Relation between fatigue threshold and fatigue limit for surface-rolled specimens

After cylinder notch fatigue specimens of 40 CrNiMo steel were rolled, their fatigue limit increased by 41%. The rolled specimens did not fracture, even though they had been loaded for 10⁷ cycles under fatigue limit stress, but a non-propagating fatigue crack was generated. Thus the value of the fatigue limit depends on the fatigue threshold value ΔK_th of the metal of the rolled layer. Plastic deformation increased ΔK_th in these experiments. It can be inferred that ΔK_th of the rolled layer increases from the occurrence of plastic deformation and microvoids on the layer. Calculation of the effect of residual stress in the crack wake on the stress intensity factor ΔK indicates that residual compression stress decreases ΔK by 21.5 MPa √M. It was calculated that rolling induced both the length of the non-propagating crack and the increase of fatigue limit. The calculated values are in accord with experiment. Analysis and calculations indicate that the non-propagating crack is generated on the rolled layer. Thus the fatigue limit is improved because rolling produces residual compression stress in the layer (which decreases the stress intensity factor), and increases ΔK_th of the layer.     

Growth and coalescence of two collinear indentation cracks in glass

Subcritical growth and coalescence of two collinear cracks of different lengths were investigated using small Knoop indentation cracks in glass. Indentation cracks subjected to bending in water showed anomalous crack growth in terms of the stress intensity factor, K_I. The crack growth velocity, dc/dt, was initially high, decreased and thereafter increased with increasing K_I. The effective stress intensity factor, K_I,eff, was calculated by adding a term describing the state of residual stress to explain this anomalous growth. Before crack coalescence, a large crack showed a crack velocity higher than expected from the coalescent crack. The coalescent crack velocity increased with K_I,eff and the slope of dc/dt−K_I,eff curves differed from that for a single crack, depending on the crack length.     

Experimental evaluation of stress field around crack tip by caustic method

The caustic method is an optical technique which is useful to determine stress intensity factor values. In this paper, the caustics method was applied to specimens which have an oblique crack, various thicknesses and an open notch to investigate the stress field around the crack tip. The results are summarized as follows:

1. The caustic method is a useful technique to determine the stress intensity factor values of the specimens which have an oblique crack or various thickness and an open notch.

2. The conventional theory of measurement concerning this method is effective when the initial curve r₀ is larger than the minimum initial curve r₀^min which was obtained in this study. It is observed that the values of r₀^min decrease as the ratio of K_II to K_I increases under mixed-mode loading, the one increases with an increase of thickness and notch opening angle.

3. The 3D stress field exists in the vicinity of crack tip; however, the stress state is nearly plane strain deformation in the case of mode I loading. In the case of mixed-mode loading, the stress state approximates to plane stress deformation as the ratio of K_II to K_I increases.

4. A method based on the distribution of the three-dimensional (3D) stress field is proposed to expediently yield the values of K_I using the caustic method in the case of r₀<r₀^min.

Enhancement of delayed failure resistance by partial unloading method

The effects of two types of pre-stressing, i.e. partial unloading (0 →K_max → K) and perfect unloading (0 → K_max → 0 → K) on the delayed failure strength were investigated using pre-cracked specimens of JIS SNCM8 steel quenched and tempered, where K_max is the maximum stress intensity factor at pre-stressing, and K is the stress intensity factor under which delayed failure test is carried out.

Both pre-stress methods can markedly increase the delayed failure strength or the lower limit stress intensity factor K_ISCC. The partial unloading method is superior to the perfect unloading method in each tempering condition (200 or 400°C) and in each environment (distilled water or 3% NaCl water). The reason why K_ISCC is increased by each pre-stressing can be explained by the decrease of surface stress at crack tip, which will suppress the corrosion reaction and prevent the invasion of hydrogen atoms into the material.     

Evaluation of fatigue crack growth behavior of GLARE3 fiber/metal laminates using a compliance method

The objectives of this study were to investigate the effectiveness of a compliance method for analyzing the fatigue crack growth of GLARE3 fiber/metal laminates. The materials tested were GLARE3-5/4 (2.6 mm thick) and GLARE3-3/2 (1.4 mm thick). Centrally notched specimens with two kinds of notch length and two kinds of fiber orientation were fatigue tested under constant amplitude loading. The expression of the experimental stress intensity factor, K_exp, for the 2024-T3 aluminum-alloy layers of a GLARE3 is formulated and K_exp were obtained from the relationship between crack length and specimen compliance. The test results clarified the following: (1) da/dN–ΔK_exp relationships roughly show the linear relationship independent of the maximum stress level, specimen thickness, notch length, and fiber orientations, (2) the da/dN–ΔK_exp relationships approximately agree with the linear part and its extension of Paris–Erdogan’s law obtained for the da/dN–ΔK relationship of the 2024-T3 aluminum-alloy, (3) the compliance method is effective for analyzing fatigue crack growth in GLARE3 laminates.     

The effect of the stress ratio on fatigue crack growth in a 3% NaCl solution

Corrosion fatigue crack growth tests have been carried out at various stress ratios for a low alloy steel SNCM 2 and type 304 stainless steel.

Measurements of the effective stress intensity factor range ratio U were performed to explain the effect of stress ratio R.

The corrosive environment decreased da/dN at R = 0.1, 0.4 and little affected da/dN at R = 0.9 for SNCM 2 and increased da/dN at all R ratios for SUS 304.

It was confirmed that there exists a threshold stress intensity factor ΔK_thCF in 3% NaCl solution for both materials tested.

The corrosive environment decreased ΔK_thCF for all conditions tested except at R = 0.1 and 0.4 for SNCM 2, where ΔK_thCF-values were nearly equal to ΔK_th-values in air. ΔK_thCF/ΔK_th was 0.6 at R = 0.9 for SNCM 2 and 0.8, 0.5 and 0.7 at R = 0.1, 0.7 and 0.9 for SUS 304, respectively.

It was shown that the complicated effect of stress ratios on crack growth for SNCM 2 can be explained using effective stress intensity factor ΔK_eff.     

Statistical evaluation of fatigue crack propagation properties including threshold stress intensity factor

The relationship between fatigue crack propagation rate, da/dn, and range of stress intensity factor, ΔK, including threshold stress intensity factor, ΔK_th, is analyzed statistically. A non-linear equation, da/dn = C{(ΔK)^m-(ΔK_th)^m}, is fitted to the data by regression method to evaluate the 99% confidence intervals. Several experimental results on fatigue crack propagation properties of welded joints are compared by using these confidence intervals.     

The solution of a displacement discontinuity for an anisotropic half-plane and its applications to fracture mechanics

By imaginal method the solution of displacement discontinuity for anisotropic half-plane is derived in this paper. According to the Betti's reciprocal theorem, the relationship between the stress intensity factor K_I and the increment Δv/Δa is established and numerical results of K_I are obtained by the twice calculation method. Furthermore, the problem of edge crack chopping is studied in great detail, and the area of contaction and stress intensity factor K_I are found. These results are very worthwhile for research of chopping fracture in theory.     

Resistance-curve method for predicting propagation threshold of short fatigue cracks at notches

A new resistance-curve method was proposed for predicting the growth threshold of short fatigue cracks near the notch root. The resistance curve was constructed in terms of the experimentally determined threshold value of the maximum stress intensity factor which was the sum of the threshold effective stress intensity range ΔK_effth and the opening stress intensity factor K_opth The ΔK_effth value was constant, irrespective of crack length or notch geometry. The relation between K_opth and crack length was independent of notch geometry. The predicted effects of the notch-root radius and the notch depth on the propagation threshold of short fatigue cracks were compared with the experimental data obtained using center-notched specimens with various notch-root radii and single-edge notched specimens with various notch depths. Excellent agreement was obtained between predictions and experiments.     

An indirect boundary element method for three-dimensional dynamic fracture mechanics

Indirect boundary element methods (fictitious load and displacement discontinuity) have been developed for the analysis of three-dimensional elastostatic and elastodynamic fracture mechanics problems. A set of boundary integral equations for fictitious loads and displacement discontinuities have been derived. The stress intensity factors were obtained by the stress equivalent method for static loading. For dynamic loading the problem was studied in Laplace transform space where the numerical calculation procedure, for the stress intensity factor K_I(p), is the same: as that for the static problem. The Durbin inversion method for Laplace transforms was used to obtain the stress intensity factors in the time domain K_I(t). Results of this analysis are presented for a square bar, with either a rectangular or a circular crack, under static and dynamic loads.     

A microcomputer control system for the measurement of fatigue crack growth data

A microcomputer-based system for the measurement of fatigue crack growth da/dn versus cyclic stress intensity factor ΔK data using compact-tension test specimens is described. The procedure has been developed to allow automatic measurement of crack growth rate under any specified combination and sequence of load conditions, i.e. ΔK and R (stress ratio) and includes the capability of establishing the threshold cyclic stress intensity factor ΔK₀. Crack extension measurement is effected from the elastic compliance evaluated from the AC component of the load and displacement signals to an accuracy of -3 μm every 1000 load cycles. Results from a typical low-alloy-steel rotor forging are presented to illustrate the use of the system.     

The effect of second principal stress on the fatigue propagation of mode I surface crack in Al2O3/Al alloy composites

Using a plate made of A2017-T6 metal matrix composites reinforced with 10 volume % and 20 volume % Al₂O₃ particles and Al alloy possesses the same composition as matrix alloy, the crack propagation rate da/dN of a mode I surface crack by the simultaneous action of plane bending and cyclic torsion are studied. And the effects of crack tip opening stress σ_top, crack opening displacement COD, biaxial stress ratio C (=second principal stress/first principal stress) and the surface roughness of crack section are examined. When stress intensity factor range ΔK is lower than the specific level, da/dN decreases with the increase of volume fraction of Al₂O₃ in C=0 and C=−0.55. But, da/dN of Al alloy becomes minimum in C=−1 and the effect of Al₂O₃ particles disappears. σ_top rises with the increase of volume fraction of Al₂O₃ particles and the decline of C. On the other hand, COD doesn’t always rise with the decline of C. These phenomena can be explained by the residual compressive stress formed at the surface layer of the specimen by the fatigue test and the surface roughness of crack section.     

A simple procedure for the accurate determination of stress intensity factors by finite element method

A simple procedure for the accurate determination of stress intensity factors K_I, K_II by the conventional finite element method is proposed. The first step of the method is to calculate the stress σ₂ of the plate without a crack. The second step is to calculate the stress σ_tip, of the plate with the crack. The value of (σ_tip−σ_g) at the crack tip element is regarded to have the intimate relation with K_I, K_II K_I, and K_II are determined from the value of (σ_tip−σ_g) and a standard solution. It is shown that the results obtained for many problems by the proposed method are in excellent coincidence with the analytical solutions. The error is below 1–3% for the most cases.     

Explicit calculation of the crack tip stress intensity factor for the double slip plane model crack

A more rigorous analysis is presented for the stationary double slip plane (DSP) crack loaded in mode III with constant friction stress on the slip planes. This analysis gives the dislocation distributions on the slip and crack planes. More important, the analysis leads to an explicit calculation of the crack tip stress intensity factor K_t without resort to use of the J-integral or the Rice-Thompson expression for dislocation crack tip shielding/antishielding factor. It is shown that K_t ≈ K for the stationary crack. With the results of this paper there are now essentially three independent methods of obtaining K_t for a DSP crack.     

Influence of material properties of SIFs determined by frozen stress

In a prior study utilizing two materials for which thermal and mechanical properties of both materials in bimaterial specimens were matched except for modulus, it was found that modulus mismatch had a negligible effect on the stress intensity factor (SIF) level and distribution for cracks in bond lines of stress frozen photoelastic bimaterial specimens. However, bond line residual stresses increased the SIF values. Since it is almost impossible to obtain commercial stress freezing materials with matching critical temperatures (T_c) with different moduli, the present study of cracks parallel to and within bond lines utilized such materials with T_c mismatch and compared results with parallel studies with matched T_c values in order to evaluate T_c mismatch effects. Results show that T_c mismatch creates mixed mode conditions in cracks parallel to the bond line with significant increases in the mode I SIF (K₁) for cracks very near the bond line but shows little effect for cracks within or away from the bond line. The absence of a modulus mismatch effect is again confirmed as well.     

Fatigue crack-growth characteristics of two magnesium alloys

Magnesium alloys are being increasingly used for engineering applications. Fatigue crack-growth data have therefore been obtained for a high strength magnesium-Zr alloy and a medium strength, weldable magnesium-Mn alloy. The results of tests on sheet material are presented in terms of the range of stress intensity factor ΔK. Critical values of ΔK necessary for fatigue crack growth ΔK_c were also obtained. The behaviour of the two alloys was similar; both rates of crack growth and ΔK_c were sensitive to mean stress. Fatigue crack growth was entirely on a 90° plane with no sign of the transition to crack growth or 45° planes usually observed in sheet materials. This was ascribed to the effects of preferred orientation of the crystal structure.     

Fatigue of V-notched members: Short crack behavior and endurance limit

A previous experimental investigation showed that the short crack behavior in severe V-notched geometries is essentially characterized by an initial transient variation of the crack opening level within the notch plastic zone. This result is exploited to derive a general formulation of the endurance limit of V-notched members. Analytical solutions for the stress intensity factor and the notch plastic zone extent are obtained to compute the effective crack driving force ΔK_eff as a function of notch geometry, crack length and nominal stress. Then, the endurance limit is determined as the nominal stress below which an initiated crack becomes non-propagating, i.e. by equating the minimum ΔK_eff value at the end of the plastic zone to a threshold value. By using Irwin's redistribution principle which allows us to make relations between the V-notch elastic and plastic fields, the following results are obtained. The endurance limit can be computed only from the V-notch “stress intensity factor” and the material threshold and cyclic yield stress. The endurance limit dependence on the threshold diminishes as the notch angle increases from zero and vanishes in the limit case of a smooth surface. When the notch contains a pre-existing crack, a Kitagawa-type endurance diagram is obtained. The uncracked notch endurance limit, the critical crack length and the slope of the decrease beyond this length, increase with increasing notch angle, and there is a total coincidence with the Kitagawa diagram in the limit case where the notch angle tends to 180°. This result shows that a global theory should govern at one and the same time the short crack behavior in smooth and severe geometries.     

The (cleavage) strength of pre-cracked polycrystals

The fracture mechanics stress intensity, K, measured for the cleavage strength of carbon steel by Professor Yokobori and colleagues, at Tohoku University and elsewhere, is shown to follow a Hall-Petch dependence on average grain diameter, l, in accordance with the model-based relationship K = c's^1/2[σ₀+kl^−1/2]; for which c' is a numerical factor, 5 is the effective length of the local plastic zone associated with unstable crack growth, σ₀ is a friction stress for appropriate dislocation movement within the polycrystal grains and k is a microstructural stress intensity intermediate between that for the plastic flow or fracture of crack-free material. The separated terms in the K relationship are matched with corresponding Hall-Petch friction stress and microstructural stress intensity measurements for yielding and fracture. In this way, the K relationship is proposed to provide a bridge for the goal set some time ago by Professor Yokobori of combining the microscopic and macroscopic (continuum) viewpoints for understanding the fracture strength properties of engineering materials.     

Automatic near-threshold fatigue crack growth rate measurements at liquid helium temperature

The development of a fully automated test apparatus for near-threshold fatigue crack growth rate measurements in a liquid helium environment is described, and some initial results for AISI 300 series stainless steels are presented. The experimental apparatus consists of a servohydraulic test machine and a cryostat, complete with a minicomputer, a programmable arbituary waveform generator, a programmable digital oscilloscope and a fully automatic liquid helium refill system. The technique uses 6.4 mm thick compact specimens subjected to systematically decreasing loads, with 24 h operation at 40 Hz, the crack growth being continuously monitored by specimen compliance measurements. The results presented in this study include da/dN vs ΔK curves and threshold fatigue stress intensity factors, ΔK_th, at 4 K for AISI 304L, 304LN and 316 stainless steels. The near-threshold fatigue behaviours of these materials are similar, and the fatigue crack growth rate trends at intermediate ΔK levels nearly agree with published results.     

The micropolar thermoelastic problem of uniform heat-flow interrupted by an insulated penny-shaped crack

The classical problem of uniform heat-flow disturbed by an insulated penny-shaped crack is solved in the context of micropolar elasticity. The mode II stress intensity factor, K_II is found to depend on two new non-dimensional parameters N and τ − N is a measure of the coupling of the displacement field with the microstructure or the medium (0 N √2) and τ is the ratio of a material characteristic length to the crack radius. K_II remains higher than its classical value when N > 0, τ > 0 and attains the classical value as N and τ vanish. A closed-form expression to K_II is obtained in the physically important limiting case of τ → 0 with N fixed. In this limit the relative increment in K_II, over its classical value, is found to be (1 − v')N² where v' is the micropolar Poisson's ratio.