The effect of the stress ratio on fatigue crack growth in a 3% NaCl solution

Corrosion fatigue crack growth tests have been carried out at various stress ratios for a low alloy steel SNCM 2 and type 304 stainless steel.

Measurements of the effective stress intensity factor range ratio U were performed to explain the effect of stress ratio R.

The corrosive environment decreased da/dN at R = 0.1, 0.4 and little affected da/dN at R = 0.9 for SNCM 2 and increased da/dN at all R ratios for SUS 304.

It was confirmed that there exists a threshold stress intensity factor ΔK_thCF in 3% NaCl solution for both materials tested.

The corrosive environment decreased ΔK_thCF for all conditions tested except at R = 0.1 and 0.4 for SNCM 2, where ΔK_thCF-values were nearly equal to ΔK_th-values in air. ΔK_thCF/ΔK_th was 0.6 at R = 0.9 for SNCM 2 and 0.8, 0.5 and 0.7 at R = 0.1, 0.7 and 0.9 for SUS 304, respectively.

It was shown that the complicated effect of stress ratios on crack growth for SNCM 2 can be explained using effective stress intensity factor ΔK_eff.     

Statistical evaluation of fatigue crack propagation properties including threshold stress intensity factor

The relationship between fatigue crack propagation rate, da/dn, and range of stress intensity factor, ΔK, including threshold stress intensity factor, ΔK_th, is analyzed statistically. A non-linear equation, da/dn = C{(ΔK)^m-(ΔK_th)^m}, is fitted to the data by regression method to evaluate the 99% confidence intervals. Several experimental results on fatigue crack propagation properties of welded joints are compared by using these confidence intervals.     

Fatigue crack initiation and growth under mixed mode loading in aluminum alloys 2017-T3 and 7075-T6

Fatigue crack initiation and growth characteristics under mixed mode loading have been investigated on aluminum alloys 2017-T3 and 7075-T6, using a newly developed apparatus for mixed mode loading tests. In 2017-T3, the fatigue crack initiation and growth characteristics from a precrack under mixed mode loading are divided into three regions—shear mode growth, tensile mode growth and no growth—on the ΔK_I-ΔK_II plane. The shear mode growth is observed in the region expressed approximately by ΔK_II > 3MPa√m and ΔK_II/ΔK_I > 1.6. In 7075-T6, the condition of shear mode crack initiation is expressed by ΔK_II > 8 MPa√m and ΔK_II/ΔK_I > 1.6, and continuous crack growth in shear mode is observed only in the case of ΔK_I/ΔK_II, 0. The threshold condition of fatigue crack growth in tensile mode is described by the maximum tensile stress criterion, which is given by Δσ_θmax √2πr 1.6MPa√m, in both aluminum alloys. The direction of shear mode crack growth approaches the plane in which K_I decreases and K_II increases towards the maximum with crack growth. da/dN-ΔK_II relations of the curved cracks growing in shear mode under mixed mode loading agree well with the da/dN-ΔK_II relation of a straight crack under pure mode II loading.     

Influence of R on effective stress range ratio and crack growth

The influence of stress ratio R and stress intensity range ΔK on crack closure and fatigue crack growth were studied. Crack closure and crack growth experiments were performed on 6063-T6 Al alloy. Crack closure stresses were measured using a surface-measurement technique with a COD gauge. The gauge was placed at different locations behind the crack tip, and it was found that the location of the gauge does not influence the closure load. The closure load was however found to be a function of R and ΔK. Fatigue crack growth rate is found to depend upon R, U and ΔK. A model for both U and da/dN has been developed.     

Temperature dependence of stage II fatigue crack growth rate

A critical assessment has been performed by compiling experimental data concerning the temperature dependence of stage II fatigue crack growth. For aluminium alloys, high strength steels, austenitic stainless steels and superalloys, the power coefficient, m, for the Paris relationship is temperature dependent and all ln(da/dN) vs ln(ΔK) curves cross at one point, designated as the pivot point (PP), which is a material-dependent parameter. The assumption is made that PP corresponds to a transition point for the fatigue crack growth mechanism.     

Fatigue crack growth characteristics of rotor steels

Room temperature fatigue crack growth rate data were generated for Ni-Mo-V (ASTM A469, Cl-4), Cr-Mo-V (ASTM A470, Cl-8) and Ni-Cr-Mo-V (ASTM A471, Cl-4 and a 156,000 psi yield strength grade) rotor forging steels. Testing was conducted with WOL type compact toughness specimens and the results presented in terms of fracture mechanics parameters. Data show that the Ni-Cr-Mo-V steels exhibit slower fatigue crack growth rates at a given stress intensity range (ΔK) than do the Ni-Mo-V steels. In addition, the Cr-Mo-V steel was found to exhibit slower growth rates than the other alloys at ΔK levels below 40 ksi √in but somewhat foster rates at ΔK levels in excess of 45 ksi √in. The fatigue crack growth rate properties of the alloys studied conform to the generalized fracture mechanics crack growth rate law where da/dN = C₀ΔK^R. It was noted that the fatigue crack growth rate parameters n and C₀ tend to decrease and increase, respectively, with increasing material toughness, K_ic.     

Fatigue crack-growth characteristics of two magnesium alloys

Magnesium alloys are being increasingly used for engineering applications. Fatigue crack-growth data have therefore been obtained for a high strength magnesium-Zr alloy and a medium strength, weldable magnesium-Mn alloy. The results of tests on sheet material are presented in terms of the range of stress intensity factor ΔK. Critical values of ΔK necessary for fatigue crack growth ΔK_c were also obtained. The behaviour of the two alloys was similar; both rates of crack growth and ΔK_c were sensitive to mean stress. Fatigue crack growth was entirely on a 90° plane with no sign of the transition to crack growth or 45° planes usually observed in sheet materials. This was ascribed to the effects of preferred orientation of the crystal structure.     

On the calculation of closure-free fatigue crack propagation data in monolithic metal alloys

A computational method is described for the determination of ΔK_b, corresponding to a fatigue crack growth rate of b/cyc, where b is the Burgers vector for a monolithic metal alloy. ΔK_b is found to be numerically equal to E√b for the case of closure-free crack growth behavior. Given that the closure-free FCP rate of many monolithic metals varies with ΔK³, the growth rate of metal alloys at ΔK ΔK_b is given by da/dN = (ΔK/E)³(1/√b. Excellent agreement is found between experimental and computed FCP data for the case of monolithic metal alloys. The limits of these relations for metal-matrix composites and ceramics are discussed.     

Low frequency fatigue crack growth behavior of a470 class 8 rotor steel at 538°C (1000°F)

Fatigue crack growth rate data were developed at various frequencies and hold times at maximum load for A470 Class 8 steel at 538°C (1000°F) by using an accelerated test method which involves alternating test frequency and temperature. These data were consistent with fatigue crack growth rate data obtained from the same material and developed according to the ASTM specification E-647-T78. This result suggests that there is no transient effect associated with the alternating test frequency and temperature and that the accelerated testing procedure can be used to expedite the development of elevated temperature fatigue crack growth rate data at very low frequencies and long hold times. At 538°C (1000°F) fatigue crack growth properties with hold time developed from both 1T-CT and multiple-edge-craek tension specimens fall in the same scatter band on the da/dN vs ΔK plot. This result indicates the applicability of ΔK to characterize the fatigue crack growth behavior with hold time at elevated temperature. Also, the model proposed by Saxena et al. was found to successfully predict the fatigue crack growth rate properties with 28 min hold time of the A470 Class 8 rotor steel at 538°C (1000°F).     

A model for predicting fatigue crack growth behaviour of a low alloy steel at low temperatures

In the present study, a model to predict the fatigue crack growth (FCG) behaviour at low temperatures is proposed for a low alloy steel (16 Mn). The experimental results indicate that fatigue ductile-brittle transition (FDBT) occurs in 16 Mn steel and the FDBT temperature (T_FDBT) is about 130 K. When T > T_FDBT, the FCG mechanism in the intermediate region is the formation of ductile striation and the FCG rates decrease with decreasing temperature. When T ≈ T_FDBT, the FCG mechanism changes into microcleavage and the fatigue fracture toughness K_fc of the steel decreases sharply. The FCG rates tend to increase as the temperature is further reduced. The test data of the FCG rates are well fitted by the formula developed by Zheng and Hirt. An approximate method to predict ΔK_th of the steel at low temperatures is proposed and then a general expression of the FCG rates is given at temperatures ranging from room temperature to T_FDBT. By means of the expressions proposed in this paper, the FCG rates at low temperatures can be predicted from the tensile properties if the endurance limit σ₋₁ and δk_th, at room temperature are known. Finally, a model for FDBT is tentatively proposed. Using this model, one can predict T_FDBT from the ductile-brittle transition curve determined from impact or slow bending tests of cracked Charpy specimens.     

Shear lips on fatigue fractures in aluminium alloy sheet material

An analysis is made of shear lip width measurements and the transition of tensile mode fatigue cracks to shear mode fatigue cracks, as observed on fatigue crack surfaces of aluminium alloy sheet material. It could be shown that these phenomena were controlled by ΔK_eff, rather than K_max or ΔK. For crack growth in air the shear lip width was approximately proportional to (ΔK_eff)², but it was significantly larger than the estimated size of the reversed plastic zone. The initiation of shear lips, the transition from plane stress to plane strain along the crack front and the environmental effect on shear lips are briefly considered in the discussion.     

Exploring the fracture toughness KIE and KIC of a medium-Strength steel plate using the surface-flaw test

The fracture toughness of a 30 CrMnSiA steel plate of three thicknesses (10,8 and 5 mm) and three widths (110,80 and 56 mm) has been investigated by using surface-flaw method under room temperature. It is not easy to compute the value of K_IE by the maximum applied load. But the values of K_IE and K_IC could be obtained easily, if the computation of the conditional applied load P₁₀ and P₅ based on the relative effective extension Δa/a₀ = 10% and 5% were adopted, together with the conditions of P_max/P₁₀ 1.2 and P_max/P₅ 1.3. The K_R — Δ_a curve, i.e. the resistance-curve described by the parameter K, has been plotted. The values of K_IC and K_IE are then the resistances corresponding to the real extensions of flaws of Δ/a₀ = 2 and 7%, respectively. These values so obtained are in good agreement with the computed values of K_IC and K_IE by using the conditional applied loads. The values of K_IC and K_IE so obtained are also in agreement with the value of K_IC converted from the J-integral and the effective value of K_IE computed by the maximum applied load, respectively.

An approximate relation between K_IC and K_IE has been found to be: K_IC = (0.85˜0.95)K_IE.

The requirements for the dimensions of specimens are: Thickness of plate: B 1.0(K_IC/σ_0.2)² or 1.25(K_ICσ_0.2)²]; Width of plate: 8 W/B 10, 4 W/2c 5; Effective length: l 2W.     

Threshold range and opening stress intensity factor in fatigue

The fatigue threshold, ΔK_th, is strongly influenced by the stress-ratio, ie by the loading conditions. Results for a Ti6A14V alloy show that a ΔK exists for non-propagating fatigue cracks which is independent of loading conditions. This ΔK is called the fatigue tolerance range and is denoted by ΔK^K. The fatigue tolerance range corresponds to that part of the ΔK_th during which the fatigue crack is open. Arguments that the fatigue tolerance range has to be explicitly incorporated in equations predicting fatigue crack growth rates are presented.     

The crack initiation and growth under high temperature creep, fatigue and creep-fatigue multiplication

This article concerns some of our recent studies on the crack initiation, early stage crack growth and its subsequent crack growth under high temperature creep, fatigue and creep-fatigue multiplication. The criteria for these and some new ideas are proposed. For instance, the relative notch opening displacement (RNOD) criterion for the crack initiation and the Q^* parameter for the crack growth are critically reviewed. Early stage crack growth and its subsequent crack growth as affected by notch tip acuity were studied. The behaviour of the tail part in the log da/dN vs log C^* curve has been attempted to explain in terms of the curve of the creep behaviour and of the crack length against time. Furthermore it was proposed that early stage crack growth, say, the so-called first stage crack growth in terms of log da/dN vs log K curve may be characterized by the parameter different from those for the so-called second stage crack growth.     

Effects of welding residual stresses on fatigue crack growth behaviour in butt welds of a pipeline steel

In the present test the fatigue crack growth rate in the parent plate, weld and cross-bond regions was measured and the results were correlated with the stress intensity range ΔK and the effective stress intensity range ΔK_eff. It is indicated that the welding residual stresses strongly affect the crack growth rate. For the weld metal and cross-bond compact tension specimens in which crack growth is along the weld line the fatigue crack growth rate increases as the crack grows. However, for the T compact tension specimen in which crack growth is perpendicular to the weld line at a constant value of applied ΔK the crack growth rate initially decreases as the crack grows. Particularly, at a low constant value of applied ΔK the crack growth rate obviously decreases and the crack fails to grow after short crack growth. When the crack grows to intersect the welded zone, the fatigue crack growth rate gradually increases as the crack grows further. It is clear that the effect of welding residual stresses on the crack growth rate is related to the position of the crack and its orientation with respect to the weld line. Finally, the models of welding residual stress redistribution in the compact tension specimens with the growing crack and its influence on the fatigue crack closure are discussed. It appears that for a butt-welded joint one of the crack closure mechanisms may be considered by the bend or rotation deformation of crack faces due to the welding residual stress redistribution as the fatigue crack grows in the welded joint.     

Effects of corrosive environments on near-threshold fatigue crack growth behavior of T1-6A1-4V

The near-threshold fatigue crack growth behavior of Ti-6A1-4V alloy has been investigated in low O₂ steam (< 1 ppm), high O₂ steam (40ppm), and boiling water with various concentrations of Nad and/or Na₂₂SO₄. At load ratio (R) of 0.5, high O₂ steam increased the crack propagation rates in the threshold region, relative to low O₂ steam. However, at R = 0.8, the near-threshold crack growth rates in low and high O₂ steam were comparable. Values of threshold stress intensity range, ΔK_th, slightly increased with an increase in the concentration of NaCl in the solution. Varying solution pH from 5.0 to 10.0 in a 0.1 g NaCl plus 0.1 g Na₂SO₄ per 100ml H₂O solution had no effect on the rates of near-threshold crack propagation. Increasing the hydrazine level from 30 to 10⁷ ppb in the same salt solution also did not change the resistance to crack growth. Comparing the present results with the previous data on 403 stainless steel, the near-threshold crack propagation rate performance in Ti-6Al-4V alloy is superior to that in 403 steel in both the steam and salt solution environments.     

The micropolar thermoelastic problem of uniform heat-flow interrupted by an insulated penny-shaped crack

The classical problem of uniform heat-flow disturbed by an insulated penny-shaped crack is solved in the context of micropolar elasticity. The mode II stress intensity factor, K_II is found to depend on two new non-dimensional parameters N and τ − N is a measure of the coupling of the displacement field with the microstructure or the medium (0 N √2) and τ is the ratio of a material characteristic length to the crack radius. K_II remains higher than its classical value when N > 0, τ > 0 and attains the classical value as N and τ vanish. A closed-form expression to K_II is obtained in the physically important limiting case of τ → 0 with N fixed. In this limit the relative increment in K_II, over its classical value, is found to be (1 − v')N² where v' is the micropolar Poisson's ratio.     

Resistance-curve method for predicting propagation threshold of short fatigue cracks at notches

A new resistance-curve method was proposed for predicting the growth threshold of short fatigue cracks near the notch root. The resistance curve was constructed in terms of the experimentally determined threshold value of the maximum stress intensity factor which was the sum of the threshold effective stress intensity range ΔK_effth and the opening stress intensity factor K_opth The ΔK_effth value was constant, irrespective of crack length or notch geometry. The relation between K_opth and crack length was independent of notch geometry. The predicted effects of the notch-root radius and the notch depth on the propagation threshold of short fatigue cracks were compared with the experimental data obtained using center-notched specimens with various notch-root radii and single-edge notched specimens with various notch depths. Excellent agreement was obtained between predictions and experiments.     

Probabilistic description of fatigue crack growth in polycrystalline solids

A stochastic model describing the crack evolution and scatter associated with the crack propagation process has been built on the basis of the discontinuous Markovian process. The evolution and scatter are identified in terms of constant probability curves whose equation is derived as In P_r(i) = B(e^KI₀ − e^Ki), i ≥ I₀, where i is the number of cycles, B and K are crack-length-dependent variables, P_r(i) is the probabiliity of the crack being at position r along the fracture surface after i cycles elapse and I₀ is the minimum number of cycles required for the crack to advance from one position on the fracture surface to the next. The validity of the model is established by comparing the crack growth curves generated for Al 2024-T3 at a specific loading condition with those experimentally obtained.     

Studies on fracture toughness and fractographic features in Fe---Mn base alloys

Fractographic examinations of fracture surfaces of single edge crack plate tension fracture toughness test specimens of some new Fe---Mn base maraging alloys have been conducted. The interrelations between the fractographic features, fracture toughness and other mechanical properties of these alloys have been studied. It is observed that the width of the stretched zone between fatigue and rapid fracture is related to K/σ_ys of the material where K is either K_IC, K_Q or the stress intensity for onset of microscopic slow crack growth. The stretched zone width is approximately equal to the average dimple size. Also it is of the order of the process zone size (calculated by modified Krafft's model) and the critical crack opening displacement in plane strain condition. Hahn and Rosenfield's model to estimate K_Ic was found to show much higher values in those cases where the fracture mode was predominantly cleavage, quasicleavage or intergranular.