softening and crack growth rate. Emphasis was placed on investigating the effect of load ratio on the fatigue crack growth rates of ultrafine grained microstructure. The ECAPed steel exhibited cyclic softening. After the first cycle, the tension and compression peak stresses decreased gradually with the number of cycles. Fatigue crack growth resistance and the threshold of ECAPed ultrafine grained steel were lower than that of an as-received coarse grained steel. This was attributed to a less tortuous crack path. The ECAPed steel exhibited slightly higher crack growth rates and a lower ΔK_th with an increase in R ratio. The R ratio effect on growth rates and ΔK_th was basically indistinguishable at a lower load ratio (R>0.3) compared with other alloys, indicating that the contribution of the crack closure vanished. This was explained by the fact that finer grained materials produce a lower opening load P_op due to a relatively less serrated crack path. Consequently, K_min can reach K_op readily with a smaller increment of load ratio. The crack growth rate curve for the ECAPed ultrafine grained steel exhibited a linear extension to the lower growth rate regime than that for the coarse grained as-received steel. This behavior can be explained by a reverse crack tip plastic zone size (r_p) that is always larger than the grain size.     

On the combined influences of Young''s modulus and stress ratio on the LEFM fatigue crack growth process: A new mechanistic approach

A new mechanistic approach (NMA) was used recently to examine the physical aspects of LEFM (long) fatigue crack growth (FCG) process in crack-ductile materials in stages I and II. In this paper, NMA is extended to examine both the physical and analytical aspects of the combined effects of Young's modulus, E and stress ratio, R, in the same stages of the same materials. It is shown that, (i) with submicroscopic cleavage or reversed shear mechanism operating in the pure form, E is the most influential intrinsic “material” property controlling FCG, (ii) E-dependence of da/dN is a natural consequence of near-crack-tip displacement control proposed previously, and (iii) the demonstrated similarity of FCG curves and the existence of characteristic “pivot points” on these curves for a “class of materials” results from E-influence which continues even at a higher R. A simple analytical model based on “strain intensity factor,” K₀, which contains E-influence implicitly and controls da/dN in all materials irrespective of class, is proposed. Model-predicted K₀-based theoretical values of threshold, “Idealised Master Growth Curves (IMGCs)” and mechanism transition point, all agreed excellently with experimental data for at least three classes of materials, i.e. steels, Al-alloys and Ti-alloys at extreme R-values of 0 and ≥ 0.6. The K₀-parameter concept is used here to raise the status of the analysis of the E-effect from a simple “normalisation” to that of direct data “representation”. Using NMA existing empirical relations are given some sound theoretical base. In addition to aiding in a clearer physical understanding of the FCG process, the unique IMGCs developed for different R-values are considered useful in quick, accurate and conservative life estimations, and performing failure analyses usually required in selection and design of materials.     

Enhancement of delayed failure resistance by partial unloading method

The effects of two types of pre-stressing, i.e. partial unloading (0 →K_max → K) and perfect unloading (0 → K_max → 0 → K) on the delayed failure strength were investigated using pre-cracked specimens of JIS SNCM8 steel quenched and tempered, where K_max is the maximum stress intensity factor at pre-stressing, and K is the stress intensity factor under which delayed failure test is carried out.

Both pre-stress methods can markedly increase the delayed failure strength or the lower limit stress intensity factor K_ISCC. The partial unloading method is superior to the perfect unloading method in each tempering condition (200 or 400°C) and in each environment (distilled water or 3% NaCl water). The reason why K_ISCC is increased by each pre-stressing can be explained by the decrease of surface stress at crack tip, which will suppress the corrosion reaction and prevent the invasion of hydrogen atoms into the material.     

Fatigue crack growth behavior of cracked aluminum plate repaired with composite patch

In this study, we investigated the fatigue crack growth behavior of cracked aluminum plate repaired with bonded composite patch especially in thick plate. Adhesively bonded composite patch repair technique has been successfully applied to military aircraft repair and expanded its application to commercial aircraft industry recently. Also this technique has been expanded its application to the repair of load bearing primary structure from secondary structure repair. Therefore, a through understanding of crack growth behavior of thick panel repaired with bonded composite patch is needed. We investigated the fatigue crack growth behavior of thick panel repaired with bonded composite patch using the stress intensity factor range (ΔK) and fatigue crack growth rate (da/dN). The stress intensity factor of patched crack was determined from experimental result by comparing the crack growth behavior of specimens with and without repair. Also, by considering the three-dimensional (3D) stress state of patch crack, 3D finite element analyses were performed to obtain the stress intensity factor of crack repaired by bonded composite patch. Two types of crack front modeling, i.e. uniform crack front model and skew crack front model, were used. The stress intensity factor calculated using FEM was compared with the experimentally determined values.     

Flexural fatigue characteristics of sandwich structures at different loading frequencies

The effects of frequency on the fatigue behavior of S2 glass fiber–vinylester reinforced sandwich composites with two different PVC cores have been investigated. Flexural fatigue tests were performed on sandwich beams with core densities of 130 and 260 kg/m³ at frequencies of 3 and 15 Hz, at a stress ratio, R=0.1 and at four different load levels viz. 90%, 85%, 80% and 75% of the ultimate load. S–N diagrams were generated and it was observed that the fatigue strength increased with core density, and the number of cycles to failure, N_f, increased with increase in frequency. In all cases failure was dominated by a primary shear crack in the core however, the crack path and crack propagation rates varied with frequency. The fatigue crack growth rate (FCGR) in the core of the H130 sandwich beams was subsequently investigated and the relationship between the crack growth rate, da/dN, and the cyclic stress intensity range, ΔK, was determined. It was found that crack growth rate decreased with increase in loading frequency.     

Stage II fatigue crack growth

The linear part of the fatigue crack growth diagram is found to be divided into Stages IIa and IIb by the point O whose coordinates K^* and A are dependent on the physical and structural characteristics of the material. In Stage IIa K_eff remains constant as the microcrack advances in increments corresponding to the dislocation cell structure size, λ, pausing for (dN−1) cycles to accumulate the elastic energy required for the crack opening. During Stage IIb K_op remains constant and the microcrack opens during each cycle and advances irrespective of the substructure but in accordance with an increasing value of K_eff. The effects of temperature and vacuum on K^* are considered; the A values correspond to those of λ and are independent of the above effects.     

Matrix fatigue cracking in fiber composites

A model is developed for fatigue growth of matrix cracks in metals reinforced with aligned continuous elastic fibers. The mechanics of elastic cracks bridged by frictionally constrained fibers is used to develop the model, which provides estimates of the tip value of the stress intensity factor amplitude, ΔK_TIP. It is found that when the applied load amplitude is held fixed during fatigue crack growth, ΔK_TIP, and thus the rate of growth approach an asymptotic value independent of crack length. The residual strength after fatigue crack growth is also discussed. In some cases, the residual strength is unaffected by prior fatigue growth. But, in another regime, the matrix crack length allows fibers to begin breaking before the matrix crack grows. The strength is then inversely proportional to the square root of fatigue crack length.     

A study of the effects of mechanical and environmental variables on fatigue crack closure

Using the potential drop technique, fatigue crack closure has been monitored in pin loaded SEN specimens of -titanium, a titanium alloy and EN24 steel. The specimens were tested in tension-tension under conditions closely approximating to plane strain, and closure was only detected in vacua of better than 133 mN m⁻² (10⁻³ torr). No significant closure was detected in air. The extent of the crack area closed at minimum load varied with air pressure, applied stress, R ratio (R = L_min/L_max), crack length, material, and loading mode. Additional experiments made with a dip gauge showed that the COD/applied load response of the crack was non-linear in vacuum above minimum load in the fatigue cycle confirming that crack closure was occcurring. It is shown that for a given material, loading mode and air pressure, the effect of loading and crack length variables on crack area closed at minimum load can be characterised in terms of the parameter (K²_min-ΔK², this being proportional to the calculated COD at minimum load. The extent of closure in vacuum is influenced extensively by this parameter.     

Influence of R on effective stress range ratio and crack growth

The influence of stress ratio R and stress intensity range ΔK on crack closure and fatigue crack growth were studied. Crack closure and crack growth experiments were performed on 6063-T6 Al alloy. Crack closure stresses were measured using a surface-measurement technique with a COD gauge. The gauge was placed at different locations behind the crack tip, and it was found that the location of the gauge does not influence the closure load. The closure load was however found to be a function of R and ΔK. Fatigue crack growth rate is found to depend upon R, U and ΔK. A model for both U and da/dN has been developed.     

The unusual near-threshold FCG behavior of a single crystal superalloy and the resolved shear stress as the crack driving force

An investigation of the fatigue crack growth (FCG) behavior of PWA 1480 single crystal nickel base superalloy was conducted. Typical Paris region behavior was observed above a δK of 8 MPa√m. However, below that stress intensity range, the alloy exhibited highly unusual behavior. This behavior consisted of a region where the crack growth rate became essentially independent of the applied stress intensity. The transition in the FCG behavior was related to a change in the observed crack growth mechanisms. In the Paris region, fatigue failure occurred along {111} facets, however at the lower stress intensities, (001) fatigue failure was observed. A mechanism was proposed, based on barriers to dislocation motion, to explain the changes in the observed FCG behavior. The FCG data were also evaluated in terms of a recently proposed stress intensity parameter, K_rss. This parameter, based on the resolved shear stresses on the slip planes, quantified the crack driving force as well as the mode I ΔK, and at the same time was also able to predict the microscopic crack path under different stress states.