Crack deflection in the nonlinear zone of ultra-high-strength steel fatigue crack growth curve

The fatigue crack growth rate (FCGR) of 10Ni5CrMoV steel under variable load ratios was investigated. The microscopic observations of growth direction and microstructural analysis were conducted by means of electron backscatter diffraction and transmission electron microscopy. The results showed that FCGR of 10CrNi5MoV steel increased with the increasing load ratio in the mid-growth rate regime; however, it did not completely conform to the Paris Formula. A nonlinear zone existed in the logarithmic coordinate system of the FCGR curve and was unaffected by load ratio. The main impact factors for the appearance of the nonlinear zone were grain size and the size of the plastic zone surrounded fatigue cracks. In the nonlinear zone of the FCGR curve, an apparent crack deflection phenomenon occurred.     

Fatigue crack growth characteristics of inertia friction welded Ti17 alloy

Fatigue crack growth rates (FCGR) of the inertia friction welded Ti17 alloy joint was studied at room temperature (RT) and 400 °C at a stress ratio of 0.1. Microstructural analysis and mechanical tests were also carried out. The results show that at RT, FCGR of weld metal with recrystallisation microstructure was higher compared with the base metal and the thermo‐mechanically affected zone. At 400 °C, however, the difference of the FCGR became insignificant. Fractographic observation showed that the failure of the base metal was dominated by slip band in transgranular mode at both RT and 400 °C, whereas crack in weld metal grew in intergranular mode at RT but in transgranular mode at 400 °C. The combined effects of lower yield strength and bigger yield‐ultimate tensile strength difference may be responsible for the higher fatigue crack growth (FCG) resistance of inertia friction welded Ti17 alloy at elevated temperature.     

Fatigue crack growth property of laser beam welded 6156 aluminium alloy

Fatigue crack growth behaviours in different welding zones of laser beam welded specimens were investigated using central crack tension specimens for 6156 aluminium alloy under constant amplitude loading at nominal applied stress ratio R = 0.5, 0.06, ?1. The experimental results showed that base metal (BM) exhibited superior fatigue crack resistance compared to weld metal (WM) and heat‐affected zone (HAZ). Crack growth resistance of WM was the lowest. The exponent m values for BM and HAZ at different stress ratios are close and around 2.6, while m for WM at different stress ratio is around 4.7. The discrepancy between crack growth rates for WM and BM is more evident with increasing stress ratio, while it is a little change for HAZ and BM. Change of the microstructure in WM deteriorates the resistance of fatigue crack growth compared to BM. It was mainly due to grain boundary liquation and dissolving of second‐phase particles in the weld region. It was also found that the variety of fatigue crack resistance for different welding zones is in conformity with the change of hardness. BM with the highest hardness exhibited the maximum resistance for fatigue crack, and WM with the lowest hardness exhibited the minimum fatigue crack resistance.     

Evaluation of temperature‐sensitive fatigue crack propagation of a high‐speed railway wheel rim material

The fatigue crack growth rate (FCGR) of ER8C high‐speed railway wheel rim material was tested at various service temperatures. The temperature sensitivity of fatigue crack propagation was evaluated, and the effect of temperature on the crack propagation mechanism was analyzed. The obtained results indicate a fatigue ductile‐to‐brittle transition (FDBT) point at ?20°C for the ER8C wheel rim materials. A reverse relationship was found between FCGR and temperature for the near threshold and Paris regimes when the temperature was below the FDBT point. However, no evident changing rule was found when the temperature was above this transition point. An evident fatigue crack propagation mode transition was found from lamellar tearing to intergranular cracks, which was related to the FDBT for the near‐threshold regime.     

The influence of porosity on the fatigue crack growth behavior of Ti–6Al–4V laser welds

The effect of porosity––a common welding defect––on the fatigue crack growth rate (FCGR) in Ti–6Al–4V laser welds was investigated. The experimental results reveal that porosity was present in partial penetration welds over a narrow fusion zone (FZ) with martensite structure. The FCGR of the FZ was lower than that of the base plate. The fracture surface morphology of weld metal was much rougher as compared to that of the base plate. Randomly oriented martensite in the FZ led to local cleavage fracture along a preferred plane, thus, altering the crack growth direction significantly out of the primary crack plane. The zigzag crack path in the FZ resulted in a reduced FCGR at a given ΔK compared to the base plate. Besides, the porous weld showed a serration on the crack growth curve, and behaved the similar crack growth characteristics as the defect free one. SEM fractography revealed that the deflection of crack path around porosity together with local notch blunting as the crack tip pierced into porosity, balanced the increased FCGR for the occurrence of instant crack advance as the crack front reached the porosity at a low stress ratio. In contrast, the serration and drop in FCGR occurred sparingly at a high stress ratio as the crack front met the porosity.     

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.     

Fatigue crack growth resistance of 7075 Al alloy after equal channel angular pressing

This work presents experimental results on effects of severe plastic deformation (SPD) and subsequent natural ageing on tensile mechanical properties and fatigue crack growth resistance of fine‐grained 7075 Al alloy. The alloy was subjected to equal channel angular pressing (ECAP) after solution treatment. Fatigue crack propagation tests were conducted in room condition, at load ratio R = 0.1 and different load ranges on small disk shaped compact tension specimens. Fatigue fracture surface is also investigated using scanning electron microscopy observations and showed more ductile fatigue crack growth in the unECAPed specimen. Despite the increased tensile strength after ECAP, the ductility that controls low‐cycle fatigue behaviour has decreased. It is found that ECAP has resulted in a remarkable change in Paris regime parameters and a significant increase in fatigue crack growth rate. The decrease in fatigue crack growth resistance and ΔK_c after ECAP can be attributed to the decrease in alloy's ductility.     

TIG与FSW焊接工艺下2219铝合金疲劳裂纹扩展性能研究

目的 研究钨极惰性气体保护焊（TIG）和搅拌摩擦焊（FSW）对2219铝合金焊接接头疲劳性能的影响,并探究这2种不同焊接技术条件下焊接接头疲劳裂纹的产生与裂纹扩展原理,了解2种焊接接头的抗裂纹扩展能力,为工程实践应用提供数据参考。方法 采用疲劳裂纹扩展试验方法,测试上述2种焊接工艺条件下焊缝金属和热影响区组织的疲劳裂纹扩展速率da/d N和阈值,使用光学显微镜和扫描电子显微镜观察并分析金相组织和疲劳断口形貌特征。结果 疲劳裂纹倾向于沿裂纹处萌生,裂纹的存在成为主要的裂纹扩展源头,有利于加速裂纹向前延伸。热影响区由于组织结构不均匀,不同位置的晶粒尺寸存在明显差异,疲劳裂纹扩展路径倾向于沿靠近焊缝一侧向靠近母材区域扩展。TIG焊接工艺下焊缝金属和热影响区的裂纹扩展速率明显低于FSW焊接工艺下的焊缝金属和热影响区,与此同时,TIG焊接接头表现出优良的抗疲劳裂纹扩展性能。结论 通过此研究,建议2219铝合金焊接接头采用TIG焊接工艺,抗疲劳裂纹扩展效果更佳。     

Effect of overload on fatigue crack retardation of aerospace Al-alloy laser welds using crack-tip plasticity analysis

Investigations on fatigue crack growth retardation due to single tensile and periodic multiple over load in strength undermatched laser beam welded 3.2 mm thick aerospace grade aluminium alloy 2139-T8 sheets are conducted. The effect of overload on the fatigue crack propagation behaviours of the homogenous base metal and welded panels (200 mm wide, centre cracked) was compared using experimental and FE analysis methods. The effective crack tip plasticity has been determined in homogeneous M(T) specimens using Irwin’s method and in both homogeneous and laser welded specimen by calculating crack tip plastic strain using FE analysis for single tensile overload. The crack retardation due to the overload in welded specimens is described by the Wheeler Model. The crack tip plastic zone size in the welded specimen was determined by FE analysis using maximum plastic zone extension at the mid sheet thickness. The results show that the Wheeler Model can be implemented to the highly heterogeneous undermatched weld to describe the crack retardation in fatigue following single tensile overload. Fatigue crack growth retardation due to single overload is found to be larger than the base metal. However, after periodic multiple overload, shorter crack retardation has occurred for undermatched welds than the base metal.     

Fatigue crack propagation in API 5L X‐70 pipeline steel longitudinal welded joints under constant and variable amplitudes

Fatigue crack propagation (FCP) under constant and variable amplitude loading in base metal (BM), weld metal (WM) and heat affected zone (HAZ) of longitudinal welded joints of an API X‐70 pipeline steel was investigated. Constant amplitude loading tests were performed at R = 0.1 and 0.5, whereas for variable amplitude testing single peak tensile overloads (OLs) alternating between 75 and 100% of maximum load were applied at 2.5 mm intervals in crack growth. Results of SE(B) specimens tested under constant and variable amplitude loading revealed that BM, WM and HAZ regions subjected to R = 0.5 and low ΔK‐values presented the highest crack growth rates. At higher ΔK values FCP rates in all the studied regions were similar and the R effect on FCP rate was no more observed. Crack growth retardation due to OLs was observed at the three studied regions, showing a decrease on the FCP delay with a decreasing on ΔK.     

TRANSIENT RETARDATIONS IN FATIGUE CRACK GROWTH FOLLOWING A SINGLE PEAK OVERLOAD

Retardation in the fatigue crack growth rate following the application of a single peak overload in a fatigue loading sequence has been studied for a low carbon structural steel. Tests have been performed at load ratios of R= 0.2 and R= 0.6 at a baseline stress intensity range, ΔK_b, corresponding to fatigue crack growth rates in the Paris regime. Single peak overloads were applied at a crack-length to specimen-width ratio of a/W= 0.5. At the load ratio of R= 0.6 monotonic or “static” fracture modes were observed upon application of the overload, and these produced an immediate increase in growth rate. A subsequent retardation is attributed to the presence of a residual compressive stress field ahead of the crack tip. A similar retardation was observed at a load ratio of 0.2. The importance of residual stress was established by performing stress relieving experiments. In addition, removal of the surface deformation after an overload by machining “T” sidegrooves resulted in an extended transient, which could not be explained by residual machining stresses.     

Analysis of fatigue crack growth behavior of SS 316(N) welds using the unified approach

Fatigue crack growth (FCG) behavior of SS 316(N) weld has been evaluated at different R‐ratios at room temperature and compared with that of the base metal. The FCG resistance of weld is better than that of the base material and is due to the residual stresses developed during the welding. The data were analyzed using the unified approach that considers the two‐parametric (ΔK and K_max) nature of fatigue. The R‐ratio effects in both the base and weld metals are accounted for without invoking the extrinsic parameters, such as plasticity‐induced crack closure. Since the residual stresses are of the monotonic type, they affect the crack growth via the K_max‐parameter. The crack growth trajectory plots were developed, and they show how the two crack tip driving forces, ΔK and K_max, change to overcome the FCG resistance of the weld in relation to that of the base metal. The results also show that the effects from the compressive residual stresses are more dominant at low R‐values and occur via the K_max parameter.     

FATIGUE BEHAVIOR OF A RAIL STEEL

The fatigue behavior of a hot-rolled, control-cooled, plain carbon eutectoid rail steel has been characterized. The data include monotonic and cyclic stress-strain curves, low cycle fatigue data and near-threshold fatigue crack growth rate behavior in air and in vacuo. The effects of environment and mean stress on the near-threshold fatigue crack growth rates of rail steel are significant. At a low stress ratio (R), ΔK_o is lower in vacuum (7 MPa √m) than in moist air (10 MPa √m). At high R, ΔK_o is higher in vacuum (6 MPa √m) than in air (4 MPa √m). The beneficial effect of moist air on FCGR at low ΔK and low R is attributed to an increase in closure due to fracture surface roughness and oxide film.     

Fatigue crack growth in fibre metal laminates with multiple open holes

The fatigue crack growth behaviour of hybrid S2‐glass reinforced aluminium laminates (Glare) with multiple open holes was investigated experimentally and analytically. It was observed that the presence of multiple‐site fatigue damage would increase crack growth rates in the metal layers as two propagating cracks converged. An analytical crack growth model was established for predicting crack growth rates based on empirical Paris equation. The effective stress intensity factor at crack tips is a function of mode I far‐field stress intensity factor, crack opening stress intensity factor and effective non‐dimensional stress intensity factor that incorporated the crack‐bridging effect in fibre metal laminates. The predicted results under different applied stress can capture the trend of averaged crack growth rates in experiments, although deviation exists in the predictions.     

Influence of heat treatment on fatigue crack growth of austempered ductile iron

Fatigue crack growth (FCG) behavior has been investigated for two different grades of austempered ductile irons (ADIs). These ADIs were produced from an alloyed ductile iron (DI) and heat treated respectively at two austempering temperatures, 300 and 360°C, to generate two different ausferrite microstructures. FCG tests using compact tension (CT) specimens were conducted under load control with three load ratios, R = 0.1, 0.5 and 0.7. The fatigue crack growth rates (FCGRs) of the given ADIs were compared with those of the as-cast DI with a bull's eye microstructure to examine the influence of austempering treatment on the FCG behavior of DI. The FCG behavior for the given materials was found to be dependent on the matrix structure with a demonstration that the as-cast DI had a better FCG resistance than did the ADIs at low K regime and vice versa at high K regime. As for the comparison made between the two ADIs, the one austempered at 360°C exhibited a lower FCG rate as a result of its coarse ausferrite microstructure, higher volume fraction of retained austenite, and greater toughness. The ADIs also demonstrated a load ratio dependence of intrinsic FCGR; that is, the enhancement of the FCGR with an increase in R value could not be rationalized by the crack closure effects.     

A comprehensive investigation on the effects of laser and shot peening on fatigue crack growth in friction stir welded AA 2195 joints

The effects of various surface treatment techniques on the fatigue crack growth performance of friction stir welded 2195 aluminum alloy were investigated. The objective was to reduce fatigue crack growth rates and enhance the fatigue life of welded joints. The crack growth rates were assessed and characterized for different peening conditions at a stress ratio (R) of 0.1, and 0.7. The surface and through-thickness residual stress distribution were also investigated and presented for the various regions in the weld. Tensile residual stresses introduced during the welding process were found to become significantly compressive, particularly after laser peening. The effect of the compressive stresses was deemed responsible for increasing the resistance to fatigue crack growth of the welds. The results indicate a significant reduction in fatigue crack growth rates using laser peening compared to shot peening and native welded specimens. This reduced fatigue crack growth rate was comparable to the base unwelded material.     

Correlation of one-dimensional fatigue crack growth at cold-expanded holes using linear fracture mechanics and superposition

This work assesses the ability of linear elastic fracture mechanics (LEFM) with superposition to correlate the growth of one-dimensional fatigue cracks at cold-expanded open holes under constant amplitude loading. Care is taken in the work to accurately: control the test setup to ensure one-dimensional crack growth, determine residual stress in the coupons, measure crack growth, determine the fatigue crack growth rate (FCGR), compute stress intensity factors, and correlate fatigue crack growth rate with stress intensity factor range ΔK and stress ratio R. The work used long dog-bone coupons having a gage section 38.1 mm wide and a centrally located 7.09 mm diameter hole. The coupons were fabricated from 2.03 mm thick 7075-T6 sheet. The small coupon thickness and alignment of the loading fixture to eliminate bending resulted in one-dimensional crack growth. Residual stress due to cold expansion (CX) was measured using the contour method, as a function of position on the crack plane. Residual stress measurements gave typical results for the average residual stress field, with near-yield compression at the hole giving way to tension further out. Measurements on multiple coupons showed ±10% variability in residual stress. Crack growth behavior of multiple as-machined (AM) coupons (without CX) tested at R of 0.1 or 0.5 agreed with earlier results published in the literature. The scatter in lifetime, defined as the range of lifetime divided by the average lifetime, was less than 30% in the AM coupons. Crack growth behavior of multiple CX coupons tested at the same two applied stress ratios was consistent with predictions by linear superposition, where the predictions used a correlation for fatigue crack growth rate as a function of ΔK and R based on crack closure concepts and a piecewise log–log fit to FCGR versus ΔK_eff data from tests of non-residual stress bearing material and from the literature. Scatter in lifetime of CX coupons was 152% at R = 0.1 and 69% at R = 0.5. While the scatter in CX coupon lifetime is considerably greater than for AM coupons, it is found consistent with the observed 10% variability in residual stress. The work therefore demonstrates the ability of LEFM with superposition to accurately correlate the behavior of coupons with and without residual stresses.     

Overloads in ductile and brittle materials

The first part of the paper presents fatigue crack propagation experiments with single overloads at different overload ratios and specimen thickness in a very ductile austenitic steel. The results show that in the Paris regime in a ductile material, the overload effect can be explained solely in the framework of the change of the plasticity‐induced crack closure. Other effects such as strain hardening, blunting, additional damage, crack deflection and branching are not significant. Whether or not this behaviour can be observed in less ductile materials and also in the threshold regime is investigated in the second part. Periodic overload experiments were performed on a relatively ductile 2124, and a more brittle 359, particle‐reinforced aluminium alloy. In the Paris regime, the retardation in the 2124 reinforced alloy showed the expected behaviour for a ductile material, whereas in the 359 reinforced cast alloy, an acceleration of the mean growth rate was observed. Near the threshold the difference between the two alloys and the effect of the periodic overloads decreased.     

On the fatigue crack growth behaviour of selective laser melting fabricated Inconel 625: Effects of build orientation and stress ratio

The building of Inconel 625 material was carried out using the selective laser melting method, and its fatigue crack growth property at ambient temperature was experimentally investigated. Compact‐tension specimens with different building orientations were utilized to determine the stress intensity factor threshold and fatigue crack growth rate curves at different stress ratios (R). The results indicated that the fatigue crack growth properties in the near threshold stress intensity factor and Paris regions were greatly affected by the loading factor, as well as the orientation of the alloy. The mechanism of fatigue crack growth at different stages was observed and discussed using scanning electron microscopy. Finally, based on the framework of the linear elastic fracture, a new and applicable effective driving force factor range was introduced to replace the traditional stress intensity factor range (ΔK) with good accuracy for all of the fatigue crack growth test data, considering both the stress ratio and orientation.