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.     

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 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 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.     

FATIGUE GROWTH OF PHYSICALLY SMALL INCLINED CRACKS

The growth of physically small, self initiated, inclined corner and through-the-width cracks is investigated in a carbon steel under tension fatigue (R= 0.05). A preliminary procedure involving crack initiation under far-field cyclic compression is used. This precracking method is adopted to minimize the effect of residual damage at the tip of the crack grown (and arrested) under cyclic compression. Thus, the subsequent tensile fatigue crack propagates through a region with no (or very small) residual stress or damage. Experiments indicate that the early growth rate of the inclined corner cracks is discontinuous with a few decelerations. During the intermittent propagation period the corner cracks only extend into the thickness (depth) of the specimen and do not propagate along the width direction. However, after reaching a certain aspect ratio, the inclined flaws grow in a steady (continuous) manner in both the thickness and width directions. Through-the-width cracks, both inclined and perpendicular to loading direction, do not show the discontinuous growth pattern typical of the inclined corner cracks, but exhibit only one minimum in the crack growth rate behaviour.     

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.     

CONFOCAL SCANNING LASER MICROSCOPY MEASUREMENTS OF THE GROWTH AND MORPHOLOGY OF MICROSTRUCTURALLY SHORT FATIGUE CRACKS IN A1 2024-T351 ALLOY

Abstract— A new technique for studying the growth and morphology of microstructurally short fatigue cracks is described. The technique allows short crack growth, crack depth, and crack front configuration to be measured using Confocal Scanning Laser Microscopy (CSLM). Good agreement is shown between CSLM measurements of the initial stage of crack growth (along an inclined shear plane), crack depth and aspect ratio, together with the measurements obtained using a surface layer removal technique. It is also found that non-propagating short fatigue cracks have approximately the same aspect ratios in different specimen orientations and that the aspect ratio is independent of stress amplitude.     

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.     

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.     

VARIABLE AMPLITUDE LOADING OF SMALL FATIGUE CRACKS IN 6261-T6 ALUMINIUM ALLOY

Abstract— Constant and variable amplitude (VA) loading fatigue studies were carried out on a 6261 aluminium alloy using cylindrical plain hour-glass specimens. Crack growth was monitored via surface replication using cellulose acetate.
Crack growth results at constant amplitude loading show the typical intermittent high and low periods of growth rate associated with crack-microstructure interactions. Acceleration in growth rate during an overload block depends on crack length and stress amplitude ratio. It appears to pass through a maximum at a crack length corresponding to the first microstructural barrier. Microstructural-based modelling is therefore required for small fatigue cracks, rather than solely closure-based modelling. The Navarro-de los Rios model of short fatigue crack growth appears able to provide good indications of crack growth rates under VA block loading, and gives reasonable life predictions.
For short cracks (surface length < 80 μm) and a small overload ratio (6.7%), crack growth may show severe retardation during the overload block. This is ascribed to crack tip blunting being more important than the increase in stresses when closure is low. It appears from a Miner's rule type exercise, that VA block loading has its major effect on growth at a surface crack length of 20 μm. This means that the crack initiation period cannot be ignored in life prediction models for small fatigue cracks.     

IN SITU SEM MEASUREMENTS OF CRACK CLOSURE FOR SMALL FATIGUE CRACKS IN ALUMINIUM 2024-T351

Abstract Crack closure has been measured for a range of small, self-initiated fatigue cracks using in situ SEM loading. Cracks were grown at positive R ratios in the aluminium alloy 2024-T351 and at nominal ΔK levels that extend substantially below the corresponding long crack threshold. The crack closure stress of the small cracks decreased and the K_cl level increased with increasing crack size until the long crack value near threshold was reached. For cracks of depth larger than about one grain size, a good correlation was obtained between small and long crack growth rate data in terms of ΔK_eff     

THE EFFECTS OF STRESS RATIO ON THE GROWTH BEHAVIOUR OF SMALL FATIGUE CRACKS IN AN ALUMINUM ALLOY 7075-T6 (WITH SPECIAL INTEREST IN STAGE I CRACK GROWTH)

Abstract— The growth behaviour of small fatigue cracks has been investigated on aluminum alloy 7075-T6 at stress ratios R of 0, −1 and −2. The effects of stress ratio are discussed with special interest in the stage I region of small crack growth. Cracks which initiated at R =−1 and −2, grew by a stage I mechanism up to a certain depth followed by stage II crack growth. The stage I to stage II transition occurred under a constant maximum stress intensity factor which was approximately consistent with the threshold effective stress intensity range, λ K _eff,th, for large cracks. At R = 0, on the other hand, stage I crack growth was not observed because of crack initiation at inclusions. Small cracks grew more rapidly than large cracks subjected to the same nominal stress intensity ranges at all the stress ratios, and they grew below the threshold stress intensity range, λ K _th, for large cracks. Stage I cracks, in particular, showed much higher growth rates than large cracks and grew even below λ K _eff,th. It is suggested that stage II crack growth rates should be characterized in terms of an effective stress intensity range, while a micromechanics approach will be necessary to evaluate stage I crack growth rates.     

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.     

THE APPLICABILITY OF NEURAL NETWORKS IN MODELLING THE GROWTH OF SHORT FATIGUE CRACKS

This paper examines the use of a neural network to model the chaotic behaviour of the growth of short fatigue cracks which are characterized by a decreasing crack growth rate with increasing crack length. Fatigue crack growth is modelled in terms of the Hobson short fatigue crack growth law. The neural network is exclusively trained and tested on Hobson's experimental data of short fatigue cracks propagating in a 0.4% carbon steel. The empirical constants d, α and C of Hobson's growth law are determined from the neural network predictions and are found to be within the following approximate ranges 63 < d < 400 (μm), −0.27 < α < 0.08 and 1 × 10⁻⁴ < C < 509 × 10⁻⁴ with no proportional relationship observed between the constant C and the applied cyclic stress. It is shown that neural networks are a viable computational tool for modelling the chaotic behaviour of short fatigue crack growth.     

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.     

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.     

INITIATION AND GROWTH OF FRETTING FATIGUE CRACKS IN THE PARTIAL SLIP REGIME

Abstract— —Recent work addressing the problems of fretting fatigue crack initiation and propagation under a carefully controlled axi-symmetric Hertzian contact is described. Both experimental work, enabling the fretting damage, sites of initiation, and crack trajectory to be viewed, and theoretical work, permitting a prediction of those processes are presented. Good correlation between the two strands of work is found. In particular, the initiation criterion proposed by Ruiz, Boddington and Chen for a very different geometry is found to work well, and would seem to indicate its potential as a design tool.     

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.     

THE GROWTH OF SMALL FATIGUE CRACKS IN A LOW CARBON STEEL; THE EFFECT OF MICROSTRUCTURE AND LIMITATIONS OF LINEAR ELASTIC FRACTURE MECHANICS

The growth characteristics of small fatigue cracks were studied under rotary bending in a low carbon steel prepared with two ferrite grain sizes of 24 and 84 μm, and were compared with the growth characteristics of large through cracks in fracture mechanics type specimens. The effect of microstructure on crack growth rates and the interaction in growth behaviour between two neighboring small cracks were examined experimentally, and also the critical crack lengths above which linear elastic fracture mechanics (LEFM) is applicable were evaluated for small crack growth and for fatigue crack thresholds. It is found that small cracks grow much faster than large ones and also show growth rate perturbations due to grain boundaries. It is indicated that the critical crack lengths for fatigue crack thresholds are significantly shorter than those for small crack growth.     

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.