Effect of Environment on Fatigue Crack Wake Dislocation Structure in Al-Cu-Mg

Fatigue-induced dislocation structure was imaged at the crack surface using transmission electron microscopy (TEM) of focused ion beam (FIB)-prepared cross sections of naturally aged Al-4Cu-1.4Mg stressed at a constant stress intensity range (7?MPa??m) concurrent with either ultralow (~10^?8?Pa?s) or high-purity (50?Pa?s) water vapor exposure at 296?K (23?°C). A 200-to-600-nm-thick recovered-dislocation cell structure formed adjacent to the crack surface from planar slip bands in the plastic zone with the thickness of the cell structure and slip bands decreasing with increasing water vapor exposure. This result suggested lowered plastic strain accumulation in the moist environment relative to the vacuum. The previously reported fatigue crack surface crystallography is explained by the underlying dislocation substructure. For a vacuum, $ \left\{ { 1 1 1} \right\} $ facets dominate the crack path from localized slip band cracking without resolvable dislocation cells, but cell formation causes some off- $ \left\{ { 1 1 1} \right\} $ features. With water vapor present, the high level of hydrogen trapped within the developed dislocation structure could promote decohesion manifest as either low-index $ \left\{ { 100} \right\} $ or $ \left\{ { 1 10} \right\} $ facets, as well as high-index cracking through the fatigue-formed subgrain structure. These features and damage scenario provide a physical basis for modeling discontinuous environmental fatigue crack growth governed by both cyclic strain range and maximum tensile stress.     

Crack Propagation in Flexural Fatigue of Concrete

In this paper the behavior of concrete subjected to flexural fatigue loading is studied. Notched concrete beams were tested in a three-point bending configuration. Specimens were subjected to quasi-static cyclic and constant amplitude fatigue loading. The cyclic tests were performed by unloading the specimen at different points in the postpeak part of the quasi-static loading response. Low cycle, high amplitude fatigue tests were performed to failure using four different load ranges. The crack mouth opening displacement was continuously monitored throughout the loading process. Crack propagation caused by quasi-static and fatigue loads is described in terms of fracture mechanics. It is shown that the crack propagation in the postpeak part of the quasi-static load response is predicted using the critical value of the mode I stress intensity factor (KIC). The ultimate deformation of the specimen during the fatigue test is compared with that from the quasi-static test; it is demonstrated that the quasi-static deformation is insufficient as a fatigue failure criterion. It is observed that crack growth owing to constant-amplitude fatigue loading comprises two phases: a deceleration stage when there is a decrease in crack growth rate with increasing crack length, followed by an acceleration stage where the rate of crack growth increases at a steady rate. The crack length where the rate of crack growth changes from deceleration to acceleration is shown to be equal to the crack length at the peak load of the quasi-static response. Analytical expressions for crack growth in the deceleration and acceleration stages are developed, wherein the expressions for crack growth rate in the deceleration stage are developed using the R-curve concept, and the acceleration stage is shown to follow the Paris law. It is observed that the crack length at failure for constant amplitude fatigue loading is comparable to that of the corresponding load in the postpeak part of the quasi-static response. Finally, a fracture-based fatigue failure criterion is proposed.     

Analytical Prediction of Fatigue Crack Propagation in Metals

An analytical model for fatigue crack propagation of long cracks in metals and metal alloys is presented. The key features of the model are an extension of Griffith’s theory of fracture to include fatigue, a dislocation model for the crack tip opening displacement, and cyclic plasticity-induced closure. The net cyclic stretch of the process zone at the crack tip plays a major role in the fatigue crack propagation under cyclic loading. Only constant amplitude loading is considered in this paper. The model predictions utilize only the readily available material properties, such as Young’s modulus, yield strength, threshold stress intensity factor, and the fracture toughness. There are no empirical fitting constants. The model predictions are validated by an extensive amount of published fatigue crack growth studies. The agreement between the model predictions and the experimental data is good.     

粉末冶金构件疲劳裂纹的扩展寿命

 针对航空发动机粉末冶金旋转盘件的疲劳裂纹扩展特性,以标准紧凑拉伸试样裂纹扩展数据为基础,基于Paris公式获得了材料典型温度下的裂纹扩展参数,并利用简单件对所采用的裂纹扩展计算方法进行了验证。进行了粉末冶金旋转构件的裂纹扩展试验,继而进行断口分析,通过测量疲劳条带获得了裂纹扩展寿命。同时,采用有限元方法计算出粉末冶金构件的裂纹扩展寿命,与实测值吻合较好,验证了裂纹扩展寿命分析方法的有效性及实用性。     

缺口小裂纹的疲劳扩展速率

将复型技术应用于疲劳小裂纹扩展试验中的裂纹长度测量。在等载荷比R=0.1、不同平均载荷水平影响的疲劳条件下,板试样V型缺口小裂纹疲劳扩展速率做了试验测试;通过结果分析,提出了缺口小裂纹疲劳扩展速率表达式,并以ε_P为控制参数,求出45^*钢的计算式。     

Crystallography of Fatigue Crack Initiation and Growth in Fully Lamellar Ti-6Al-4V

Fatigue crack initiation in titanium alloys is typically accompanied by the formation of planar, faceted features on the fracture surface. In the present study, quantitative tilt fractography, electron backscatter diffraction (EBSD), and the focused ion beam (FIB) have been used to provide a direct link between facet topography and the underlying microstructure, including the crystallographic orientation. In contrast to previous studies, which have focused mainly on the α-phase crystal orientation and the spatial orientation of the facets, the present analysis concentrates on the features that lie in the plane of the facet and how they relate to the underlying constituent phases and their crystallographic orientations. In addition, due to the anisotropic deformation behavior of the three basal slip systems, the orientation of the β phase as it relates to facet crystallography was investigated for the first time. The implication of the β-phase orientation on fatigue crack initiation was discussed in terms of its effect on slip behavior in lamellar microstructures. The effect of the local crystallographic orientation on fatigue crack initiation was also investigated by studying cracks that initiated naturally in the earliest stages of growth, which were revealed by FIB milling. The results indicate that boundaries that are crystallographically suited for slip transfer tend to initiate fatigue cracks. Several observations on the effect of the crystallographic orientation on the propagation of long fatigue cracks were also reported.     

Fatigue Crack Initiation and Microcrack Propagation in X7091 Type Aluminum P/M Alloys

Fatigue crack initiation in extruded X7091 RSP-P/M aluminum type alloys occurs at grain boundaries at both low and high stresses. By a process of elimination this grain boundary embrittlement was attributed to A1₂O₃ particles formed mainly during atomization and segregated to some grain boundaries. It is not due to the small grain size, to Co₂Al₉, to 17 precipitates at grain boundaries, nor to a precipitate free zone. Thermomechanical processing after extrusion of X7091 with 0.8 pct Co was done by Alcoa to produce large recrystallized grains. This resulted in initiation of fatigue cracks at slip bands, and the resistance to initiation of fatigue cracks at low stresses was much greater. Microcrack growth is, however, much faster in the thermomechanically treated samples, as well as in ingot alloys, than in extruded and aged X7091.     

Fatigue Crack Propagation in Friction Stir Welded and Parent AA6082

The fatigue crack propagation characteristics of a friction stir welded Al‐Mg‐Si alloy, 6082, have been investigated. The electrical potential drop method was used for measurements. A low and a high load ratio (R) level were tested. At low load ratio (R=0.1) and a low stress intensity δK the propagation rate in the weld was higher than in the parent material by a factor of 3 to 5. However, the propagation rates were approaching each other close to fracture. At high load ratio (R=0.8) the propagation rate was similar in the parent material and weld. The weld crack growth rate was about the same at low and high R (except close to fracture), while the parent material growth rate increased at high R. Paris law was used to describe the measured crack propagation rates in the weld. In the case of the parent material, showing an R‐dependence, Forman's law was used.     

Cryogenic S–N Fatigue and Fatigue Crack Propagation Behaviors of High Manganese Austenitic Steels

In the current study, the S–N fatigue and the fatigue crack propagation (FCP) behaviors of high manganese austenitic steels, including Fe24Mn and Fe22Mn, were studied, and the results were compared with STS304 (Fe-1Si-2Mn-20Cr-10Ni). The S–N fatigue tests were conducted at 298 K and 110 K (25 °C and ?163 °C), respectively, and at an R ratio of 0.1 under a uniaxial loading condition. The FCP tests were conducted at 298 K and 110 K (25 °C and ?163°C), respectively, and at R ratios of 0.1 and 0.5, respectively, using compact tension specimens. The resistance to S–N fatigue of each specimen increased greatly with decreasing temperature from 298 K to 110 K (25 °C to ?163 °C) and showed a strong dependency on the flow stress. The FCP behaviors of the austenitic steels currently studied substantially varied depending on testing temperature, applied ΔK (stress intensity factor range), and R ratio. The enhanced FCP resistance was observed for the Fe24Mn and the Fe22Mn specimens particularly in the near-threshold ΔK regime, while the enhancement was significant over the entire ΔK regimes for the STS304 specimen, with decreasing temperature from 298 K to 110 K (25 °C to ?163 °C). The S–N fatigue and the FCP behaviors of high manganese austenitic steels are compared with STS304 and discussed based on the fractographic and the micrographic observations.     

Improved Fracture Toughness and Resistance to Fatigue Crack Propagation in ESR Steels

Abstract

Two types of alloy steels (En 24 and En 52 steels) have been electro slag refined and the improvement in their mechanical properties has been assessed. ESR has improved the tensile ductility, plane strain fracture toughness, room temperature CVN energy, fatigue strength and has decreased fatigue crack growth rates. The K _lc values for the ESR steel are nearly twice those estimated in the unrefined steel. Fatigue crack growth rates in region I and region III are found to be decreased considerably in the ESR steel while they are unaffected in region II. The improvement in the mechanical properties has been explained in terms of the removal of large sized nonmetallic inclusions and reduction in sulfur content in the ESR steel.

Résumé

Deux types d'aciers alliés (En 24 et En 52) ont été affinés par refusion sous laitier (ESR) et l'amélioration de leurs propriétés mécaniques a été évaluée. Le procédé ESR a amélioré la ductilité en traction, la ténacité en déformation plane, l' énergie CEV à température ambiante, la résistance à la fatigue et a diminué les taux de croissance des fissures de fatigue. Les valeurs de K_lc des aciers ESR sont presque le double de celles estimees pour les aciers non affinés. Les taux de propagation des fissures de fatigue dans les domaines I et III sont considérablement moins élevés dans les aciers ESR alors qu'ils ne sont pas affectés dans la région II. L'amélioration des propriétés mécaniques a été expliquée en termes de l'enlèvement des inclusions non métalliques de taille importante et de la réduction de la teneur en soufre des aciers ESR.     

Calorimetric Measurement of the Plastic Vtork of Fatigue Crack Propagation in 4140 Steel

A calorimetric technique has been developed for measurement of the effective surface energy of fatigue crack propagation,U, and the cyclic plastic work in the plastic zone,Q. The technique has several distinct advantages over existing methods. Measurements on 4140 steel (650 °C temper) show thatU andQ are direct functions of the stress intensity factor,hK, and indirect functions of crack growth rate,daldN. Measurement of the change ofU andQ after the application of a tensile overload supports this conclusion and provides strong evidence supporting crack closure theories. Formerly with the Materials Science and Engineering Department and Materials Research Center, Northwestern University, Evanston, IL.     

Environmentally Influenced Mixed Mode Fatigue Crack Propagation of Titanium Metal Matrix Composites

Effect of humid air environments on the mixed mode fatigue crack propagation behavior of B₄C-B and BORSIC reinforced Ti-6A1-4V metal matrix composites was studied. Humid environments enhanced the mixed mode fatigue crack propagation rates in the as-received titanium matrix composites atR = 0.1. The effect was more pronounced in the transverse and 45 deg specimens. A transition in failure modes from fiber splitting in humid air to interfacial splitting in dry environments was observed at a load ratio of 0.1. The transition took place at around 100 Pa water vapor pressure, where a steep rise in fatigue crack propagation rate was noticed. AtR = 0.5, however, no fiber splitting was observed in humid air. Fatigue crack closure load measurements revealed that closure loads were higher in humid air than in dry environments. The fiber splitting is suggested as an environmentally induced crack closure effect, where plastically deformed matrix sets up stress fields (radial and mode III stresses) on the brittle boron fibers weakened by the humidity.     

Effect of Thermomechanical Fatigue on Precipitation Microstructure in Two Precipitation-Hardened Cast Aluminum Alloys

Thermal loading induces modifications of the precipitation microstructure of Al–Si–Cu–Mg alloys. This study focuses on the effect of deformation on precipitation microstructure during thermomechanical loadings. Several specimens were thermomechanically cycled while others were exposed to the same thermal cycles without any mechanical loading. The nature and morphological characteristics of the precipitation microstructure of the thermomechanically cycled specimens are compared to those of the thermally aged ones, using transmission electron microscopy (TEM), in order to assess the effect of deformation on the precipitation microstructure and especially on the kinetics of precipitate growth. The absence of any significant effect of superimposed straining during thermal cycling is discussed. Implications for the prevision of yield strength degradation during service operation are briefly presented.

     

热变形对中铬半钢热疲劳裂纹扩展动力学的影响

研究了热变形对中铬半钢热疲劳裂纹扩展动力学的影响。结果表明 :中铬半钢的热疲劳裂纹扩展符合 L =b Na(a<1)的关系。变形量小于 4 0 %时 ,随变形量的增加 ,裂纹扩展速率减小 ,其激活能随之增大。这些变化是由于碳化物形状的改变和粒状碳化物的析出所致。     

S–N Fatigue and Fatigue Crack Propagation Behaviors of X80 Steel at Room and Low Temperatures

In the present study, the S–N fatigue and the fatigue crack propagation (FCP) behaviors of American Petroleum Institute X80 steel were examined in the different locations of the base metal (BM), weld metal (WM), and heat-affected zone (HAZ) at 298 K, 223 K, and 193 K (25 °C, ?50 °C, and ?80 °C). The resistance to S–N fatigue of X80 BM specimen increased greatly with decreasing temperature from 298 K to 193 K (25 °C to ?80 °C) and showed a strong dependency on the flow strength (½(yield strength + tensile strength)). The FCP rates of X80 BM specimen were substantially reduced with decreasing temperature from 298 K to 223 K (25 °C to ?50 °C) over the entire ?K regime, while further reduction in FCP rates was not significant with temperature from 223 K to 193 K (?50 °C to ?80 °C). The FCP rates of the X80 BM and the WM specimens were comparable with each other, while the HAZ specimen showed slightly better FCP resistance than the BM and the WM specimens over the entire ?K regime at 298 K (25 °C). Despite the varying microstructural characteristics of each weld location, the residual stress appeared to be a controlling factor to determine the FCP behavior. The FCP behaviors of high strength X80 steel were discussed based on the microstructural and the fractographic observations.     

U71Mn和U75V钢轨钢疲劳短裂纹的扩展行为

在扫描电镜下对U71Mn和U75V钢轨钢的Ⅰ型低周疲劳加载和准静态加载下裂纹扩展的过程进行了观察.研究发现,从整体上看材料没有产生明显的宏观塑性变形,属准解理断裂.但从微观上看,裂纹的微观扩展路径曲折、不连续,常伴有分枝裂纹的形成.可观察到局部有韧窝、滑移线等典型的韧性断裂特征.尤其是U71Mn钢轨钢中还伴有局部的撕裂等更强烈的变形.钢轨钢U71Mn比U75V的抗疲劳裂纹扩展性能和韧性略优.     

钴磷镀层表面热疲劳裂纹的萌生及扩展机理

在自约束型热疲劳试验机上对化学镀钴磷合金镀层进行了热疲劳试验,采用光学显微镜、扫描电子显微镜研究了在热应力作用下镀层表面热疲劳裂纹萌生、扩展的方式和形态。结果表明:200次冷热循环后,V型缺口处发生塑性变形,并且随冷热循环的进行,热疲劳裂纹由缺口底部萌生并沿着循环方向扩展。重点分析了钴磷合金镀层表面热疲劳裂纹的萌生及扩展机理。     

TC4-DT损伤容限型钛合金疲劳裂纹扩展特性的研究

研究了典型的损伤容限型钛合金Ti-6A1-4V ELI（TC4-DT）的断裂韧度KIC、疲劳裂纹扩展速率da／dN以及疲劳门槛值△Kth等损伤容限性能与微观组织的关系，讨论了不同应力比（尺值）条件下片状组织与双态组织的疲劳裂纹扩展特性，并与Ti-6A1-4V（TC4）钛合金进行了比较分析。研究结果为高损伤容限型钛合金的微观组织设计和探讨微观组织对损伤容限性能的影响机理奠定了基础。     

Effect of Rare Earth Element on Formation and Propagation of Thermal Fatigue Crack in Low-Chromium Semi-Steel

The formation and growth of thermal fatigue crack in low chromium semi steel were investigated by means of optical microscope and scanning electron microscope, and the function of RE in low-chromium semi steel was analyzed. The results show that the thermal fatigue cracks are mainly generated at eutectic carbides, and the cracks not only grow and spread but also join each other. RE can improve the eutectic carbide‘s morphology, inhibit the generation and propagation of thermal fatigue cracks, and therefore promote the activation energy for the crack‘s propagation, which is especially more noticeable in case of the RE modification in combination with heat treatment. The mathematical model of the crack propagation is put forward.     

Hydride-Phase Formation and its Influence on Fatigue Crack Propagation Behavior in a Zircaloy-4 Alloy

The hydride-phase formation and its influence on the fatigue behavior of a Zircaloy-4 alloy charged with hydrogen gas are investigated. First, the microstructure and fatigue crack propagation rate of the alloy in the as-received condition are studied. Second, the formation and homogeneous distribution of the delta zirconium hydride in the bulk and its effect on the fatigue crack propagation rate are presented. The results show that in the presence of hydrides, the zirconium alloy exhibits reduced toughness and enhanced crack growth rates. Finally, the influence of a preexisting fatigue crack in the specimen and the subsequent hydride formation are examined. The residual lattice strain profile around the fatigue crack tip is measured using neutron diffraction. It is observed that the combined effects of residual strains and hydride precipitation on the fatigue behavior are more severe leading to propagation of the crack under near threshold loading.