Cyclic torsion very high cycle fatigue of VDSiCr spring steel at different load ratios

Cyclic torsion fatigue tests with superimposed static torsion loads are performed with VDSiCr spring steel with shot-peened surface in the high cycle fatigue (HCF) and very high cycle fatigue (VHCF) regime. Fatigue properties are investigated at load ratios R = 0.1, R = 0.35 and R = 0.5 up to limiting lifetimes of 5 × 10⁹ cycles with a newly developed ultrasonic torsion testing method. Increasing the load ratio reduces the shear stress amplitude that the material can withstand without failure. Fatigue cracks are initiated at the surface in the HCF regime. In the VHCF regime, cracks are preferentially initiated internally in the matrix, below the surface layer with compression residual stresses, and less frequently at the surface. Cyclic and mean shear stresses with 50% survival probability in the VHCF regime are presented in a Haigh diagram. Linear line approximation delivers a mean stress sensitivity of M = 0.33 for load ratios between R = −1 and R = 0.5.     

Very high cycle fatigue of nitrided 18Ni maraging steel sheet

Thin sheets of nitrided 18Ni maraging steel are tested under cyclic tension (load ratio R = 0.1) in the very high cycle fatigue (VHCF) regime. The ultrasonic fatigue testing method with a cycling frequency of about 20 kHz has been further developed for these experiments. Sheet specimens with 0.35 mm thickness are mounted on a carrier specimen, they are pre-stressed and are forced to vibrate jointly. Between 10⁷ and 10⁹ cycles, fatigue cracks are initiated exclusively at internal TiN inclusions. The areas of the crack initiating inclusions projected perpendicular to the applied tensile stress are evaluated. The square root of inclusion areas, (area_INC)^1/2 lies between 2.5 μm and 5.3 μm. Considering inclusions as cracks, their stress intensity range is between ΔK_INC = 1.3 MPa m^1/2 and 2.4 MPa m^1/2. The sizes of crack initiating inclusions influence fatigue lifetimes. This is considered in a crack propagation model and by presenting lifetimes versus the stress amplitudes multiplied by (area_INC)^1/12. A mean lifetime of 10⁹ cycles is found at a stress amplitude of 22% of the tensile strength, which is comparable to other high strength steels tested under cyclic tension.     

Very high cycle fatigue properties of high‐strength spring steel 60SiCrV7

The very high cycle fatigue properties of spring steel 60SiCrV7 for automotive suspension system with different hydrogen contents were studied by using ultrasonic fatigue testing and fatigue crack growth testing. The results show that the S–N curves exhibit continuous drop of fatigue lives and no obvious horizontal line exists. Similar fracture surface features were observed for all the specimens that failed mainly from internal inclusions with surrounding granular bright facet (GBF). Fatigue strength decreases remarkably with increasing hydrogen content. The applied stress intensity factor range at the periphery of GBF ΔK_GBF is approximately proportional to 1/3 power of the square of GBF area. The average values of ΔK_GBF for uncharged specimens are close to crack growth threshold ΔK_th, which indicates that ΔK_GBF could be regarded as the threshold value governing the beginning of stable fatigue crack propagation. The increase of hydrogen content tends to reduce ΔK_GBF.     

Very high cycle fatigue behaviour of 2000-MPa ultra-high-strength spring steel with bainite–martensite duplex microstructure

The very high cycle fatigue and fatigue crack growth (FCG) behaviours of 2000-MPa ultra-high-strength spring steel with different bainite–martensite duplex microstructures (designated as B-M1 and B-M2) obtained through isothermal quenching and fully martensite (designated as M) for comparison were studied in this paper by using ultrasonic fatigue testing and compact-tension specimens. It was found that for the B-M1 sample with well-controlled thin and uniformly distributed bainite, the fatigue crack threshold Δ K _th is higher and FCG rate da / dN at an early stage is lower than those of the M sample. Therefore, the former has rather longer fatigue life at high stress amplitude, though both have almost identical fatigue strength. However, the fatigue properties of bainite–martensite duplex microstructure are significantly deteriorated with the formation of large bainite. Furthermore, like that of the M sample, the S–N curves of the B-M1 and B-M2 samples also display continuous declining type and fish-eye marks were always observed on the fracture surface in the case of internal fractures, which were mainly induced by inclusion. A granular bright facet (GBF) was observed in the vicinity around the inclusion. For each of the three samples, the stress intensity factor range at the boundary of inclusion (Δ K_inc ) decreases with increasing the number of cycles to failure ( N _f), while the stress intensity factor range at the front of GBF(Δ K _GBF) is almost constant with N _f and equals to its Δ K _th. This indicates that Δ K _GBF might be the threshold value governing the beginning of stable crack propagation.     

Influence of surface residual stresses on gigacycle fatigue response of high chromium cold work tool steel

The effect of surface compressive residual stresses (RS) induced by surface grinding and polishing on the gigacycle fatigue behavior of medium‐carbon high‐chromium alloy cold work tool steel was evaluated. Two test series were performed: Specimens of series I revealed high compressive RS of about ‐800 MPa at the surface, resulting from grinding with fine emery paper, which treatment had definitely a beneficial influence on the fatigue endurance strength. The existence of surface RS was also revealed to be responsible for the location of the fatigue crack initiation. High compressive RS favored internal crack origins. In this case crack nucleation sites were primary carbide clusters in the interior of the specimen, forming so‐called fish‐eyes at the fracture surface. In contrast, specimens of test series II had only very low RS, which enabled crack initiation near/at the surface at primary carbides/clusters. Furthermore, it has been shown that the high initial RS are prone to partial relaxation through cyclic loading for which the mechanisms are currently unknown. In this case near‐surface induced failure was obtained. It was possible to confirm the experimentally obtained data by the use of the concept of local fatigue strength as function of effective RS. The relaxation of high initial RS was experimentally confirmed through RS measurements at runout specimens (10¹⁰ cycles without failure).     

Effect of loading type on fatigue properties of high strength bearing steel in very high cycle regime

Very high cycle fatigue tests under axial loading at frequencies of 95 Hz and 20 kHz were performed to clarify the effect of loading type on fatigue properties of a high strength bearing steel in combination with experimental result of this steel under rotating bending. As a result, this steel represents the single P-S-N (probabilistic-stress-life) curve characteristics for surface-induced fracture and interior inclusion-induced fracture, just like that under rotating bending. However, fatigue strength is lower, where the run-out stress at 10⁹ cycles is evaluated to be 588 MPa, less than that under rotating bending with about 858 MPa. Occurrence probability of larger and deeper inclusion-induced fracture is much higher than that under rotating bending. Furthermore, the formation process of fine granular area (FGA) is independent of the type and frequency of loading, which is very slow and is explained as the crack nucleation process under the special dislocation mechanism. The stress intensity factor range at the front of FGA, ΔK_FGA, is approximately regarded as the threshold value controlling the stable propagation of interior crack. For the control volume of specimen under axial loading, the estimated value of fatigue limit by FGA is similar to experimental run-out stress value at 10⁹ cycles, but that by inclusion is larger. However, the corresponding estimated results under rotating bending are all conservative.     

Very high cycle fatigue mechanism of carbide-free bainite/martensite steel micro-alloyed with Nb

In this study, the carbide-free bainite/martensite (CFB/M) steel was micro-alloyed with Nb (CFB/M-Nb). The very high cycle fatigue (VHCF) behaviors of this CFB/M-Nb steel were investigated by ultrasonic fatigue test. Especially, different microstructures of the CFB/M-Nb steel were deliberately designed to disclose the VHCF failure mechanism. In addition, the effect of hydrogen in the formation of the optical dark area (ODA) was analyzed, which was thought to control the formation of ODA by concentrating around interior inclusions. Results show the hydrogen cannot be considered to dominate the formation of ODA. Mostly important, “soft or coarsely soft structure induced fatigue crack” should be responsible for the primary VHCF failure mechanism of CFB/M-Nb steel.     

Very high cycle fatigue properties of bearing steel under axial loading condition

It has been observed to appear a step-wise or duplex S–N curve under the test of rotary bending fatigue using high strength steel. This behavior was caused by the transition of fracture mode from surface-induced fracture to subsurface inclusion-induced fracture. The aim of this study is to clarify the S–N characteristic under an axial loading fatigue in the very high cycle fatigue regime. In order to investigate the mean-stress effects, fatigue tests were carried out in air at room temperature under three applied stress ratios of ?1, 0 and 0.5 using a hour-glass shaped specimen of high carbon–chromium bearing steel, JIS SUJ2. From the results, three types of fracture mode were observed on the fracture surface, such as surface-induced fracture, subsurface inclusion-induced fracture without granular bright facet (GBF) area and that with GBF area around an inclusion. Fatigue lifetime for transition in the fracture mode depended on the applied stress ratio. Shape of the S–N curve was a smooth and continuous under three testing conditions in spite of the occurrence on the three types of fracture. Detail discussion for fatigue fracture behavior was made through the observation of fracture surface and from point in view of the fracture mechanics. In addition, an effect of residual stress in the specimen surface layer on the transition of fracture mode was discussed and compared with the experimental results.     

Very high cycle fatigue characteristics of a chrome‐molybdenum steel treated by ultrasonic nanocrystal surface modification technique

Characterization of very high cycle fatigue (VHCF) performance is of significant issue for ensuring long‐term durability and reliability of machinery and structural components due to the growing industrial demands and significant requirements of the advanced systems. In this study, VHCF characteristics of nanocrystallized skins (nanoskin) on JIS SCM435 (AISI 4137) steels were investigated as three different nanoskins on the surface, which was fabricated by altering the static load of ultrasonic nanocrystal surface modification (UNSM) treatment. The fatigue characterization, which shows linearly proportional correlation in the range of 80–120 µm depth of subsurface, was subjected to severe plastic deformation by altering the static loads of UNSM treatment to 40, 70 and 100 N, respectively. The fatigue strength increased up to 30% in the regime of VHCF. The improved strength mainly resulted from the generation of nanocrystalline structure, the enhanced surface uniformity, hardness and residual stress.     

Crack growth process in GBF area of SUJ2 bearing steel in very high cycle fatigue regime

Abstract

The crack growth process in GBF of high strength bearing steel JIS SUJ2 is qualitatively investigated by low–high two-step variable amplitude loading (TSAL) tests. It is demonstrated that the GBF size reduces with the increase in applied stress amplitude, and that the GBF size at a given stress amplitude is a constant which is independent of inclusion size at the crack origin. The fatigue life at a given stress amplitude, which is proportional to ?8 power of the inclusion size, reduces with increasing inclusion size. It was shown by TSAL tests that GBF was formed at the earlier stage (approximate 10⁵ cycles corresponding to less than 1% total fatigue life in the regime N_f≧10⁷ cycles) and propagated hardly until near to the final life (more than 90% total fatigue life). After that the GBF crack will propagate rapidly to the ultimate size in a short time.     

Effect of internal hydrogen on very high cycle fatigue of precipitation-strengthened steel SUH660

The fatigue life of SUH660 steel is dominated by crack initiation in the region of very high cycle fatigue owing to the new crack initiation behavior near the tip of temporarily arrested crack. The effect of internal hydrogen on very high cycle fatigue life is investigated focused on crack initiation life via fatigue and Vickers hardness tests. Hydrogen inhibits cracks initiation, and accelerates the increase in crack initiation lives with decreasing stress in low and medium hardness zones. Hydrogen increases the hardness in low and medium hardness zones. Hydrogen extends new crack initiation lives and causes longer very high cycle fatigue life.     

Comparison of different statistical models for description of fatigue including very high cycle fatigue

In this paper the fatigue behaviour of welded joints and helical compression springs are analysed using two different statistical models. The data consist of results from low cycle, high cycle and very high cycle fatigue and different number of investigated specimens. In particular, the software program ProFatigue is used for derivation of the probabilistic S–N field from experimental fatigue data. The program, based on a former regression Weibull model, allows the estimation of the parameters involved in the S–N field model, providing an advantageous application of the stress based approaches in the fatigue design of mechanical components. The results obtained are compared with the customary Wöhler-curve, represented as a straight line in a double-logarithmic scale. Application to probabilistic assessment of cumulative damage and further program enhancement can be now envisaged.     

Investigation of crack initiation and propagation behavior of AISI 310 stainless steel up to very high cycle fatigue

Fatigue behavior up to very high cycles for AISI 310 stainless steel has been investigated. The fatigue crack initiated from the surface of the material. It was found that up to 10⁶ cycles, cracks initiated from the carbide precipitates at grain boundaries. However, above 10⁶ cycles, the cracks initiated from persistent slip bands found at the surface of the specimen. At lower stress levels, slip bands were developed without initiating the cracks. The horizontal asymptote S–N curve from 10⁶ to 10⁹ cycles was attributed to the development of slip bands all over the surface of the specimen, before crack initiation.     

Approaches to fatigue life assessment applied in the very high cycle regime

Designers and calculation engineers are becoming increasingly interested in the latest results on very high cycle fatigue (VHCF). Often, the influence of loading with a very high number of cycles on component behaviour is estimated conservatively, but the exact safety margin is unknown. This paper gives an overview of failure mechanisms in the HCF‐ and VHCF‐regions and of material and component related influences, which have to be considered in the fatigue life assessment. The state of the art of design codes, recommendations from the literature and initial investigations on variable amplitude loading in the VHCF‐regime are presented. This review indicates that further research activities are necessary to improve fatigue life assessment in order to allow a reduction of safety margins.     

Manifestations of dynamic strain aging under low and high cycle fatigue in a type 316LN stainless steel

Influence of Dynamic strain aging (DSA) under low cycle fatigue (LCF) and high cycle fatigue (HCF) loading was investigated by conducting LCF and HCF tests on specimens over a wide range of temperature from 573 to 973 K. DSA was found to be highly pronounced in the temperature range of 823–873 K. DSA was seen to have contrasting implications under LCF and HCF deformation. The cyclic hardening owing to DSA caused an increase in the cyclic stress response under LCF, leading to decrease in cyclic life. On the other hand, the DSA-induced strengthening suppressed the crack initiation phase under HCF where the applied stress remains fixed, leading to an increase in the cyclic life.     

Influence of non-metallic inclusions on fatigue life in the very high cycle fatigue regime

The present paper deals with the influence of non-metallic inclusions on fatigue life in the high cycle fatigue and the very high cycle fatigue regime. For that purpose, several castings of steel 42CrMo4 (AISI 4140, DIN EN 1.7225) were produced by using recently developed novel metal-melt filters. The specimens were tested in hot-isostatically pressed and heat treated condition. After fatigue failure every fracture surface was intensively investigated by scanning electron microscopy in order to define the type, the size, the chemical composition, the morphology and the location of the crack initiating discontinuity. Subsequently, Murakami’s √area model was used for the evaluation of the influence of non-metallic inclusions on the fatigue life. In the present investigation four common types of chemical compositions of crack initiating discontinuities were identified. Furthermore, four different internal failure types and their influence on the fatigue life in cast steel were investigated and described. Thus, the present contribution proposes a basic correlation determined from fatigue lives in case of various internal crack initiation types. The key parameters for fatigue life prediction in case of internal fatigue failure in the very high cycle fatigue regime are (i) the size of the crack initiating discontinuity, (ii) the inclusion depth and (iii) the crack initiating failure type.     

Initiation and propagation behaviour of fatigue cracks in hard-shot peened Type 316L steel in high cycle fatigue

Observations of fatigue crack growth behaviour were made during rotating‐bend testing of hard‐shot peened Type 316L steel. From the results of these observations, the crack that developed in the axial direction was observed and the mechanism of the fatigue crack properties was clarified as follows: (1) Small circumferential surface fatigue cracks were detected at 60% of the fatigue lifetime. These cracks propagated very slowly in both the circumferential and radial directions. (2) When a radial crack reached a depth of between 150 and 350 μm, axial fatigue cracks were formed. (3) In the next stage, either the radial or the axial fatigue cracks continued propagating, or an inwards growing radial crack formed from the axial crack. (4) In the final stage, the circumferential surface crack began to grow rapidly and resulted in fracture. (5) The fracture type of hard‐shot peened Type 316L is a particular type of surface fracture.     

Factors influencing the GBF size of high strength steels in the very high cycle fatigue regime

The influences of major factors including applied stress amplitude, inclusion size and hydrogen content on granular-bright-facet (GBF) size of high strength steels in the very high cycle fatigue regime were studied in this article. It was found that the GBF size is determined by the applied stress amplitude and material hardness. If the applied stress amplitude is lower, the GBF size is larger. When a specimen containing bigger inclusions, the applied stress amplitude to form GBF can be reduced which results in the increase of GBF size. Hydrogen has different effects on the GBF size. The related reasons were discussed.