THE EFFECT OF STRESS RATIO ON THE FATIGUE THRESHOLD CONDITION OF PHYSICALLY SMALL CRACKS

An approach is proposed to predict the intrinsic threshold of physically small cracks without invoking crack closure considerations. The basic assumption invoked is that a Δ K representation is valid for short cracks, hence the lower-bound threshold value, ΔK_0(s)(min) for short cracks can be numerically equated with the lower-bound threshold value of long cracks, ΔK*_{0(l)(min), s} of the same material. Several experimental observations provide a basis for this rationalization. The approach allows a quantitative prediction of stress ratio and crack length dependence of Δ K _0(S) which provides good agreement with experimental data for several low-strength steels and aluminium alloys. This alternative procedure may be found useful in design applications.     

THE INFLUENCE OF MICROSTRUCTURE ON THE GROWTH OF SMALL FATIGUE CRACKS

Abstract— Recent experimental work on the growth of small fatigue cracks is surveyed and critically analyzed. It is shown that microcracks grow at anomalous rapid rates relative to large ones only when certain criteria, involving crack size, plastic zone size, and micro-structural element size, are met. Retardation and arrest of microcracks is found to correlate with microstructural element size, hence with crystallographic influence.     

THE GROWTH OF SMALL CORROSION FATIGUE CRACKS IN ALLOY 2024

Abstract— The corrosion fatigue crack growth characteristics of small surface and corner cracks in aluminium alloy 2024 is established. The damaging effect of salt water on the early stages of small crack growth is characterized by: (1) crack initiation at constituent particle pits, (2) intergranular microcracking for a≤100μm, and (3) transgranular small crack growth for a≥100μm. In aqueous 1% NaCl and at a constant anodic potential of −700 mV_SCE, small cracks exhibit a factor of three increase in fatigue crack growth rates compared to laboratory air. Small cracks exhibit accelerated corrosion fatigue crack growth rates at low levels of Δ K (< 1 MPa√m) below the long crack Δ K _th value. When exposed to Paris regime levels of crack tip stress intensity, small corrosion fatigue cracks exhibit growth rates similar to that observed for long cracks. Similar small and long crack growth behavior at various levels of R suggest that crack closure effects influence the corrosion fatigue crack growth rates of small cracks for a≥100 μm. Contrary to the corrosion fatigue characteristics of small cracks in high strength steels, no pronounced chemical crack length effect is observed for alloy 2024 exposed to salt water.     

THE EFFECT OF ENVIRONMENT ON THE GROWTH OF SMALL FATIGUE CRACKS

Abstract— The growth of "large" and "small" cracks in 7075–T6 aluminum is characterized in moist air and dry nitrogen. It is found that in both environments, the small cracks grow faster than large ones, but unlike large cracks, which grow much faster in air than in nitrogen, the small cracks extend in each environment at about the same average rate. The absence of environmental effect is found to be only apparent, a change to an inherently slower mode of growth in air offsetting the crack-accelerating influence of moisture. Subsurface grain boundaries apparently retard microcrack growth in both environments. Possible rationales for the rapid growth of small cracks are discussed.     

THE GROWTH OF MICROSTRUCTURALLY SMALL FATIGUE CRACKS IN A FERRITIC-PEARLITIC STEEL

Abstract— The growth behaviour of microstructurally small fatigue cracks was investigated with smooth specimens of a ferritic-pearlitic steel, S45C. under rotating bending. The effects of microstructure, particularly the role of pearlite structure, on crack growth were evaluated based on detailed microscopic observations. In the region smaller than a certain crack length. small cracks tended to grow preferentially in the ferrite structure, and the crack growth rates decreased markedly at ferrite-pearlite boundaries when small cracks grew into the pearlite from the ferrite. The above region of crack length, i.e. the length of microstructurally small cracks, depended on stress level, increasing with decreasing stress level. The growth mechanism is also discussed in terms of the results obtained from fractogrdphy.     

THE GROWTH OF SMALL FATIGUE CRACKS IN 7075–T6 ALUMINUM

Abstract— The growth of 'small', half-penny shaped surface fatigue cracks in a precipitation hardened aluminum alloy is compared with the growth of 'large'cracks in fracture mechanics type specimens. It is found that the small cracks grow much faster than LEFM equivalent large ones, and also experience growth rate perturbations. It is suggested that localized microplasticity in nominally elastic specimens is responsible for the rapid growth of small cracks and that grain size limitations on the microplastic regions cause transient decelerations and sometimes permanent arrest, in crack growth.     

FATIGUE CRACK GROWTH FROM SMALL SEMI-ELLIPTIC HYDROGEN-INDUCED CRACKS IN QIN STEEL

Abstract— Small semi-elliptic hydrogen-induced cracks were produced in QIN (HY80) steel. Fatigue crack growth rate behaviour and threshold values for these cracks were investigated at several positive stress ratios ( R = 0.2 to 0.7) and compared with results from long through-cracks. At low R values the hydrogen-induced cracks gave higher thresholds, and lower crack growth rates at the same nominal Δ K value in the near threshold region. At high R values the growth rates of both crack types were almost identical. The results are explained by a combination of crack tip blunting and roughness induced closure of the intergranular hydrogen crack.     

AN EXPERIMENTAL INVESTIGATION OF THE GROWTH OF SMALL CORNER FATIGUE CRACKS IN ALUMINIUM 6061-T651

Results of an experimental investigation of the fatigue growth of small corner cracks emanating from small flaws are presented. Growth-arrest behaviour was observed, and increases in crack length during growth periods were of the order of the transverse grain size. For the test material, the corner crack front intersects, on average, only three–six grains in the small crack regime monitored, so only a small number of constrained, interior grains is encountered. It is suggested that the presence of partially constrained surface grains may contribute to the 'anomalous' growth behaviour which has been observed by a number of investigators.
The crack growth histories of the test data presented exhibit considerable scatter. It is shown that a Student's t -test can be used to estimate confidence intervals in order to provide a measure of the observed scatter. The variation in confidence intervals in the transition from small to long fatigue crack growth is discussed.     

THREE-DIMENSIONAL CRACK-SHAPE EFFECTS DURING THE GROWTH OF SMALL SURFACE FATIGUE CRACKS IN A TITANIUM-BASE ALLOY

Abstract— A basic study was performed on the evolution of three-dimensional shapes of small surface fatigue cracks during fatigue, and the effect of this evolution on small-crack growth behavior of a titanium-base alloy. Specifically, the nature and the magnitude of variations in crack aspect ratio, a/c (a is the crack depth and c is the half-surface crack length), during cyclic crack growth and its impact on growth rates have been studied. Experiments were performed on naturally initiated micro-cracks in a microstructure consisting of equiaxed primary-α₂ phase in a Widmanstätten (transformed β) matrix. Several cracks under stress ratio (R) levels of 0.1 and ?1, were studied. A specialized experimental system, consisting of a laser interferometer (to measure precisely the small-crack surface displacements), and a photo microscope (to automatically and continuously photograph the fatigue micro-cracks) was employed in the study. Apparent aspect ratios of surface cracks were calculated from the compliance response and the surface crack length data as a function of fatigue cycles. These data enabled accurate calculations of growth rates at the surface crack tip as well as the tip at depth in the bulk over the entire crack growth period, thus giving an insight into the crack growth process. Measurements of closure levels of small cracks were also performed and were used to partly account for the differences in growth rates. In the comparisons of small-crack growth data with the large-crack data, surface growth rates correlated relatively well with the large-crack data. Growth rates at depth exhibited large variations due to the irregularity of crack fronts at this location, and these rates deviated significantly from the large-crack behavior. Additionally, these growth rates varied between different cracks. An attempt was made to rationalize these observations in terms of the effects of inhomogeneities present in the microstructure.     

INITIATION AND GROWTH OF CRACKS IN BIAXIAL FATIGUE

Abstract— Observations of fatigue crack growth in smooth specimens under biaxial loading are reviewed, with particular reference to the Stage I to Stage II and Stage II to Stage I transitions. Further results are presented for 1% Cr-Mo-V steel and AISI 316 stainless steel at various temperatures, showing that all cracks may be classed as either Stage I or Stage II. Predictive criteria are suggested for the typè of crack obtained, and the mechanisms for elevated temperature crack initiation are discussed.     

UNSTABLE AND STABLE CRACK GROWTH: IMPLICATIONS FOR THE BEHAVIOUR OF SMALL AND LONG FATIGUE CRACKS

Abstract— The effects of the changes of crack shapes on the behaviour of small cracks were investigated on single edge crack specimens and small surface crack specimens with different initial crack shapes. Experimental results obtained from beach mark measurements on the fracture surfaces indicated that the behaviour of small cracks was strongly dependent on the crack shape itself. While the initial shape of a small crack was unstable with respect to the state of specimen-geometry-stress system, the crack gradually adjusted its shape to a specific preferred shape by means of non-uniform growth. In addition, the deceleration and subsequent acceleration of crack growth corresponds to the transition from unstable to stable crack growth.     

FRACTURE MECHANICS OF PHYSICALLY SHORT CRACKS

Mechanical Engineering Research Institute, Academy of Sciences of the U.S.S.R., Griboedova Str., 4 Moscow Centre, Moscow 101830, U.S.S.R.     

FATIGUE GROWTH OF SURFACE CRACKS IN THE ELASTIC-PLASTIC REGION

Surface crack growth has been studied in centre notched and smooth panels of low carbon steel under symmetric axial elastic-plastic cyclic straining. The crack shape, followed by heat tinting, has been found to be approximately semi-circular for crack radii 0.3–5 mm. Both smooth and notched specimens have been fatigued until fracture. The smallest notches of 0.1 mm in radius and depth approximately represent defects of a critical size under present loading conditions. Crack propagation rates have been measured and plotted vs ΔJ. Both present part through-crack data and previous long through-crack data in the elastic and the elastic-plastic regions are compatible. A single dependence of dl/dN vs ΔJ is obtained.     

SCATTER CHARACTERISTICS OF FATIGUE LIFE AND THE BEHAVIOUR OF SMALL CRACKS

Usually, there is large scatter in fatigue data and this should be evaluated quantitatively when fatigue data are applied to the design of machines and structures. Consequently it is important to clarify the physical basis of scatter in fatigue life. In this present study, rotary bending fatigue tests were performed on an annealed 0.21% carbon steel. At least sixteen smooth specimens were fatigued at each of three stress ranges and successive observations of the surface were studied for all the specimens using the plastic replica method. By examining the initiation and propagation behaviour of cracks the physical basis of scatter in fatigue life is analysed and discussed. To estimate the scatter characteristics quantitatively, the distributions of crack initiation life, propagation life, fatigue life and crack length were individually studied by assuming a Weibull distribution for each set of data.     

DETECTING SMALL FATIGUE CRACKS BY ACOUSTIC MICROSCOPY

Abstract— The acoustic microscope has shown great potential for use in fatigue experiments. A comparison between acoustic and optical images of fatigued Aluminium Lithium alloy specimens shows that the acoustic microscope has the ability to monitor very small cracks. Since it is easy (a) to find cracks and to locate their tips, (b) to detect damage ahead of a crack tip, (c) to distinguish cracks from slip bands and (d) to monitor the coalescence of cracks, the acoustic microscope can now be used with increasing confidence for obtaining data and understanding the mechanisms involved in metal fatigue.     

CLOSURE AND GROWTH OF MODE I CRACKS IN BIAXIAL FATIGUE

Abstract— —The closure behavior of mode I fatigue cracks under biaxial loading is studied with an elastic-plastic plane stress finite element model. Biaxial stresses are shown to have a significant impact on crack closure behavior at higher maximum stresses. In general, normalized crack opening stresses are highest for equibiaxial loading and lowest for pure shear loading. The differences are apparently negligible for maximum applied stresses less than about 0.4 σ₀. Experimental crack growth data are quantitatively consistent with these trends. Correlations of the experimental data with a simple Δ K _eff were successful as first-order engineering estimates. Changes in forward and reversed plastic zone sizes with biaxiality are not entirely consistent with trends in crack growth rates.     

SMALL FATIGUE CRACKS IN AN AUSTENITIC STAINLESS STEEL

The present study concerns nucleation and growth of small surface cracks during the low-cycle fatigue of a nitrogen-containing austenitic stainless steel. Metallographic replicas as well as longitudinal sectioning were used to record the developing crack pattern on the specimen surface. The influence of grain size and nitrogen content is considered. Small surface cracks are observed after about 10% of the fatigue life. The nucleation of cracks continues until about half of the lifetime, when the crack density saturates. This saturation phenomenon is related to the local unloading effect of growing cracks.
The mean crack length increases continuously as a power-law until specimen failure. However, small grains and a low nitrogen content amplify the effect of crack–grain boundary interactions resulting in an intermediate retardation in growth.
At high nitrogen contents, the crack growth characteristics are very much related to the slip bands formed. This results in a more simultaneous growth of cracks, a more jagged feature of the cracks introducing a higher roughness-induced crack closure effect, and, consequently, better fatigue properties.     

A STUDY OF THE GROWTH OF SMALL FATIGUE CRACKS IN A HIGH STRENGTH STEEL USING A SURFACE ACOUSTIC WAVE TECHNIQUE

Abstract— An ultrasonic surface acoustic wave technique for studying the growth behaviour of small fatigue cracks is described. The technique allows crack depth and opening stress to be monitored continuously during the course of a fatigue test. Results are given for a 1740 MPa yield strength, silicon-modified, AISI 4340 steel tested under zero-to-tension cyclic loading. Good agreement is shown between acoustically determined crack depth and that measured by post-fracture optical microscopy. The monitoring of changing crack depth-to-surface length ratios during tests is also demonstrated. Acoustically determined crack opening stresses were found to be about 10% higher than values determined by measurements of crack tip opening displacements by scanning electron microscopy. Effects on crack growth of two different specimen surface preparations, electropolishing and diamond paste polishing, are also reported. Growth rates in electropolished specimens were as much as an order of magnitude higher than in diamond paste polished specimens which had a shallow but significant layer of compressive residual stress.     

AN ENGINEERING ASSESSMENT OF FATIGUE CRACK GROWTH OF IRREGULARLY ORIENTED MULTIPLE CRACKS

Abstract— Knowledge of the behaviour of interacting and irregularly oriented multiple cracks is very limited. The recharacterisation rules for such cracks are usually empirical. In order to provide more reasonable rules for an engineering assessment of fatigue growth of irregularly oriented multiple cracks, this paper first studies the mechanics of fatigue growth of two-dimensional non-coplanar cracks. Uniaxial and biaxial fatigue testing on specimens with various multiple cracks are then carried out. Possible errors in the assessment of the cracks using the current rules are discussed. An improved procedure for the fatigue life assessment is developed.