Fatigue of 7075-T651 aluminum alloy under constant and variable amplitude loadings

The fatigue crack growth (FCG) behavior of 7075-T651 aluminum alloy was studied under constant and variable amplitude loadings in vacuum, air and 1% NaCl solution. In the study of constant amplitude loading fatigue, the stress ratios were 0.1 and 0.85 and the loading frequency was 10 Hz. In the study of variable amplitude loading fatigue, the load spectrums were tension type and tension–compression type, and the average loading frequency was about 5 Hz. The results of FCG tests, under constant and variable amplitude loadings, validated the unified two parameter driving force model, accounting for the residual stress and stress ratio effects on fatigue crack growth.     

Fatigue life prediction based on crack closure for 6156 Al-alloy laser welded joints under variable amplitude loading

A fatigue prediction approach is proposed using fracture mechanics for laser beam welded Al-alloy joints under stationary variable amplitude loading. The proposed approach was based on the constant crack open stress intensity factor in each loading block for stationary variable amplitude loading. The influence of welding residual stress on fatigue life under stationary variable amplitude was taken into account by the change of crack open stress intensity factor in each loading block. The residual stress relaxation coefficient β = 0.5 was proposed to consider the residual stress relaxation for the laser beam welded Al-alloy joints during the fatigue crack growth process. Fatigue life prediction results showed that a very good agreement between experimental and estimated results was obtained.     

Investigation of cold expansion of short edge margin holes with pre‐existing cracks in 2024‐T351 aluminium alloy

The United States Air Force has requirements to inspect and cold expand potentially thousands of fastener holes for an aircraft fleet, and the presence of existing cracks at those fastener holes is expected. Fatigue experiments were performed to investigate the resulting fatigue crack growth life of a fastener hole that contained a representative ‘unknown’ crack at the time of inspection (approximately 0.050 in. in length) at a short edge margin hole that was then cold expanded and compare that to a non‐cold expanded hole and a cold expanded hole with no pre‐existing cracks. The United States Air Force analytical approach used to account for the benefit due to cold expansion was compared to the experimental data and does not consistently provide conservative predictions.     

Analytical study of fatigue crack growth in AA7050 notched specimens under spectrum loading

An analytical study of fatigue crack growth in aluminium alloy 7050-T7451 notched specimens under a fighter aircraft wing root bending moment spectrum was conducted. The crack growth data were measured by quantitative fractography for three groups of specimens with different stress concentration geometrical features. Under spectrum loading and for each spectrum peak stress level, a minimum of five specimens were tested. Based on the analysis of the measured spectrum crack growth data using linear elastic fracture mechanics, it was found that the concept of geometry factors formulated in the stress intensity factor could not collapse the crack growth rate data derived from each stress concentration feature, particularly near the small crack growth region. In order to investigate the possible reasons for this, three-dimensional elastic-plastic finite element analysis was used to determine notch plastic zone sizes for each stress concentration geometry. As a consequence, an alternative crack growth driving force by considering both notch elastic-plastic stress field and gross net-section stress field was proposed and used to interpret the fatigue crack growth data under spectrum loading. It was found that the predictions of crack growth under spectrum loading for different stress concentration factors at different peak load levels agree reasonably well with the experimental results.     

Comparative research on the accumulative damage rules under multiaxial block loading spectrum for 2024-T4 aluminum alloy

Different multiaxial multi-block loading and random block loading spectra were used to conduct variable amplitude fatigue tests on 2024-T4 aluminum alloy. These spectra were derived from 16 kinds of constant amplitude multiaxial loadings. Five accumulative damage models were introduced and the critical damages given by these models were compared with the experimental results. It is demonstrated that Palmgren–Miner-Law and Shamsaei’s approach both led to good coincidences with the experimental results, Manson’s damage curve approach (DCA) and Morrow’s rule were not suitable for both multiaxial multi-block loading and random block loading spectra, while Carpinteri’s model was inapplicable to 2024-T4 aluminum alloy.     

The effects of load sequencing on the fatigue life of 2024-T3 aluminum alloy

Current fatigue life analysis of metallic rotorcraft dynamic components are based on a linear cumulative damage concept known as Miner's rule. This type of analysis assumes that there is no load sequence effect that occurs during the fatigue loading history. Past studies have shown that linear cumulative damage analysis of fatigue tests has produced life predictions that have been conservative as well as unconservative. Some of this uncertainty has been attributed to the fact that load sequence effects do exist in most fatigue load spectra. As a first phase the study reported herein was done to evaluate the load sequencing effects that could exist in commercial fixed-wing fatigue load spectra. To evaluate these effects a typical commercial wing spectra was reordered using a scheme that had previously been shown in fatigue block loading to produce the shortest fatigue lives. This scheme starts with the smallest load range in a load sequence and proceeds in ascending order until the largest load range is reached. Tests on open hole test specimens made of 2024-T3 aluminum alloy were conducted on the normal sequence of loads as well as the reordered scheme called lo–hi. Test results showed no significant differences between the fatigue lives of the normal load sequence and the reordered load sequence. A computer program called FASTRAN which calculates total fatigue life using only crack growth data was shown to predict the fatigue life of the spectrum tests with acceptable accuracy.     

Variation of local stress ratio and its effect on notch fatigue behavior of 2024-T4 aluminum alloy

Fatigue tests and finite element analysis of notched specimen were carried out to investigate the variation of local stress ratio at notch root and its influence on fatigue strength. The S–N curve of 2024-T4 aluminum alloy was kinked at the critical nominal stress amplitude, above which the local stress ratio became low due to the development of local plastic deformation at notch root. The predicted fatigue lives based on linear fracture mechanics approach were in agreement with the experimental results below the critical nominal stress amplitude. The predicted fatigue lives based on the SWT parameter, where the variation of local stress ratio was taken into account, were in good agreement with the experimental results above the critical nominal stress amplitude.     

Prediction of fatigue crack growth under constant amplitude loading and a single overload based on elasto-plastic crack tip stresses and strains

It is generally accepted that the fatigue crack growth (FCG) depends mainly on the stress intensity factor range (ΔK) and the maximum stress intensity factor (K_max). The two parameters are usually combined into one expression called often as the driving force and many various driving forces have been proposed up to date. The driving force can be successful as long as the stress intensity factors are appropriately correlated with the actual elasto-plastic crack tip stress-strain field. However, the correlation between the stress intensity factors and the crack tip stress-strain field is often influenced by residual stresses induced in due course.A two-parameter (ΔK_tot, K_max,tot) driving force based on the elasto-plastic crack tip stress-strain history has been proposed. The applied stress intensity factors (ΔK_appl, K_max,appl) were modified to the total stress intensity factors (ΔK_tot, K_max,tot) in order to account for the effect of the local crack tip stresses and strains on fatigue crack growth. The FCG was predicted by simulating the stress-strain response in the material volume adjacent to the crack tip and estimating the accumulated fatigue damage. The fatigue crack growth was regarded as a process of successive crack re-initiations in the crack tip region. The model was developed to predict the effect of the mean and residual stresses induced by the cyclic loading. The effect of variable amplitude loadings on FCG can be also quantified on the basis of the proposed model. A two-parameter driving force in the form of: was derived based on the local stresses and strains at the crack tip and the Smith-Watson-Topper (SWT) fatigue damage parameter: D = σ_maxΔε/2. The effect of the internal (residual) stress induced by the reversed cyclic plasticity manifested itself in the change of the resultant (total) stress intensity factors controlling the fatigue crack growth.The model was verified using experimental fatigue crack growth data for aluminum alloy 7075-T6 obtained under constant amplitude loading and a single overload.     

Fatigue crack growth in 7249‐T76511 aluminium alloy under constant‐amplitude and spectrum loading

Fatigue crack growth tests were conducted on compact, C(T), specimens made of 7249‐T76511 aluminium alloy. These tests were conducted to generate crack growth rate data from threshold to near fracture over a wide range of load ratios (R). Four methods were used to generate near threshold data: (1) ASTM E‐647 load reduction (LR), (2) compression pre‐cracking constant‐amplitude (CPCA), (3) compression pre‐cracking LR, and (4) constant crack mouth opening displacement LR method. A crack closure analysis was used to develop an effective stress‐intensity factor range against rate relation using a constraint factor (α = 1.85). Simulated aircraft wing spectrum tests were conducted on middle crack tension, M(T), specimens using a modified full‐scale fatigue test spectrum. The tests were used to develop the constraint‐loss regime (plane strain to plane stress; α = 1.85 to 1.15) behaviour. Comparisons were made between the spectrum tests and calculations made with the FASTRAN life prediction code; and the calculated crack growth lives were generally with ±10% of the test results.     

Investigations on fatigue crack growth under variable amplitude loading in wheelset axles

The present paper summarizes the results of fatigue crack growth simulations for hollow wheelset axles. Within the scope of this paper different influencing factors of the remaining lifetime have been identified. Therefore different simulations using NASGRO have been performed with different initial crack depth as well as aspect ratios. Moreover the influence of press fitting on the remaining lifetime has been pointed out. Preliminary experimental studies using standardized fracture mechanical specimens have been used in order to optimize time- and cost-consuming component testing.     

Effect of friction stir processing conditions on fatigue behavior and texture development in A356-T6 cast aluminum alloy

Friction stir processing (FSP) was applied to A356-T6 cast aluminum alloy to modify the microstructure and to eliminate casting defects under two different tool rotational speeds. Plane bending fatigue tests had been conducted, revealing that FSP could enhance the fatigue strength where the lower rotational speed condition gave better results. The enhancement of fatigue strength was attributed to the elimination of casting defects. Crystallographic analysis by EBSD revealed that the texture induced by FSP had detrimental effect on growth resistance. The lower rotational speed condition resulted in the weaker texture, and consequently, further increase of fatigue strength was achieved compared with the higher rotational speed condition.     

On the relation between micro- and macroscopic fatigue crack growth rates in aluminum alloy AMS 7475-T7351

This paper discusses the relationship between striation spacing, i.e., the microscopic crack propagation rate, as measured in postmortem fractographic inspection of fatigue fractured surfaces, and the macroscopic crack propagation rate, i.e., da/dN, as monitored during fatigue crack growth tests. Compact tensile specimens C(T) in prevalent plane-strain conditions were extracted in LT orientation from the center of a 2-in. thick rolled plate of a SAE-AMS 7475-T7351 Al alloy. Testpieces were fatigue tested according to ASTM-E647 standard, at room temperature in a servo-hydraulic closed-loop MTS testing machine operating with the unloading elastic compliance technique. da/dN-ΔK data points were collected in the Paris’ law validity region, with crack growth rates typically ranging from 0.18 to 2.02 μm/cycle. Topographical survey was conducted on the test specimen fracture surfaces in a scanning electronic microscope in order to determine striation spacing created during the fatigue test. Macro- and micro-crack growth rates were compared and good correlation have been obtained for the data within the range of ΔK assessed in the study. Results of crack growth rates have been quantitatively evaluated in terms of fatigue life estimation.     

Fatigue behaviour and life prediction of fibre reinforced metal laminates under constant and variable amplitude loading

ABSTRACT Fatigue crack growth of fibre reinforced metal laminates (FRMLs) under constant and variable amplitude loading was studied through analysis and experiments. The distribution of the bridging stress along the crackline in centre‐cracked tension (CCT) specimen of FRMLs was modelled numerically, and the main factors affecting the bridging stress were identified. A test method for determining the delamination growth rates in a modified double cracked lap shear (DCLS) specimen was presented. Two models, one being fatigue‐mechanism‐based and the other phenomenological, were developed for predicting the fatigue life under constant amplitude loading. The fatigue behaviour, including crack growth and delamination growth, of glass fibre reinforced aluminium laminates (GLARE) under constant amplitude loading following a single overload was investigated experimentally, and the mechanisms for the effect of a single overload on the crack growth rates and the delamination growth rates were identified. An equivalent closure model for predicting crack‐growth in FRMLs under variable amplitude loading and spectrum loading was presented. All the models presented in this paper were verified by applying to GLARE under constant amplitude loading and Mini‐transport aircraft wing structures (TWIST) load sequence. The predicted crack growth rates are in good agreement with test results.     

An investigation on the high stress sensitivity of fatigue life of rolled AZ31 magnesium alloy under constant amplitude fatigue loading

In the present work, an investigation on the high stress sensitivity of the fatigue life of the AZ31 rolled magnesium alloy under constant amplitude fatigue loading has been carried out. Different damage parameters were involved to quantify fatigue damage accumulation at the various scales of material volume corresponding to the changing fatigue damage mechanisms that prevail at the various stages of the fatigue life. The experimental work included mainly nano‐indentation measurements to evaluate hardness evolution at the nano‐scale due to cyclic plasticity, results of micro‐crack monitoring by using the replication technique and fractographic analysis to obtain the fracture characteristics of the fatigue specimens after failure. The hexagonal close‐packed structure of the alloy and the resulting difficulty for the activation of five independent slip systems required for homogeneous plastic deformation were considered to determine the high stress sensitivity of the fatigue life observed for the rolled AZ31 alloy under the investigated loading conditions.     

Grain size effects in a Ni-based turbine disc alloy in the time and cycle dependent crack growth regimes

The fatigue crack growth (FCG) behaviour in a Ni-based turbine disc alloy with two grain sized variants, in a low solvus high refractory (LSHR) superalloy has been investigated under a range of temperatures (650–725 °C) and environments (air and vacuum) with trapezoidal waveforms of 1:1:1:1 and 1:20:1:1 durations at an R = 0.1. The results indicate that a coarse grained structure possesses better FCG resistance due to the enhanced slip reversibility promoted by planar slip as well as the reduction in grain boundary area. The fatigue performance of the LSHR superalloy is significantly degraded by the synergistic oxidation effect brought about by high temperature, oxidising environment and dwell at the peak load, associated with increasingly intergranular fracture features and secondary grain boundary cracking. Secondary cracks are observed to be blocked or deflected around primary γ′, carbides and borides, and their occurrence closely relates to the roughness of the fracture surface, FCG rate and grain boundary oxidation. The apparent activation energy technique provides a further insight into the underlying mechanism of the FCG under oxidation–creep–fatigue testing conditions, and confirms that oxidation fatigue is the dominant process contributing to the intergranular failure process. At high enough crack growth rates, at lower temperatures, cycle dependent crack growth processes can outstrip crack-tip oxidation processes.     

Nonsteady crack and craze behavior in PMMA under cyclical loading: III. Effect of load history on cohesive force distribution on the craze

Measurements of crack opening and craze profiles are made under a range of loading histories including cyclical deformations that lead to nonsteady crack propagation histories. Of particular interest is the comparison of the distribution of traction transmission of a newly formed craze relative to a cyclically stressed one as it approaches the slow-down phase. Real time, interferometric measurements provide precise and multiple craze profiles during individual cycles. Cyclic deformations reduce the stiffness of a craze in its center resulting in a stress drop as part of the craze strength evolution; also, its thickness changes nonuniformly during the acceleration/retardation phases of the advancing craze/crack. The implications are, that for quasi-statically formed crazes the craze material can be reasonably well characterized by a stress-strain relation, while that is no longer readily true for a cyclically deforming crack, since rate dependent characteristics of the craze and bulk material intervene. Cracks unloaded as part of cyclical deformation histories exhibit crack closure (compression) near the trailing end of the craze. This revised version was published online in July 2006 with corrections to the Cover Date.     

Influence of microstructure on fatigue crack propagation under bending in the alloy Ti–6Al–4V after heat treatment

The paper presents the test results obtained for fatigue crack growth in Ti–6Al–4V titanium alloy subjected to bending. The tests were performed in plane specimens with the stress concentrators being a one‐sided sharp notch. The tested specimens were made of the oxygenated Ti–6Al–4V subjected to various variants of heat treatment. The tests were carried out at the fatigue test stand MZGS‐100 under loading frequency 28.4 Hz. From the obtained results of fatigue and structural tests it appears that schemes of crack propagation and fatigue lives of the considered alloy are different depending on a structure obtained as a result of a given heat treatment.