Fatigue behaviour and mean effects in grey cast iron

Strain cycle fatigue concepts are well integrated into fatigue life prediction methodologt for wrought components. Concepts developed for wrought materials cannot be directly extended to cast materials because of differences in the fatigue mechanisms, but the framework of a life prediction method for cast iron components will be similar. Observations and results of constant-amplitude completely reversed fatigue tests performed in strain and load control are reported for a pearlitic grey cast iron. Mean amplitude tests in both control modes have been conducted to evaluate the effects of mean stresses and strains. A parameter of the form (σ_maxΔ∈) gives good correlation of all the fatigue tests performed and provides a simple relationship to fatigue life.     

On the fatigue damage micromechanisms in Si‐solution–strengthened spheroidal graphite cast iron

Graphite nodules in spheroidal graphite cast iron (SGI) play a vital role in fatigue crack initiation and propagation. Graphite nodules growth morphology can go through transitions to form degenerated graphite elements other than spheroidal graphite nodules in SGI microstructure. These graphite particles significantly influence damage micromechanisms in SGI and could act differently than spheroidal graphite nodules. Most of the damage mechanism studies on SGI focused on the role of spheroidal graphite nodules on the stable crack propagation region. The role of degenerated graphite elements on SGI damage mechanisms has not been frequently studied. In this work, fatigue crack initiation and propagation tests were conducted on EN‐GJS‐500‐14 and observed under scanning electron microscope to understand the damage mechanisms for different graphite shapes. Crack initiation tests showed a dominant influence of degenerated graphite elements where early cracks initiated in the microstructure. Most of the spheroidal graphite nodules were unaffected at the early crack initiation stage, but few of them showed decohesion from the ferrite matrix and internal cracking. In the crack propagation region, graphite/ferrite matrix decohesion was the frequent damage mechanism observed with noticeable crack branching around graphite nodules and the crack passing through degenerated graphite elements. Finally, graphite nodules after decohesion acted like voids which grew and coalesced to form microcracks eventually causing rapid fracture of the remaining section.     

Round‐robin prediction of the fatigue limit of a ring of spheroidal graphite cast iron

A round‐robin investigation has been performed, where stress analysts from eight different organisations carried out a total of 11 predictions of the expected fatigue limit of a diametrically loaded cast ring subjected to fluctuating tensile or compressive loading. Whereas geometry, load parameters, and type and quality of material (spheroidal graphite cast iron EN‐GJS‐600‐3) had been prescribed, the participants were free to use computational tools and models, and fatigue assessment models and data of their own choice. The objectives of the investigation were to compare the 11 predictions (i) among themselves, and (ii) with a posteriori experimental fatigue limits determined by means of stair‐case testing. The fatigue limit predictions showed coefficients of variation of as large as 25%. Even for a group of analysts from a single organisation, the coefficients variation were around 15%. Fatigue tests gave mean fatigue limits 60% (tensile loading) and 30% (compressive loading) above the a priori predictions. Possible reasons for the large deviations between single predictions and for their conservatism have been proposed. It seems that design engineers (i) make use of the available room for interpretation of models and data, and (ii) have an unconscious tendency to make conservative assumptions. Only if models and data for fatigue assessment are prescribed in great detail, can the ‘scatter’ among fatigue limit predictions be expected to decrease below 15–25%. Improved ‘absolute’ predictions would require more accurate fatigue data.     

Elevated temperature low cycle fatigue of grey cast iron used for automotive brake discs

This paper evaluates the fatigue life properties of low carbon grey cast iron (EN-GJL-250), which is widely used for automotive brake discs. Although several authors have examined mechanical and fatigue properties at room temperatures, there has been a lack of such data regarding brake discs operating temperatures. The tension, compression and low cycle fatigue properties were examined at room temperature (RT) and at brake discs’ working temperatures: 500 °C, 600 °C and 700 °C. The microstructure of the material was documented and analysed. Tensile stress–strain curves, cyclic hardening/softening curves, stress–strain hysteresis loops, and fatigue life curves were obtained for all the above-mentioned temperatures. It was concluded, that Young’s modulus is comparable with both tension and compression, but yield its strength and ultimate strength are approximately twice as great in compression than in tension. All the mechanical properties remained quite stable until 500 °C, where at 700 °C all deteriorated drastically. During fatigue testing, the samples endured at 500 °C on average at around 50% of cycles at room temperature. Similar to other materials’ properties, the cycles to failure have dropped significantly at 700 °C.     

Numerical computation of thermal fatigue crack growth of cast iron

Thermal fatigue experiments have been carried out on a single‐edge wedge specimen of the SiMo cast iron to reproduce the conditions experienced by exhaust manifolds during operation. The leading edge temperature was cycled between 20 and 750 °C and the temperature distribution on the specimen surface was measured by thermocouples throughout the thermal cycle. Due to the complexity of the loading and interaction effects between cracks, numerical simulation of crack propagation and shielding effects in multicracked structures appear a useful way to analyze this problem. Therefore, 3D thermo‐mechanical computation was performed with the finite element code ABAQUS of both un‐cracked and multicracked specimen. This computation allowed us to assess the temperature, stresses and strains distribution over a thermal fatigue specimen and the estimation of the crack growth rate using the energy criteria based on the calculation of the J‐integral crack tip.     

The thermal fatigue resistance of vermicular cast iron coupling with H13 steel units by cast-in process

This paper focuses on improving the thermal fatigue resistance on the surface of vermicular cast iron coupling with inserted H13 steel blocks that had different cross sections, by cast-in processing. The microstructure of bionic units was examined by scanning electron microscope. Micro-hardness and thermal fatigue resistance of bionic samples with varied cross sections and spacings were investigated, respectively. Results show that a marked metallurgical bonding zone was produced at interface between the inserted H13 steel block and the parent material – a unique feature of the bionic structure in the vermicular cast iron samples. The micro-hardness of the bionic samples has been significantly improved. Thermal resistance of the samples with the circular cross section was the highest and the bionics sample with spacing of 2 mm spacing had a much longer thermal fatigue life, thus resulting in the improvement for the thermal fatigue life of the bionic samples, due to the efficient preclusion for the generation and propagation of crack at the interface of H13 block and the matrix.     

An energetic approach in thermomechanical fatigue for silicon molybdenum cast iron

Abstract

The purpose of this paper is to define a low cycle fatigue criterion in order to predict the failure of engineering structures. The major problem in defining a predictive fatigue criterion is that it should be applicable for structures submitted to complex multiaxial thermo-mechanical loadings but should be identifiable from simple experiments on specimens. After a short critical review of the principal criteria used in low cycle fatigue it will be shown that the dissipated energy per cycle permits a correlation of isothermal and anisothermal results obtained on silicon molybdenum cast iron in the case of specimens and also on structures.     

Stress/strain simulation model for grey cast iron

A simple model for estimating the stress/strain response of grey cast iron subjected to variable amplitude cyclic loading is presented. Material properties for the model are readily determined from the tensile and compressive stress/strain curve of the material.     

Some observations on the strength and fatigue properties of samples extracted from cast iron water mains

The strength and fatigue properties of cast iron samples taken from water distribution mains have been investigated. Specimens were sourced from three sections of pipe which had experienced varying amounts of corrosion in service, enabling the variable of pipe condition to be incorporated within the study.
The strengths in four-point flexure of small specimens from the pipes examined were described using Weibull statistics; different characteristic strengths and Weibull moduli were obtained, according to the pipe condition. A further set of samples from each pipe were subjected to flexural fatigue at a range of stress levels (different stress levels were chosen for each pipe based on the short-term strength properties) and residual strength tests were carried out on the surviving samples from one stress level for each pipe. There is evidence of a fatigue effect for all sample sets. There were slight differences in the residual strength behaviour – the residual strength of the survivors was reduced in the samples from the section in best condition while the residual strength of the survivors from the other two pipe sections was relatively unaffected. These trends are discussed with reference to condition and fatigue stress level.
The results suggest that mechanical fatigue may be a factor in the failure of water distribution pipes. The results may have implications for large diameter trunk mains as well as the small diameter water distribution pipes tested here. To assess the effect in more detail, consideration needs to be given to scaling effects in fatigue and the likely levels of any fatigue stress seen in service.     

Fracture toughness and growth of short and long fatigue cracks in ductile cast iron EN‐GJS‐400‐18‐LT

Heavy components of ductile cast iron frequently exhibit metallurgical defects that behave like cracks under cyclic loading. Thus, in order to decide whether a given defect is permissible, it is important to establish the fatigue crack growth properties of the material. In this paper, results from a comprehensive study of ductile cast iron EN‐GJS‐400‐18‐LT have been reported. Growth rates of fatigue cracks ranging from a few tenths of a millimetre (‘short’ cracks) to several millimetres (‘long’ cracks) have been measured for load ratios R=?1, R= 0 and R= 0.5 using a highly sensitive potential‐drop technique. Short cracks were observed to grow faster than long cracks. The threshold stress intensity range, ΔK_th, as a function of the load ratio was fitted to a simple crack closure model. Fatigue crack growth data were compared with data from other laboratories. Single plain fatigue tests at R=?1 and R= 0 were also carried out. Fracture toughness was measured at temperatures ranging from ?40 °C to room temperature.     

Influence of nitriding on the fatigue behavior and fracture micromechanisms of nodular cast iron

Surface modification processes are increasingly used to fully exploit material potential in fatigue critical applications because fatigue strength is sensitive to surface conditions. Nitriding is extensively adopted with ferrous materials because it forms a hard and strong surface layer and a system of superficial compressive residual stresses. Fatigue, however, is strongly dependent also on defects and inhomogeneity. When nitriding is applied to nodular cast iron, the relatively thin hardened layer (about 300 μm) contains graphite nodules (diameter of the order of 30 μm), casting defects and a heterogeneous matrix structure. The paper presents and discusses the influence of nitriding on the fatigue response and fracture mechanisms of nodular cast iron. A ferritic nodular cast iron and a synthetic melt with different content of effective ferrite were initially gas-nitrided. Then, (i) structural analysis of nitrided layers, (ii) fatigue testing with rotating bending specimens, and (iii) fatigue fracture surface inspection were performed. Performance and scatter in fatigue performance is discussed by selective inspection of fracture surfaces and identification fracture micromechanisms. A semiempirical model explains observed trends in test results and is used for the process optimization. __________ Translated from Problemy Prochnosti, No. 1, pp. 85–88, January–February, 2008.     

Influence of casting surfaces on fatigue strength of ductile cast iron

Quantitatively evaluating the fatigue strength of ductile iron (DI) with casting surfaces involves several complicated factors such as surface roughness, transition of microstructures from surface to interior, several types of defects and residual stresses. Tension–compression fatigue tests have been performed using DI having casting surfaces composed of a ferritic structure, a ferrite‐pearlitic structure and a pearlitic structure. Residual stresses were relieved by annealing in order to separately evaluate each factor. The parameter model was applied for quantitative evaluation of fatigue strength. Surface roughness was considered to be mechanically equivalent to a defect, and the effective defect size due to the interaction between the surface roughness and a defect was defined. The present study proposes a method of evaluating the maximum defect size using statistics of extremes and the lower bound of the scatter of fatigue strength, for practical design.     

AlSi10Mg(Cu)铸铝合金的热疲劳裂纹萌生及早期扩展行为

微观观察AlSi10Mg(Cu)铸铝合金在热疲劳裂纹的萌生和早期扩展过程,重点研究共晶硅粒子对热疲劳裂纹行为的影响。结果表明:热疲劳裂纹萌生于脱粘共晶硅粒子与铝基体间的开裂界面,原因是共晶硅粒子与铝基体的热膨胀系数不同,引起热循环过程中两相热应变不协调,从而在两相界面处产生循环应力而引起疲劳破坏。热疲劳裂纹的扩展在长度和宽度上同时进行,具有良好塑性的铝枝晶对疲劳裂纹的扩展起阻碍作用。对热疲劳过程中共晶硅粒子周围应力场的模拟分析进一步解释了实验现象。     

Features of fatigue crack growth due to repeated thermal shock

Abstract Thermal shock loading, such as that which occurs when a hot material is sprayed with cold water, produces a very high stress level near the exposed surface that eventually may lead to the development of cracks. Further growth of the cracks under repeated thermal shock is a very complex phenomenon due to the transient nature of the highly non-linear thermal stresses and the strong influence of the environment. There are cases in industry where cracks created by thermal shocks have arrested and stopped, and others where the cracks have progressed. Understanding this difference in behaviour is very important to the operators of pressure plant. This paper describes an experimental examination of crack growth in pressure vessel steel specimens exposed to repeated thermal shock. A test-rig that achieves large-scale thermal shocks through the repeated water quenching of heated flat plate specimens is used. The effect of steady-state loads on the growth is also analysed. Environmental effects due to the aqueous nature of the testing environment are found to be a major contributor to the crack growth kinetics.     

Influence of chunky graphite on mechanical and fatigue properties of heavy-section cast iron

This research work aimed to find out the influences of the different amounts of chunky graphite on mechanical and fatigue properties of GJS 800 ductile cast iron. Chunky graphite has been a problem of heavy section thick-walled ductile cast iron components. Chunky graphite is branched and interconnected as a network within eutectic cells and has been observed to form in thermal centres of heavy ductile cast iron sections during solidification. This research work proved that chunky graphite in the microstructure decreases the ultimate tensile strength, the elongation to fracture and fatigue life significantly, but does not influence on the yield stress of ductile cast iron GJS 800 substantially. Low nodular count and nodularity rate also decrease the fatigue life of ductile cast iron, and the difference of fatigue life of specimens containing chunky graphite or having low nodular count and nodularity rate is not large. Influence of the amount of chunky graphite on fatigue life increases until 20% chunky graphite content, and above that the fatigue life does not decrease substantially.     

共晶碳化物团球化对铸铁激光熔敷层抗裂性的影响

为提高铸铁表面大面积激光熔敷层抗裂性问题，通过冶金因元素控制熔敷层组织形态在熔敷材料中加入碱金属元素钾，研究了在激光快速加热条件下钾对铸铁激光熔敷层组织团球化的影响，进而分析了该球状组织对熔敷层抗裂性的影响，结果表明随熔敷金属内钾含量增多熔敷层内共晶碳化物组织呈球状及孤岛状，这种组织明显提高了熔敷层抗裂性，此外大量的渗碳体组织确保了熔敷层具有较高的耐磨性；获得了无裂纹的大面积搭接熔敷层，其对应合金系统为Fe-C-Si-Ni-K。     

Fatigue life assessment of nodular cast iron containing casting defects

The fatigue behaviour of a nodular cast iron containing casting defects has been investigated in the high-cycle fatigue regime. In this paper, we propose a fatigue life assessment model for flawed materials based on a fracture mechanics approach which takes into account the position and size of the defect, short crack behaviour and the notch effect introduced by the defect. The fatigue behaviour of smooth samples, and long and short crack behaviour have been experimentally determined in order to identify the relevant mechanical parameters; these being introduced into the model. An experimental study has been made both in air and in vacuum in order to account for the position of the defect, noting that internal defects are supposed to be under vacuum conditions. Experimental results, which are based on a two-crack front-marking technique specially developed for this study, show that the propagation of natural cracks is controlled by the effective stress intensity factor in air as well as in vacuum. The K calculation for a short crack in the stress field of a notch is analysed using numerical elastic–plastic results. Comparison between experimental results and the computation of fatigue life for fatigue lives less than 10⁶ cycles shows that the fatigue behaviour of nodular cast iron is controlled by a propagation process. The model proposed is thus relevant for fatigue lives less than 10⁶ cycles so that the defect can be considered as a crack and the initiation stage neglected. Closer to the fatigue limit, this study shows that the initiation stage should be considered in the assessment of fatigue life of nodular cast iron, because a single macroscopic propagation assessment is not enough to describe the whole fatigue life. The defect cannot be considered as a pre-existent crack in the high-cycle fatigue range (>10⁶ cycles), and the initiation stage that contains microcrack propagation around the defect should be evaluated when assessing the high-cycle fatigue life of nodular cast iron.     

A probabilistic approach for thermal shock fatigue life of glass

This paper presents a probabilistic approach for predicting fatigue life of glass subjected to near‐ΔT_C (critical temperature difference) thermal shock which exhibits little subcritical crack extension. First, thermal shock fatigue life N_f was derived as a function of temperature difference ΔT, fracture probability F and Biot's modulus β from the slow crack growth concept in conjunction with the Weibull distribution model. Next, thermal shock fatigue tests as well as flexural tests were performed for borosilicate glass to measure ΔT_C and N_f versus ΔT. The parameters associated with slow crack growth were then determined from the experimental results while the heat transfer coefficient h or β was obtained with the aid of finite element analysis. Thirdly, the thermal shock fatigue diagram (ΔT?N_f curves) was depicted for various values of β. Finally, crack length was simulated on the basis of the present approach.     

In situ characterization of humidity effect on the fatigue damage evolution of a cast aluminium alloy

In this paper, the feedback signal of ultrasonic fatigue system was used to deduce the accumulated fatigue damage in situ using the ultrasonic nonlinearity parameter. It was observed that, compared with the decrease in resonant frequency, the ultrasonic nonlinearity parameter shows a greater sensitivity to fatigue damage evolution (i.e. crack initiation and propagation). Ultrasonic nonlinearity parameters obtained from tests conducted under various environmental humidity levels were monitored and analysed. Through changes in the ultrasonic nonlinearity parameter, it was concluded that both of the fatigue crack initiation life and crack propagation life were reduced by increasing the humidity levels.     

Computation and application of local solidification times of grey cast iron cast in metallic moulds

Heat conduction equations applicable to the solidification of grey cast iron cast in moulds of the same material were solved for the cases of plate and cylindrical shaped castings made by pouring the metal at different temperatures into moulds of different wall thicknesses preheated to different temperatures, when the heat transfer coefficient at the casting-mould interface was assumed to have different values. An explicit finite difference method was used to solve the equations with the aid of a digital computer. Local solidification times at different nodal points were determined from the solutions and a relationship between the local solidification time and the location in a ‘casting’ was established. The application of local solidification times for predicting the microstructure and estimating the ultimate tensile strength of these “castings” cast in metallic moulds has been demonstrated.