FATIGUE DAMAGE IN 1045 STEEL UNDER VARIABLE AMPLITUDE BIAXIAL LOADING

Abstract— During constant amplitude loading, two different types of crack systems have been reported In the high cycle fatigue (HCF) region, cracks nucleate on a small number of maxium shear strain amplitude planes One of these cracks becomes a dominant crack and leads to failure of the specimen In the low cycle fatigue (LCF) region, equally developed microcracks are observed over the entire gage section and grow during the majority of the life. The failure is due to a linking in which the microcracks join up during the last few cycles of the fatigue life.
To investigate the interaction of these two types of crack systems in biaxial fatigue, experiments were performed on thin-wall tubular specimens in tension, torsion and combined tension-torsion loading The test program included step loading and block loading in which two equivalent strain amplitudes were employed. One of the equivalent strain amplitudes is in the HCF region and the other was in the LCF region
Fatigue lives were predicted from constant amplitude damage curves when a single crack system dominated the fatigue process Two competitive crack systems were sometimes developed on the maximum shear strain amplitude planes in a single specimen under block loading This resulted in a conservative prediction of the fatigue life.     

Multiaxial small fatigue crack growth in metals

Observations related to the formation and growth of small cracks ranging from subgrain dimension up to the order of 1 mm are summarized for amplitudes ranging from low cycle fatigue (LCF) to high cycle fatigue (HCF) conditions for polycrystalline metals. Further efforts to improve the accuracy of life estimation which address LCF, HCF and LCF–HCF interactions must consider various factors that are not presently addressed by conventional elastic–plastic fracture mechanics (EPFM) or linear elastic fracture mechanics (LEFM) approaches based on long, self-similar cracks in homogeneous, isotropic materials, nor by conventional HCF design tools such as the ε–N curve, the S–N curve, modified Goodman diagram and fatigue limit.Development of microstructure-sensitive fatigue crack propagation relations relies on deeper understanding of small crack behavior, including (a) interactions with microstructure and lack of constraint for microstructurally small cracks, (b) heterogeneity and anisotropy of cyclic slip processes associated with the orientation distribution of grains, and (c) local mode mixity effects on small crack growth. The basic technology is not yet sufficiently advanced in these areas to implement robust damage tolerant design for HCF. This paper introduces an engineering model which approximates the results of slip transfer calculations related to crack blockage by microstructure barriers; the model is consistent with critical plane concepts for Stage I growth of small cracks, standard cyclic stress–strain and strain–life equations above threshold, and the Kitagawa diagram for HCF threshold behaviors. It is able to correlate the most relevant trends of small crack growth behavior, including crack arrest at the fatigue limit, load sequence effects, and stress state effects.     

Short fatigue crack propagation during low-cycle,high cycle and very-high-cycle fatigue of duplex steel – An unified approach

The present paper reviews experimental results on the fatigue damage of austenitic–ferritic duplex steel under various load levels ranging from LCF to VHCF, placing the focus towards the relationship between the crystallographic orientation of individual grains and grain patches that exhibit slip band formation, fatigue crack initiation and growth. A combination between fatigue testing of electropolished specimens and analytical electron microscopy (SEM/EBSD, TEM) revealed that under LCF loading conditions almost all the ferrite and the austenite grains showed plasticity, while under HCF and VHCF loading conditions, slip band formation was limited to the softer austenite grains and a low plastic activity is observed in the ferrite. Once being formed, the bands generate high stress concentrations, where they impinge the α–γ phase boundaries, eventually, leading to the crack initiation. This is discussed by applying a numerical simulation approach based on the finite-element (FEM) and the boundary-element (BEM) method.     

Initiation of corrosion fatigue cracks at defined grain boundaries in bicrystals

The fatigue tests in air show that persistent slip bands (PSB's) and cracks nucleate very early at special grain boundaries. At stress amplitudes for which no persistent slip band nucleation was observed in single crystals and which were oriented for single slip, cracks still nucleate at grain boundaries. The endurance limit for special bicrystals lay 50% below the endurance limit of polycrystals. In air, the cracks nucleate at the boundary but propagate within the PSB. From the stress amplitudes at which PSB's nucleate in single crystals and in bicrystals, which have one grain with the same orientation as the single crystals, the additional shear stress due to elastic anisotropy was measured to be 55 MPa. These tests yield an understanding of the behavior of short cracks, which nucleate at special boundaries but cannot propagate further, if they hit an unfavorably oriented boundary for which higher local stresses for propagation were needed.With the same bicrystals, corrosion fatigue tests were carried out in ammonium carbonate solutions. In the solution, crack nucleation was found to depend on frequency and amplitude. Contrary to the behavior in air, the cracks nucleate at and propagate along the grain boundary. Specimens which last for 10⁵ cycles in air only survive 6·10³ cycles at the lowest frequencies tested. In addition, if the stress amplitude is reduced by 27%, it was observed that, for a given frequency, the fatigue life is reduced by more than 90% relative to the fatigue life in air at the same stress level. The susceptibility of special boundaries against corrosion fatigue combined with the observed dependencies on stress amplitude and frequency could be understood on the basis of the slip step dissolution model for SCC.     

Experimentelle Charakterisierung und zweidimensionale Simulation der mikrostrukturbestimmten Ermüdungsrissausbreitung in einer β‐Titanlegierung

In this project the initiation and propagation of short fatigue cracks in the metastable β‐titanium alloy TIMETAL®LCB is investigated. By means of an interferometric strain/displacement gauge system (ISDG) to measure the crack opening displacement (COD) and the electron back scattered diffraction technique (EBSD) to determine the orientation of individual grains the microstructural influence on short crack initiation and growth can be characterized. Finite element calculations show a high influence of the elastic anisotropy on the initiation sites of cracks. Crack propagation takes place transgranulary along slip planes as well as intergranulary along grain boundaries. The crack growth rate depends strongly on the active mechanism at the crack tip which in turn is influenced by crack length, the applied stress and the orientation of the grains involved. The value of the steady state crack closure stress changes from a positive value at low applied stresses (roughness induced) to a negative one at higher applied stresses (due to plastic deformations at the crack tip). The crack growth simulation is realised by a two‐dimensional boundary element technique, which contains the ideas of Navarro und de los Rios. The model includes the sequence of the applied stress amplitude as well as the experimental measured roughness induced crack closure.     

Fatigue crack nuclei in austempered ductile cast iron

ABSTRACT Short fatigue crack nuclei in austempered ductile cast iron have been studied using optical microscopy, scanning electron microscopy, atomic force microscopy and X‐ray microtomography and by electron backscatter diffraction analysis. Fatigue cracks nucleate at graphite nodules and shrinkage microporosity. The crack nuclei are arrested and retarded by barriers in the microstructure, by either blocking of slip at boundaries or owing to the requirement for tilt and twist of the stage I crystallographic crack at grain boundaries. These observations indicate that both the size of the defects, such as graphite nodules and microporosity, and the size of the prior austenite grains control the largest crack nucleus that can develop, and hence determine the component fatigue limit.     

Influence of foreign object damage on fatigue crack growth of gas turbine aerofoils under complex loading conditions

Foreign object damage (FOD) has been identified as one of the main life limiting factors for aeroengine blades, with the leading edge of aerofoils particularly susceptible. In this work, a generic edge ‘aerofoil’ geometry was utilized in a study of early fatigue crack growth behaviour due to FOD under low cycle fatigue (LCF), high cycle fatigue (HCF) and combined LCF and HCF loading conditions. Residual stresses due to FOD were analyzed using the finite element method. The longitudinal residual stress component along the crack path was introduced as a nodal temperature distribution, and used in the correction of the stress intensity factor range. The crack growth was monitored using a nanodirect current potential drop (DCPD) system and crack growth rates were correlated with the corrected stress intensity factor considering the residual stresses. The results were discussed with regard to the role of residual stresses in the characterization of fatigue crack growth. Small crack growth behaviour in FODed specimens was revealed only after the residual stresses were taken into account in the calculation of the stress intensity factor, a feature common to LCF, HCF and combined LCF + HCF loading conditions.     

Effect of predamage from low cycle fatigue on high cycle fatigue strength of Ti-6Al-4V

Effects of prior low cycle fatigue (LCF) cycling on the subsequent high cycle fatigue (HCF) limit stress corresponding to a life of 10⁷ cycles are investigated for Ti-6Al-4V at room temperature. Tests are conducted at 420 Hz on an electrodynamic shaker-based system at several different LCF maximum loads and under subsequent HCF at R=0.1, 0.5 and 0.8 using a step loading procedure. Under these load combinations, which include the possibility of overload or underload effects if cracks form, there is no statistically significant effect of the prior LCF on the subsequent HCF limit stress. While LCF loading at a high stress of 900 MPa is seen to result in strain ratcheting, no distinct features on the fracture surface and different mechanisms of crack propagation from those obtained at lower maximum loads were observed. LCF loading up to 50% of expected life did not produce any indications of crack formation from either the stress limit data or the fracture surfaces.     

Prediction of Fatigue Lives of MAR‐M247 LC Based on the Crack Closure Concept

Low cycle fatigue (LCF), high cycle fatigue (HCF), and combined LCF and HCF tests are carried out on MAR‐M247 LC at 650 °C in air environment. Under combined LCF and HCF loading, block striations form on the fracture surface which are used to complete an effective crack growth curve by using the linear summation model. Crack growth lives starting from equivalent initial flaw sizes are calculated by the crack closure code FASTRAN and compared with experimental fatigue lives. Under HCF loading, predicted and experimental fatigue lives agree well for lifetimes above 10⁵ cycles. Lower lifetimes are overestimated indicating that the linear summation model is not valid for MAR‐M247 LC in this loading range. Interactions between the non‐crystallographic HCF crack growth and striated crack growth that is caused by the LCF loading are probably responsible for this behavior.     

Effect of LCF on HCF crack growth of Ti-17

An improved understanding of fatigue crack growth phenomena applicable to titanium engine disks was developed through complimentary experimental and analytical investigations of Ti-17. The effect of low cycle fatigue (LCF) on the high cycle fatigue (HCF) threshold and rate of crack propagation was studied. A simplified variable-amplitude spectrum, consisting of high-R cycles, corresponding to HCF loading, and periodic R=0.1 cycles, corresponding to LCF loading, was used to demonstrate a load-interaction effect. When the ratio of HCF to LCF cycles was 100 or more the fatigue crack growth lifetimes were significantly lower than predicted using linear damage summation methods assuming no load-interaction effect. Thus, it was concluded that the LCF cycle accelerated the fatigue crack growth rate of subsequent HCF cycles, even when closure was concluded to be negligible. A phenomenological model was formulated based on hypothesized changes in the propagation resistance, K_PR, and fit to the test data. The model confirmed that the periodic LCF cycles increased fatigue crack growth rates of subsequent HCF cycles.     

驻留滑移带与晶界和孪晶界的交互作用

对含有退火孪晶的多晶铜进行了不同塑性应变幅下的应变疲劳实验,利用扫描电镜及其电子通道衬度技术（SEM-ECC）观察了表面滑移形貌、疲劳裂纹和位错组态,研究了驻留滑移带与晶界和孪晶界的交互作用．结果表明,在晶界附近和远离晶界处观察到位错组态分布的不均匀现象．这种不均匀性导致多晶铜中疲劳裂纹首先沿着普通大角晶界开裂,在孪晶界处由于应变相容性较好而难以产生疲劳裂纹．     

Modelling of short crack propagation – Transition from stage I to stage II

The propagation behaviour of short cracks under cyclic loading is simulated using a mechanism-based model for two-dimensional crack propagation in stage I. Experimental investigations on a duplex steel have been performed to characterise the different barrier effects of grain and phase boundaries, so that the crack propagation can be simulated in a real microstructure. The model allows the activation of additional slip systems resulting in a crack propagation on multiple slip bands, which is the preliminary step to stage II crack growth. By use of virtual microstructures based on Voronoi diagrams, it is possible to simulate the overall fatigue-crack propagation process starting from a microstructurally short crack in a single grain until the crack has crossed several (10–20) grains with just one model.     

Low‐cycle fatigue/high‐cycle fatigue interactions in notched Ti‐6Al‐4V*

Combined low‐cycle fatigue/high‐cycle fatigue (LCF/HCF) loadings were investigated for smooth and circumferentially V‐notched cylindrical Ti–6Al–4V fatigue specimens. Smooth specimens were first cycled under LCF loading conditions for a fraction of the previously established fatigue life. The HCF 10⁷ cycle fatigue limit stress after LCF cycling was established using a step loading technique. Specimens with two notch sizes, both having elastic stress concentration factors of K_t = 2.7, were cycled under LCF loading conditions at a nominal stress ratio of R = 0.1. The subsequent 10⁶ cycle HCF fatigue limit stress at both R = 0.1 and 0.8 was determined. The combined loading LCF/HCF fatigue limit stresses for all specimens were compared to the baseline HCF fatigue limit stresses. After LCF cycling and prior to HCF cycling, the notched specimens were heat tinted, and final fracture surfaces examined for cracks formed during the initial LCF loading. Fatigue test results indicate that the LCF loading, applied for 75% of total LCF life for the smooth specimens and 25% for the notched specimens, resulted in only small reductions in the subsequent HCF fatigue limit stress. Under certain loading conditions, plasticity‐induced stress redistribution at the notch root during LCF cycling appears responsible for an observed increase in HCF fatigue limit stress, in terms of net section stress.     

In situ observations of crack propagation and role of grain boundary microstructure in nickel embrittled by sulfur

In situ observations of crack propagation in sulfur-doped coarse-grained nickel were performed for the specimens with grain boundary microstructure pre-determined by SEM/EBSD analysis. The role of grain boundary microstructure was studied in the crack propagation in nickel embrittled by grain boundary segregation of sulfur. It was found that the main crack tends to predominantly propagate along random boundaries, and the crack propagation rate can be locally accelerated at the grain boundary network with a high connectivity of random boundaries. On the other hand, the cracks can propagated along fracture-resistant low-Σ coincidence site lattice (CSL) boundary only when the trace of the grain boundary is arranged being almost parallel to slip bands in the adjacent grains. The local crack propagation rate was found to become lower when a crack propagated along low-Σ CSL boundaries. Moreover, when the crack propagation is inhibited by low-Σ CSL boundaries, the branching of propagating crack occurs at partially cracked triple junctions. The crack propagation can locally slow down due to the occurrence of crack branching. The optimum grain boundary microstructure for the control of sulfur segregation-induced brittle fracture is discussed on the basis of new findings obtained from the in situ observations on crack propagation and fracture processes in polycrystalline nickel.     

Basic issues in the mechanics of high cycle metal fatigue

Mechanics issues related to the formation and growth of cracks ranging from subgrain dimension to up to the order of one mm are considered under high cycle fatigue (HCF) conditions for metallic materials. Further efforts to improve the accuracy of life estimation in the HCF regime must consider various factors that are not presently addressed by traditional linear elastic fracture mechanics (LEFM) approaches, nor by conventional HCF design tools such as the S-N curve, modified Goodman diagram and fatigue limit. A fundamental consideration is that a threshold level for ΔK for small/short cracks may be considerably lower than that for long cracks, leading to non-conservative life predictions using the traditional LEFM approach. Extension of damage tolerance concepts to lower length scales and small cracks relies critically on deeper understanding of (a) small crack behavior including interactions with microstructure, (b) heterogeneity and anisotropy of cyclic slip processes associated with the orientation distribution of grains, and (c) development of reliable small crack monitoring techniques. The basic technology is not yet sufficiently advanced in any of these areas to implement damage tolerant design for HCF. The lack of consistency of existing crack initiation and fracture mechanics approaches for HCF leads to significant reservations concerning application of existing technology to damage tolerant design of aircraft gas turbine engines, for example. The intent of this paper is to focus on various aspects of the propagation of small cracks which merit further research to enhance the accuracy of HCF life prediction. Predominant concern will rest with polycrystalline metals, and most of the issues pertain to wide classes of alloys.     

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.     

Atomic-scale simulation of α/γ-iron phase boundary affecting crack propagation using molecular dynamics method

Phase boundaries play significant roles in the crack initiation and propagation behavior of duplex phase materials such as nanoscale bainite–austenite (α/γ) microstructures. Simulation of α/γ-iron phase boundary interacting with crack propagation was carried out using molecular dynamics method. Bi-phase systems consisting of α-iron with body-centered cubic structure and γ-iron with face-centered cubic structure, were constructed. Phase boundaries were created using Nishiyama–Wasserman and Kurdjumov–Saches (K–S) orientation relationships, respectively. Eight orientations of cracks in α- or γ-phase were analyzed to illustrate the orientation dependence of crack growth. Finnis–Sinclair potential for Fe fit by Mendelev was used to describe interatomic potentials. Tensile load was applied normal to the crack surface. Simulation results reveal that in most cases phase boundary provides an obstacle to slip and dislocation motion during crack propagation, except in two orientations with K–S relation. New-cracks always nucleate phase boundary as a result of slip blocking and dislocation pileups. Bcc/fcc iron phase boundary is therefore demonstrated to be a great contribution to the strengthening of nanoscale duplex steel.     

Fatigue of a nickel base superalloy with bimodal grain size

Room temperature fatigue tests in the form of four point bending were performed at a frequency of 20 Hz and a load ratio R= +0·1 on electropolished Waspaloy specimens taken from a forged turbine disc. Samples, which had a partially recrystallised microstructure with a bimodal grain size, were removed from the outer rim of the disc. The S-N curve was similar to that reported for a fully recrystallised structure with a coarse grain size, from the same turbine disc. The dominant crack initiation sites were found to be inclusions with a subsequent stage I crack growth generally along slip bands. Other crack initiation sites observed included slip bands, annealing twins, and grain boundaries. Fatigue deformation occurred by the propagation of planar slip bands. Slip band cracks formed more frequently in coarse grains than expected from their volume fraction. Fluctuations in short crack growth rate were observed and were associated with microstructural features such as grain boundaries and twin boundaries, both of which acted as barriers in the early stages of crack growth. The short crack growth rate versus stress intensity range graph was similar to those from uniform fine grained Waspaloy.

MST/3413     

ON THE NUCLEATION OF FATIGUE CRACKS IN PURE POLYCRYSTALLINE α-IRON

Abstract— This paper presents the results of an investigation of fatigue crack initiation in pure polycrystalline α-iron as a function of testing frequency (0.01–1000 Hz). Three distinct types of fatigue crack initiation mechanisms were identified:
(i) At low frequencies, <0.5 Hz, cracks were observed to nucleate at intrusions, extrusions and grain boundaries. However over the frequency range studied the cracks at the intrusions and extrusions were not associated with the final fatigue failure. The results suggest that in pure iron frequencies <0.01 Hz are required for fatigue failure to be initiated at intrusions and extrusions.
(ii) At frequencies ≤0.01 Hz at high strain amplitudes, cracks nucleated at the intersection of grain boundaries with the free surface as a result of the incompatable deformation of surface grains. The subsequent propagation of these cracks resulted in fatigue failure.
(iii) Tests performed at low strain amplitude at 5 Hz and 1000 Hz initiated surface grain boundary cracking without any significant associated change of grain shape.
The results of the present investigation indicate that fatigue failure in pure iron alloys (at frequencies >0.01 Hz) is initiated not at intrusions and extrusions but at grain boundaries.     

Microcrack growth and fatigue behavior of a duplex stainless steel

The kinetics of microcrack growth during cycling has been studied in a S32205 duplex stainless steel in the as-received and aged (100 h at 475 °C) conditions. Cylindrical specimens with a shallow notch were subjected to a constant plastic strain range of 0.3% in both thermal conditions. The characteristic features of surface damage and crack growth showed striking differences in microcrack density, nucleation location and propagation rate between the two thermal conditions even though the fatigue lives are comparable. In the as-received material, microcrack density is low and they nucleate mainly at grain and phase boundaries or second-phase particles. In the aged condition, slip markings first appear in the ferritic phase and they are the preferred site for microcrack nucleation. Crack propagation takes place along slip markings in adjacent grains for crack lengths less than 100 μm. A comparison between fatigue life and the relevant parameters of a microcrack growth law was made.