Fatigue crack initiation life prediction for aluminium alloy 7075 using crystal plasticity finite element simulations

An experimentally-validated approach for predicting fatigue crack initiation life of polycrystalline metals is developed based on crystal plasticity finite element (CPFE) simulations. In this approach, the microstructure used in the simulations possesses statistically the same grain size and crystallographic orientations as those obtained from electron back-scatter diffraction experiments. A backstress model is incorporated into the CP constitutive model to describe the mechanical behaviour of aluminium alloy (AA) 7075 under cyclic loading. The key variables of the prediction model, the energy efficiency factor and plastic strain energy density, are calibrated using a fatigue test on a round-notched AA7075 specimen at room temperature. The proposed approach is then validated by using another fatigue test to predict 69.1–87.3% of the experimentally measured fatigue crack initiation life. The effects of the microstructure and texture on the energy efficiency factor and fatigue life prediction are quantitatively determined. It is shown that for a given range of energy efficiency factors a similar range of life prediction is obtained. Since the proposed approach considers the heterogeneity of the microstructure, it can well capture the grain scale deformation localisation and therefore improve the precision of fatigue life prediction.     

A micromechanical theory of fatique crack initiation from notches

The fatigue crack initiation along the slip banks emanating from notches is analyzed theoretically with the use of the dislocation dipole accumulation model proposed previously by the authors. The complex function analysis for an elliptical notch under the anti-plane shear gives a quantitative method for assessment of the reduction of fatigue strength as a function of the notch tip radius, the notch size and the elastic stress concentration factor. Special cases of this theoretical analysis yield several semi-empirical formulae commonly used by engineers for data collection. In the derivation, the limitations for each engineering approach are clarified. The material properties are included in the present micromechanical theory as the slip band length and the dislocation frictional stress.     

A crystal plasticity based methodology for fatigue crack initiation life prediction in polycrystalline copper

Fatigue failure is the dominant mechanism that governs the failure of components and structures in many engineering applications. In conventional engineering applications due to the design specifications, a significant proportion of the fatigue life is spent in the crack initiation phase. In spite of the large number of works addressing fatigue life modelling, the problem of modelling crack initiation life still remains a major challenge in the scientific and engineering community. In the present work, we present a methodology for estimating fatigue crack initiation life using macroscale loading conditions and the microstructural phenomenon causing crack initiation. Microstructure sensitive modelling is used for predicting potential crack initiation life by employing randomly generated representative microstructures. The microstructural parameters contributing to crack initiation life are identified and accounted for by computing lattice level energy dissipation during fatigue crack initiation. This model is coupled with experimental results to improve the predictive capabilities and identification of potentially damaging weak points in the microstructures. The estimated values for crack initiation life were found to be in good agreement with the experimentally observed values of initiation life. The results have shown that this kind of approach could be successfully used to predict crack initiation life in polycrystalline materials. This work successfully provides an approach for estimating crack initiation life based upon numerical computations accounting for the microstructural phenomenon.     

Fatigue crack paths in AA2024-T3 when loaded with constant amplitude and simple underload spectra

It is well known that variable amplitude fatigue loading produces progression marks on fatigue crack surfaces that are related to the loading sequence. These marks are generally a local change in the crack path. The same pattern of loading can produce a pattern of progression marks that have differences from material-to-material or from heat treatment-to-heat treatment, yet the crack path changes that produce these markings are not considered in the prediction of the crack growth behaviour. These path changes can be used to: investigate how the crack grows, aid crack growth measurement and shed light on the mechanism that forms striations. Consequently, an understanding of these path changes and their fundamental cause in structurally significant alloys is important to the explanation of how fatigue cracks grow and how their life can be predicted.In this paper, a number of simple loading sequences were used to investigate the influence that underloads have on the crack path, to develop a better understanding of the formation of fatigue striations and the coarser crack path changes associated with loading changes. The material chosen was aluminium alloy (AA)2024-T3. The results from the tests reported here were compared to previously investigated AA7050-T7451 specimens that were loaded in a similar manner. It is shown that the fatigue crack surfaces that were produced here were the direct consequence of the applied loading interacting with the crystal structure of the material. By changing the loading, via the addition of underloads it was possible to produce fatigue crack surfaces that where composed of not only striations but ridges, depressions and fissures. These features give an indication of the crack growth mechanism. Although, AA2024-T3 and AA7050-T7451 have different chemical compositions, mechanical properties and micro-structures, it was shown that both materials share essentially similar fracture features corresponding to crack propagation at the cycle-by-cycle level. It also appears that despite the above noted differences, similar failure mechanisms may take place.     

A meshless grain element for micromechanical analysis with crystal plasticity

This study concerns the development of a 2‐D meshless grain element for elasto‐plastic deformation and intergranular damage initiation and propagation in polycrystalline fcc metals under static loading. The crystallographic material behaviour of the grains is represented by a rate‐independent single‐crystal plasticity model while including material orthotropy. The two slip planes are arbitrarily located with respect to the crystallographic axis of the grain. A non‐linear constitutive model known as the cohesive zone model is employed to represent the inelastic interaction between the grain boundaries, thus permitting grain boundary opening and sliding. The cohesive model describes the deformation characteristics of the grain boundaries through a non‐linear relation between the effective grain boundary tractions and displacements. Because of the presence of non‐linear material behaviour both inside the grain and along the cohesive grain boundaries, the method utilizes the principle of virtual work in conjunction with the meshless formulation in the derivation of the system of non‐linear incremental equilibrium equations. The solution is obtained via an incremental procedure based on the Taylor series expansion about the current equilibrium configuration. The fidelity of the present approach is verified by considering simple polycrystalline metals of only a few grains. Copyright © 2006 John Wiley & Sons, Ltd.     

Investigation of microstructure effect on fretting fatigue crack initiation using crystal plasticity

The onset of fretting fatigue is characterized by material microstructural changes in which the extent of the damage is comparable to grain size, and hence, the microstructure characteristics could have a significant effect on fatigue crack initiation. In this paper, a three‐dimensional finite element crystal plasticity framework is presented for simulation of the fretting fatigue. Controlled Poisson Voronoi tessellation (CPVT) method is employed to generate the polycrystalline region. In the CPVT method, regularity parameter controls the shape of grains. In this study, the impact of grain size and regularity parameter on crack initiation life and initiation site has been investigated. Cumulative plastic slip was used as a parameter of microstructure‐sensitive fatigue indicator. This parameter could effectively predict the location of crack initiation and its life. The results show that regularity parameter has a significant effect on the location of crack initiation. Furthermore, the effect of grain size on the fretting fatigue life of 316L stainless steel was investigated experimentally through testing different specimens with different grain sizes, to validate the simulation results.     

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.     

Estimation of fatigue crack initiation in the very high cycle fatigue regime for AA7075-T6 alloy using crystal plasticity finite element method

Journal of Materials Science - Fatigue crack initiation (FCI) in the very high cycle fatigue (VHCF) regime for an AA7075-T6 alloy has been estimated by introducing fatigue indicator parameters...     

Fatigue crack initiation behaviors throughout friction stir welded joints in AA7075-T6 in ultrasonic fatigue

This paper presents the results of experimental investigation on fatigue behaviors of friction stir welded joints in AA7075-T6 with ultrasonic fatigue test system (20 kHz). Two kinds of particles, Fe-rich intermetallic compounds and Mg₂Si-based particles, governed the fatigue crack initiation. The plastic deformation and recrystallization during welding process led to the changes in particle size and micro crack occurrence between thermo-mechanically affected zone (TMAZ) and nugget zone (NZ). Therefore, the fatigue crack initiation sites leaned to be located at the TMAZ in short fatigue life, or at the NZ in very high cycle fatigue regime.     

Fatigue crack initiation and growth in solder alloys

In modern electronic packaging, especially surface mount technology (SMT), thermal strain is usually induced between components during processing, and in service, by a mismatch in the thermal expansion coefficients. Since solder has a low melting temperature and is softer than other components in electronic packaging, most of the cyclic stresses and strains take place in the solder. Fatigue crack initiation and fatigue crack propagation are likely to occur in the solder even when the cyclic stress is below the yield stress. It is an objective of this research to study the behaviour of fatigue crack initiation and propagation in both lead‐containing solder (63Sn‐37Pb), and lead‐free solders (Sn‐3.5Ag). The effect of alloying (Cu and Bi addition), frequency, tensile hold time and temperature on low cycle fatigue (LCF) behaviour of the solders is discussed. Mechanisms of LCF crack initiation and propagation are proposed and LCF life prediction, based on the various models, is carried out.     

Fatigue crack initiation in alpha-beta titanium alloys

Fatigue crack initiation constitutes that part of total life, which includes the nucleation life, N_n, of an initial crack-like-discontinuity (CLD) and the growth life, N_s, of the CLD to an observable size called an initiated crack. This sequence dominates the total fatigue life of defect-free alpha-beta titanlum alloys. The mechanisms of CLD formation and its growth to the initiated crack at room temperature are reviewed in light of controlling microstructure and other metallurgical features. Recommendations are made for improving fatigue crack initiation resistance with consideration to practical limitations.     

Fatigue crack initiation and growth in riveted specimens: an optical and acoustic microscopic study

While optical microscopy on riveted specimens reveals only surface cracks, the acoustic C-scan images reveal subsurface and buried cracks emerging to the surface. This is of particular interest for fatigue cracks that initiate below the outer surface such as with chamfered riveted panels. Fatigue crack initiation and growth in riveted panels of Alclad 2024-T3 were characterized using optical microscopy and scanning acoustic microscopy to obtain C-scan images. The C-scan images were obtained using a focused transducer with a center frequency of ca 50 MHz, and the peak value of the back surface echo of the plate with countersunk rivet holes was recorded in the C-scan images. Data on the initiation and development of fatigue cracks at rivets in riveted Alclad 2024-T3 are given.     

Fatigue crack initiation and crystallographic crack growth in an austenitic stainless steel

The lifetime of a specimen under cyclic loading is usually limited by the initiation and growth of microcracks. Experimental results for the austenitic stainless steel X6 CrNiNb 18-10 are given and a model for crack initiation and crack growth in the first grains of a polycrystalline aggregate is proposed.     

A fatigue crack initiation model incorporating discrete dislocation plasticity and surface roughness

Although a thorough understanding of fatigue crack initiation is lacking, experiments have shown that the evolution of distinct dislocation distributions and surface roughness are key ingredients. In the present study we introduce a computational framework that ties together dislocation dynamics, the fields due to crystallographic surface steps and cohesive surfaces to model near-atomic separation leading to fracture. Cyclic tension–compression simulations are carried out where a single plastically deforming grain at a free surface is surrounded by elastic material. While initially, the cycle-by-cycle maximum cohesive opening increases slowly, the growth rate at some instant increases rapidly, leading to fatigue crack initiation at the free surface and subsequent growth into the crystal. This study also sheds light on random local microstructural events which lead to premature fatigue crack initiation.     

Three-dimensional finite element analysis using crystal plasticity for a parameter study of microstructurally small fatigue crack growth in a AA7075 aluminum alloy

Three-dimensional finite element analysis using a crystal plasticity constitutive theory was performed to understand and quantify various parametric effects on microstructurally small fatigue crack growth in a AA7075 aluminum alloy. Plasticity-induced crack opening stresses (S_o/S_max) were computed, and from these results the crack propagation life N was obtained. A design of experiments (DOE) technique was used to study the influences of seven parameters (maximum load, load ratio, particle modulus, the number of initially active slip systems, misorientation angle, particle aspect ratio, and the normalized particle size) on fatigue crack growth. The simulations clearly showed that the load ratio is the most influential parameter on crack growth. The next most influential parameters are maximum load and the number of initially active slip systems. The particle modulus, misorientation angle, particle aspect ratio, and the normalized particle size showed less influence on crack growth. Another important discovery in this study revealed that the particles were more important than the grain boundaries for inducing resistance for microstructurally small fatigue crack growth.     

Fatigue crack initiation and propagation under cyclic contact loading

A computational model for contact fatigue damage analysis of gear teeth flanks is presented in this paper. The model considers the conditions required for the surface fatigue crack initiation and then allows for proper simulation of the fatigue crack propagation that leads to the appearance of small pits on the contact surface. The fatigue process leading to pitting is divided into crack initiation and a crack propagation period.The model for prediction of identification of critical material areas and the number of loading cycles, required for the initial fatigue crack to appear, is based on Coffin-Manson relations between deformations and loading cycles, and comprises characteristic material fatigue parameters. The computational approach is based on continuum mechanics, where a homogenous and elastic material model is assumed and results of cyclic loading conditions are obtained using the finite element method analysis.The short crack theory together with the finite element method is then used for simulation of the fatigue crack growth. The virtual crack extension (VCE) method, implemented in the finite element method, is used for simulating the fatigue crack growth from the initial crack up to the formation of the surface pit. The relationship between the stress intensity factor K and crack length a, which is needed for determination of the required number of loading cycles N_p for a crack propagation from the initial to the critical length, is shown.     

Fatigue crack initiation and growth in AlMg4.5Mn butt weldments

The fatigue life of full-penetration and partial-penetration 5 and 25  mm thickness AlMg4.5Mn (AA5083) aluminium alloy butt weldments was investigated under ( R = 0 and R = − 1) constant amplitude loading. The fatigue lives of the tested specimens were predicted using an analytical model which estimated both the crack initiation and crack growth portions of the total fatigue life. The fatigue life of partial-penetration weldments was found to be substantially less than that of full-penetration weldments because of the greater stress concentrations of the incomplete joint penetration and the consequent absence of a substantial crack-initiation life period. Tensile mean stresses ( R = 0 versus R = − 1-test conditions) markedly reduced the fatigue life of the weldments studied and greatly diminished the duration of the fatigue crack growth period. The extra material provided by the weld reinforcement noticeably increased the fatigue life of the partial-penetration weldments. Weld angular distortion-induced bending stresses greatly affected the smaller thickness (5  mm) full-penetration weldments offsetting the fatigue strength bonus anticipated for small-size weldments. Except for the predictions for R = − 1 full-penetration weldments at long life, which the analytical model underestimated, the agreement between experiment and analytical prediction was within a factor of 2, that is, as good as can be generally expected.     

Fatigue dislocation structure and crack initiation in low carbon alloy steel

Abstract

The evolution of dislocation structure in a quenched and tempered low carbon alloy steel with increasing number of fatigue cycles has been investigated using transmission electron microscopy. The changes in dislocation structure can be divided into three stages: the production of the dislocation structure having fatigue features, the formation of microscopic fatigue slip bands, and the initiation and propagation of wide fatigue deformation bands. Microscopic fatigue cracks are formed during the propagation of these bands.

MST/1037