A comparative evaluation of K<Subscript>op</Subscript> determination and ΔK<Subscript>eff</Subscript> estimation methods

Methods for determination of the crack opening stress intensity factor (K_op) and for estimation of the effective stress intensity factor range (ΔK_eff) are evaluated for crack growth test data of aluminum alloys. Three methods of determining K_op, visual measurement, ASTM offset compliance method, and the neural network method proposed by Kang and Song, and three methods of estimating ΔK_eff, conventional, the 2/P10 and 2/PI methods proposed by Donald and Paris, are compared in a quantitative manner by using evaluation criteria. For all K_op determination methods discussed, the 2/PI method of estimating ΔK_eff provides good results. The neural network method of determining K_op provides good correlation of crack growth data. It is recommended to use 2/PI estimation with the neural K_op determination method. The ASTM offset method used in conjunction with 2/PI estimation shows a possibility of successful application. It is desired to improve the ASTM method.     

Crack propagation behaviour in fretting fatigue

Fretting fatigue and normal, or unfretting, fatigue tests of a stainless steel SUS304L and an aluminium alloy A2024-T3 were carried out to investigate the effects of the contact pressure and the stress ratio on the crack propagation behaviour. The crack propagation behaviour was represented by the crack propagation rate da/dNversus the crack length a or the stress intensity factors ΔK_eff and K_max In fretting fatigue, crack propagation was divided into two stages, namely S_I and S_II. The value of da/dN in the S_I stage was very high, even under a stress intensity factor less than the threshold for normal fatigue, and decreased gradually with crack growth because of crack closure and the decreasing fretting effect. The decrease in da/dN was marked in the case of high contact pressure and low stress ratio such as when R = −0.33, where R denotes the minimum stress divided by the maximum stress. During fretting fatigue crack closure occurred at an oblique short crack in the early stages of crack propagation in both the SUS304L steel and the A2024-T3 alloy; it also occurred at the oblique cracked surface of the shear lips formed in the A2024-T3 alloy during crack growth. However, in the S_II stage, which followed the S_I stage, da/dN increased with crack growth as for normal fatigue.     

The role of casting porosity in fatigue properties of Al−Si 319 lost foam cast alloy

The tensile, fracture toughness and fatigue properties of Al−Si 319 lost-foam-cast alloy were determined at room temperature. The fatigue properties of this alloy were also determined at 150°C. Fatigue cracks were always initiated at the largest casting pore. Initial pore sizes were measured using a scanning electron microscope. Surface replication showed that majority of the fatigue life was spent in fatigue crack propagation and permitted the estimation of the constants in the Paris power law and the threshold stress intensity factor (ΔK _th ). The role of internal casting porosity was quantified using a linear elastic fracture mechanics (LEFM) model for fatigue crack growth. The predicted lives agreed with the measured values within a factor of two.     

Fatigue crack growth behavior in ultrafine grained low carbon steel

Ultrafine grained (UFG) low carbon (0.15 wt.% C) steel produced by equal channel angular pressing (ECAP) was tested for investigating the effect of load ratio on the fatigue crack growth rate. Fatigue crack growth resistance and threshold of UFG steel were lower than that of as-received coarse grained steel. It was attributed to the less tortuous crack path. The UFG steel exhibited slightly higher crack growth rates and a lower ΔK_th with an increase of R ratio. The R ratio effect on crack growth rates and ΔK_th was basically indistinguishable at lower load ratio (R>0.3), compared to other alloys, which indicates that contribution of the crack closure vanishes. The crack growth rate curve for UFG steel exhibited a longer linear extension to the lower growth rate regime than that for the coarse grained as-received steel.     

Static and dynamic fracture analysis for the interface crack of isotropic-orthotropic bimaterial

In the present study, interfacial cracks between an isotropic and orthotropic material, subjected to static far field tensile loading are analyzed using the technique of photoelasticity. The fracture parameters are extracted from the full-field isochromatic data and the same are compared with that obtained using boundary collocation method. Dynamic photoelasticity combined with high-speed digital photography is employed for capturing the isochromatics in the case of propagating interfacial cracks. The normalized stress intensity factors for static cracks are greater when α=90° (fibers perpendicular to the interface) than when α=0° (fibers parallel to the interface), and those when α=90° are similar to ones of isotropic material. The dynamic stress intensity factors for interfacial propagating cracks are greater when α=0° than α=90°. For the velocity ranges (0.1<c/c _s1 <0.7) observed in this study, the complex dynamic stress intensity factor |K _D |, I increases with crack speedc, however, the rate of increase of |K _D | with crack speed is not as drastic as that reported for homogeneous materials.     

A formula for the crack opening level under random loading in 2024-T351 aluminum alloy

Based on the fatigue crack growth results of the previous work for 2024-T351 aluminum alloy, the crack closure behavior under random loading was analyzed, and the correlation between the crack opening ratio and the stress ratio under random loading was discussed. The crack opening ratio under random loading can be expressed as a function of the stress ratio for the largest load cycle in a random load history. The correlation obtained is found to provide good predictions for crack growth under random loading.     

Effects of Mn content and texture on fatigue properties of as-cast and extruded AZ61 magnesium alloys

Fatigue behavior of as-cast and extruded AZ61 magnesium alloys in ambient air (20 °C–55%RH) was investigated. It was found that size and distribution of cast defect influenced tensile and fatigue performance of the as-cast alloy. Fatigue limit of the as-cast alloy was significantly low compared to the extruded alloy. The casting defects served as stress concentration sites for fatigue crack nucleation. Fatigue tests were also carried out on a high Mn content alloy. All of the specimens failed from an inclusion near the specimen surface. Fatigue limit of Mg alloy with high Mn content was lower compared to that of the low Mn content alloy. Further, investigation on the effect of texture on fatigue and fatigue crack growth behavior of the extruded AZ61 magnesium alloy plate was carried out. The results showed that fatigue strength in the longitudinal direction to the extruded direction was higher compared to those in the transverse and 45° directions. Significant effect of specimen orientation on fatigue crack growth behavior for both short and long cracks was found near the threshold region. However, regardless of specimen orientation, the da/dN–ΔK_eff curves for all three kinds of specimens were in a narrow band. It is suggested that the difference in the fatigue life among the specimen orientations will be mainly due to the difference in the crack closure behavior. A transition of fracture mechanism was found for a long crack. Slip fracture mechanism was dominant above the transition point, whereas below the transition point, slip fracture mechanism was associated with cleavage fracture.     

Influences of equal biaxial tensile loads on the stress fields near the mixed mode crack

A hybrid method for photoelasticity is introduced and applied to the plane problems of isotropic polycarbonate plates with a central crack under uniaxial and equal biaxial tensile loads. Also, the influences of equal biaxial tensile loads on the isochromatic fringes, stress fields and stress intensity factors near the mixed mode crack-tip have been investigated. The results show that, when an equal lateral tensile load is added to the specimen under uniaxial tensile load, the asymmetric isochromatic fringes about the line of crack gradually become symmetric, and the slope of the isochromatic fringe loop near the crack-tip is inclined towards the crack surface according to the increasing of the inclined angle of crack. Furthermore, the shapes of distribution of all stress components are changed from asymmetric to symmetric. In the equal biaxial tensile load condition against the uniaxial tensile load condition, the values of stress intensity factors are changed little, and only the region of compressive stress of σ _x /σ _O is changed when β = 0°, but the values of K _I /K ₀ are increased and those of K _II /K ₀ become almost zero, namely, we have the mode I condition when β = 15°∼45°. This paper was recommended for publication in revised form by Associate Editor Chongdu Cho Dong-Chul Shin received the B.S., M.S. and Ph.D. degrees in Mechanical Engineering from Yeungnam University in 1995, 1997 and 2001, respectively. Dr. Shin studied at the University of Tokyo, Japan, for three years (from April, 2005 to January, 2008) as a Post-Doctoral fellow (supported by Korea Research Foundation (KRF) and Japan Society for the Promotion of Science (JSPS)). Dr. Shin is currently a Research Professor at the School of Mechanical Engineering at Pusan National University, Korea. His research interests include the static and dynamic fracture mechanics, stress analysis, and fracture criteria of piezoelectric ceramics, etc. Jai-Sug Hawong received a B.S. in Mechanical Engineering from Yeungnam University in 1974. Then he received his M.S. and Ph.D. degrees from Yeungnam University in Korea in 1976 and from Kanto Gakuin University in Japan in 1990, respectively. Prof. Hawong is currently a professor at the School of Mechanical Engineering at Yeungnam University, in Gyeongsan city, Korea. He is currently serving as vise-president of Korea Society Mechanical Engineering. His research interests are in the areas of static and dynamic fracture mechanics, stress analysis, experimental mechanics for stress analysis and composite material etc.     

Fatigue life prediction by statistical approach under constant amplitude loading

In general, the experimental data of fatigue crack growth rates scatter very much even under identical experimental condition such as a constant amplitude loading condition. It is, thus, essential to take into account the data scatter of crack growth rates by using statistical approach for a reliable fatigue crack, propagation analysis. In this study, fatigue crack propagation tests were conducted on a 1.02 mm-thick 2024-T3 aluminum alloy under a constant amplitude loading condition. The distribution of the fatigue crack propagation life is estimated by using the stochastic Markov chain model based on a modified Paris-Erdogan equation to consider the variability of the fatigue crack growth. The fatigue lives estimated by using the Markov chain model are found to be agreed well with the experimental results.     

A probabilistic analysis on variability of fatigue crack growth using the markov chain

Understanding the stochastic properties of variability in fatigue crack growth is important to maintaining the reliability and safety of structures. In this study, a stochastic model is proposed to describe crack growth behavior considering the variability of fatigue crack growth rates due to the heterogeneity of material. Fatigue life distribution is then predicted based on this model To construct this model, fatigue tests are conducted on a high strength aluminum alloy 7075 T6 under constant stress intensity factor range control. The variability of fatigue crack growth rates is expressed by random variablesZ and Γ based on the variability of material constantsC andm of the Paris-Erdogan equation. The distribution of fatigue life under constant stress intensity factor ranges is evaluated by the stochastic Markov chain model based on the Paris-Erdogan equation. The merit of the proposed model is that only a small number of tests are required to determine this function, and fatigue life required to reach certain crack length at a given stress intensity factor range can be easily predicted. Department of Mechanical Design and Production Eng.     

Failure analysis of turbine blade in atomic power plant

The turbine blade in an atomic power plant may be fractured by fatigue, stress corrosion cracking and bad fitting. Especially, fatigue fracture is caused by low stress amplitude below the yielding stress. SEM fractography does not have striation, but AFM fractography does on the fatigue fractured surface of 12% Cr steel used for the turbine blade. Surface roughness R _q measured by AFM is linearly related to the stress intensity factor range, ΔK, and is increased linearly according to the load range ΔP. Therefore, in this study, the loading condition applied to a turbine blade is predicted by the relation between the intersection of the ΔK-R _q relation and load range ΔP.     

Deformations of a simplified flip chip structure under thermal testing inspected using a real-time Moiré technique

Deformations of a Si-epoxy-FR4 (simplified flip chip) structure under thermal testing were inspected with a real-time Moiré technique. Specimens without cracks and specimens with a crack at the silicon-epoxy interface were prepared. The measurement results showed that the maximum deformation appeared at the edge. When the specimen was cooled to 20 °C, there was residual plastic deformation in the specimen. The creep effect was more dominant in the FR4-epoxy interface. Upon cooling to 20 °C, the specimen experienced partial strain recovery. To characterize the behavior of the interfacial crack, stress intensity factors K_I and K_II, and the strain energy release rate G in the vicinity of the crack tip were calculated using the measured deformations to conduct a quantitative study. It was observed that a sharp strain gradient occurred at the crack tip. K_I and K_II were dependent on temperature, and G was dominated by K_I for the interfacial crack in the specimen.     

The effects of artificial asperities on crack closing behavior in quenched and tempered medium carbon steel

To better understand the effect of an asperity on crack closure behavior, K-CMOD relations were examined using artificial asperity/wedge, inserted into the fatigue crack in a three point bending specimen made of a hardened medium carbon steel. Experimental results revealed that the unloading phase of the K vs. CMOD curve exhibited a concave shape if soft artificial asperity (Al alloy) was inserted, signifying acceleration in the CMOD decrease at zero applied load. This was mainly related to elastic and plastic deformation in the wedge material during the unloading process. On the contrary, the linear unloading portion of K vs. CMOD was obtained as hard asperity (high carbon steel) was employed, which specified deceleration in the CMOD decrease at zero applied load, where the only elastic deformation in the asperity was affected. From their unloading curves, the severity of crack closure or ??K _eff value was found to be related to the strength of the asperity material. The values of ??K _eff were examined in two different ways, e.g., (i) the remote displacement method and (ii) the adjusted compliance ratio method (ACR). The ??K _eff value, measured using both approaches, decreases with increasing wedge strength, such as hardness and yield strength. The rate of reduction in ??K _eff was, however, changed depending on the manner of ??K _eff examination, in which the ??K _eff decreased at a higher rate for the compliance ratio method and at a lower rate for the remote displacement method. The reason for this is discussed in the present work.     

Effect of different temperatures on the metallographic structure and tensile property of 2024‐T4 alloy in integral heating single point incremental forming

To study the tensile property and metallographic structure evolution of 2024‐T4 high‐strength aluminum alloy in integral heating single point incremental forming (IHSPIF), the warm tensile tests were carried out at 120–240°C with the strain rates of 0.1–0.001 s^?1. Its results could provide a certain theoretical reference to the IHSPIF. The integral heating was different from the local heating, which was to heat the overall sheet to be deformed. It was found in the tensile tests that at the strain rate of 0.01 s^?1, the optimum forming temperature was determined to be 210°C at which the ductility was the best. The material dynamically recovered at 240°C. The following IHSPIF tests were conducted at different temperatures. By observing the organization of the sidewall of the square tapered parts, the alloy dynamically recovered appeared at 210°C and its grains coarsened at 240°C. Considering the temperature interval of 30 and below the recrystallizing temperature of aluminum alloy, it was concluded that the optimal temperature for the integral heating IHSPIF was about 150°C.     

Finite Element Analysis of Localized Plasticity in Al 2024-T3 Subjected to Fretting Fatigue

Fretting fatigue is a combination of two complex mechanical phenomena, namely, fretting and fatigue. Fretting appears between components that are subjected to small relative oscillatory motion. Once these components undergo cyclic fatigue load at the same time, fretting fatigue occurs. Fretting fatigue is an important issue in aerospace structural design. Many studies have investigated fretting fatigue behavior; however, the majority have assumed elastic deformation and very few have considered the effect of plasticity. The main goal of this study is to monitor the effect of different fretting fatigue primary variables on localized plasticity in an aluminum alloy (Al 2024-T3) test specimen. In order to extract the stress distribution at the contact interface under elasto-plastic conditions, a modified finite element contact model was used. The contact model was verified through comparison with an elastic analytical solution. Then, a bilinear elasto-plastic isotropic hardening model with a von Mises yield surface was implemented to simulate the material behavior of the aluminum alloy. The effect of different fretting fatigue primary variables, such as axial stress, contact geometry, and coefficient of friction, on localized plasticity was investigated. Finally, the relationship between the location of maximum localized plasticity and Ruiz fretting damage parameter with the crack initiation site is discussed.     

材料性能对搅拌摩擦焊焊缝成形的影响

采用左螺纹圆柱搅拌头对O态和T4态2024铝合金进行搅拌摩擦焊接试验,研究了材料性能对搅拌摩擦焊焊缝成形的影响,并用软性约束分析了材料性能对焊核尺寸的影响。试验结果表明：焊缝形貌受焊核周边金属约束的影响,约束程度与材料力学性能和温度有关。O态2024铝合金对接焊时,软性约束体对塑性金属横向迁移的约束小,焊核面积和焊核宽度较T4态2024铝合金的焊核面积和焊核宽度大。两种热处理状态2024铝合金对接焊时,强度和硬度较高的T4态2024铝合金置于返回边时,在焊缝两侧、前进边的软性约束体对塑性金属的约束较返回边的软性约束体对塑性金属的约束强,焊核向返回边偏移;由于在返回边有更多的塑性金属,使其沿焊缝厚度方向向上的运动趋势增强,因此返回边的焊核高度较前进边的焊核高度高。对T4态2024铝合金进行适当的预热,会增强焊缝金属的塑化程度,使其向焊缝两侧的迁移运动趋势增强,焊核宽度及面积增大。     

Experiments and numerical approaches to ductile tearing in an 2024-T351 aluminium alloy

Ductile fracture of an 2024-T351 aluminium alloy has been investigated using a central crack panel (CCP). In order to predict rupture, two models using the local approach to fracture mechanics were verified: the uncoupled Rice and Tracey void growth model and the coupled Rousselier model based on continuum damage mechanics. A finite element analysis has been performed in order to verify the capability of these models to predict the crack extension.     

Statistical aspects of fatigue crack growth life of base metal,weld metal and heat affected zone in FSWed 7075-T651 aluminum alloy

The statistical aspects of fatigue crack growth life of base metal (BM), weld metal (WM) and heat affected zone (HAZ) in friction stir welded (FSWed) 7075-T651 aluminum alloy has been studied by Weibull statistical analysis. The fatigue crack growth tests were performed at room temperature on ASTM standard CT specimens under three different constant stress intensity factor range controls. The main objective of this paper is to investigate the effects of statistical aspects of fatigue crack growth life on stress intensity factor ranges and material properties, namely BM, WM and HAZ specimens. In this work, the Weibull distribution was employed to estimate the statistical aspects of fatigue crack growth life. The shape parameter of Weibull distribution for fatigue crack growth life was significantly affected by material properties and the stress intensity factor range. The scale parameter of WM specimen exhibited the lowest value at all stress intensity factor ranges.     

Elevated temperature deformation behavior in an AZ31 magnesium alloy

An AZ31 magnesium alloy was tested at constant temperatures ranging from 423 to 473 K (0.46 to 0.51T _m ) under constant stresses. All of the creep curves exhibited two types depending on stress levels. At low stress (σ/G<4×10⁻³), the creep curve was typical of class A (Alloy type) behavior. However, at high stresses (σ/G>4×10⁻³), the creep curve was typical of class M (Metal type) behavior. At low stress level, the stress exponent for the steady-state creep rate was of 3.5 and the true activation energy for creep was 101 kJ/mole which is close to that for solute diffusion. It indicates that the dominant deformation mechanism was glide-controlled dislocation creep. At low stress level wheren=3.5, the present results are in good agreement with the prediction of Fridel model.     

Fatigue crack propagation behavior in STS304 under mixed-mode loading

The use of fracture mechanics has traditionally concentrated on crack growth under an opening mechanism. However, many service failures occur from cracks subjected to mixed-mode loading. Hence, it is necessary to evaluate the fatigue behavior under mixed-mode loading. Under mixed-mode loading, not only the fatigue crack propagation rate is of importance, but also the crack propagation direction. In modified range 0.3≤a/W≤0.5, the stress intensity factors (SIFs) of mode I and mode II for the compact tension shear (CTS) specimen were calculated by using elastic finite element analysis. The propagation behavior of the fatigue cracks of cold rolled stainless steels (STS304) under mixed-mode conditions was evaluated by using K_I and K_II(SIFs of mode I and mode II). The maximum tangential stress (MTS) criterion and stress intensity factor were applied to predict the crack propagation direction and the propagation behavior of fatigue cracks.