CRACK INITIATION AND SMALL FATIGUE CRACK GROWTH BEHAVIOUR OF SQUEEZE-CAST Al-Si ALUMINIUM ALLOYS

Abstract— Fatigue strength, crack initiation and small crack growth behaviour in two kinds of squeeze-cast aluminium alloys, AC8A-T6 and AC4C-T6 were investigated using smooth specimens subjected to rotatary-bending fatigue at room temperature. Fatigue resistance of these alloys was almost the same as that of the wrought aluminium alloys because of their fine microstructure and of the decrease in defect size due to squeeze-casting. Fatigue crack initiation sites were at the eutectic silicon particles on the surface of specimens or at internal microporosity in the specimens. Crack initiation life, defined as a crack length of 50 μm on the specimen surface, was successfully estimated from an evaluation of initiation sites using fracture mechanics and the statistics of extrema. Small fatigue crack growth in the two kinds of alloys obeys the relation proposed by Nisitani et al. , namely that d(2c)/d N = C (σ_a/σ_B)ⁿ· (2 c ), where C is a constant and σ_B is the ultimate tensile strength. It is pointed out that an improvement in fatigue strength of cast aluminium alloys can be expected by refining the eutectic silicon rather than by an increase in static strength.     

MICROSTRUCTURAL AND ENVIRONMENTAL EFFECTS ON FATIGUE CRACK PROPAGATION IN DUPLEX STAINLESS STEELS

Abstract— Fatigue crack initiation and propagation in duplex stainless steels are strongly affected by microstructure in both inert and aggressive environments. Fatigue crack growth rates in wrought Zeron 100 duplex stainless steel in air were found to vary with orientation depending on the frequency of crack tip retardation at ferrite/austenite grain boundaries. Fatigue crack propagation rates in 3.5% NaCl solution and high purity water are increased by hydrogen assisted transgranular cyclic cleavage of the ferrite. The corrosion fatigue results are interpreted using a model for the cyclic cleavage mechanism.     

Ti单晶及多晶与孪晶相关的疲劳裂纹萌生

研究了高纯Ｔｉ单晶在ＳＥＭ中循环变形及多晶在拉－压对称疲劳和反复弯曲疲劳时与孪晶相关的疲劳裂纹萌生，发现除孪晶界外，循环孪晶带内孪晶与孪晶的碰撞、孪晶内部沿特定面以及孪晶撞击晶界也诱发了疲劳裂纹。     

FRICTIONAL EFFECTS ON FATIGUE CRACK GROWTH IN β -ANNEALED Ti-6Al-4V

Abstract— The crack tip cyclic heat generation rate, fatigue crack growth rate, and the crack closure stress were measured in a β-annealed Ti-6Al-4V for R ratios of -0.1, 0.1 and 0.2. The R = -0.1 and 0.1 cases exhibited macroscopic crack closure and the R = 0.2 case exhibited no macroscopic crack closure as measured by strain gage techniques. There was a transition in the slope of the da/dN vs Δ K curve for the closure cases and no transition for the no-closure case. The crack tip heat generation rate above the transition for the closure cases was an order of magnitude greater than for the no-closure case. Also the crack tip heat generation rate below the transition was greater for the closure cases than for the no-closure case. The transition in the heat generation rate and the crack growth rate was attributed to a transition from static frictional locking of shear branch cracks to sliding of the branch crack surfaces. Below the transition the crack faces are locked open creating a large roughness-induced closure component. When the branch cracks are allowed to undergo reverse shear, the amount of roughness-induced closure markedly decreases and the fracture surface becomes less tortuous. The relative sliding generates the increased heat.     

FATIGUE CRACK INITIATION IN ALUMINIUM ALLOYS UNDER PROGRAMMED BLOCK LOADING

Abstract— Tests for fatigue crack initiation were carried out on two different aluminium alloys. Results and analysis of initiation under constant amplitude loading are presented; elastic and elastoplastic analyses are applied. Initiation under programmed block loading is investigated and damage accumulation is discussed. Tests were performed on two notch root radii:5 and 0.5mm. The electric potential method was used to detect fatigue crack initiation. Three point bending tests on smooth specimens were carried out to follow the evolution of damage during the crack initiation phase.     

疲劳裂纹萌生的细观效应

Ｘ射线衍射分析表明，在疲劳极限载荷下循环加载１０＾７次事，退火态１６Ｍｎ在厚度约３个铁素体晶粒大小的表层内，３００Ｍ钢在厚度经１５个原奥氏体晶粒大小的表层内，喷丸强化３００Ｍ钢在距表面２００－３２０μｍ的亚表层内发生ＸＲＤ效应的明显变化。     

A MODEL FOR SMALL FATIGUE CRACK GROWTH

Abstract— Based on the assumption that normalized Kitagawa-Takahashi diagrams for different materials are the same, a unified model for microstructurally small fatigue crack and physically small fatigue crack growth rates was developed to describe their behaviour under different fatigue stress ranges. The stress-sensitive blocking effect of microstructural barriers to small fatigue crack growth is satisfactorily simulated by the model. Incorporated with the materials fatigue limit and microstructural barrier spacing, this model can be easily used in the prediction of small fatigue crack lifetime. Small fatigue crack growth rates of previous experimental studies in 7075-T6 Aluminium alloy and HT60 steel under different stress ranges are in an envelope between two boundary prediction curves corresponding to the largest and smallest stress ranges applied in the experiments. Problems concerning model accuracy and model application are also discussed in the present paper.     

PREDICTION OF THE COMPETITION BETWEEN SURFACE AND INTERNAL FATIGUE CRACK INITIATION IN PM ALLOYS

Abstract— Low cycle fatigue (LCF) testing of powder metallurgy (PM) superalloys has determined that LCF cracks initiate from defects such as pores and ceramic inclusions located either at the surface or internally. The ratio of surface-to-internal crack initiation sites depends upon experimental conditions. In the current work, a probabilistic model is presented that describes the competition between these two failure mechanisms from a single experimental parameter, μ. The model predicts the size distribution of defects which initiate LCF cracks, as well as the proportion of specimens which fail as a result of internally located defects. Model predictions were found to correlate well with experimental LCF data obtained from a N18 PM Ni-base superalloy. The model further enables evaluation of a "size effect", as it predicts that internal crack initiation is favoured for larger components/specimens.     

SMALL CRACK GROWTH IN THE ALUMINIUM–LITHIUM ALLOYS 8090 AND 8091

The relationship between microstructure and the fatigue behaviour of small cracks has been examined for the aluminium–lithium alloys 8090 and 8091 after peak ageing at 170°C. Duplex ageing and pre-stretching were used to vary the distribution of S'precipitates and thus the distribution of slip. No effect of S'distribution an small crack growth was observed in either alloy. This is thought to be due to a combination of the lack of closure and lower overall slip reversibility in small cracks. Small cracks in 8091 were found to grow slower than in 8090 due to differences in grain shape rather than texture. Small cracks in both alloys were observed to grow much faster than long cracks for equivalent ΔKs. This difference was reduced when small crack data were compared with long crack data generated at R= 0.7 due to the reduced closure. The use of ΔJ made long and small crack growth rates still more comparable.     

AN EXPERIMENTAL AND STATISTICAL INVESTIGATION OF SURFACE FATIGUE CRACK INITIATION AND GROWTH

Surface fatigue crack studies were carried out and statistically analysed from rotating bend fatigue tests in the high cycle region for three metals, copper, stainless steel and mild steel with four ferrite grain sizes. Quantitative observations of the initiation and growth behavior, including coalescence of closely spaced cracks, are discussed and a limiting condition for coalescence is proposed. Statistical properties of initiation, propagation and propagation rate of surface cracks are examined and the effect of different metals and grain sizes is discussed.     

SLOW FATIGUE CRACK GROWTH AND THRESHOLD BEHAVIOUR IN AIR AND VACUUM OF COMMERCIAL ALUMINIUM ALLOYS

Abstract— Fatigue crack growth and threshold behaviour have been examined in three commercial aluminium alloys in both air and vacuum environments. It was observed that, in air, the threshold stress intensity range Δ K _t, varied linearly with the Δ K _t ratio. In contrast Δ K , in vacuum was found to be independent of R. Over the whole growth rate range examined fatigue crack growth in vacuum was Δ K controlled and failure occurred by a dimple and ductile striation mechanism. This also applied to failure in the intermediate growth rate ranges in air. However, at slow growth rates in air, fatigue crack growth was structure sensitive and crystallographic facets were formed during the crack propagation process.     

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.     

ON FATIGUE CRACK GROWTH AND STABLE TEARING

Abstract— An experimental and analytical investigation has been performed to examine the effect of concurrent fatigue cycling and stable tearing on the crack growth fracture resistance of EN3A steel at 360°C. The steel was tested in the as-received and hardened conditions, hardening being achieved by pre-cracking at a load comparable to the elastic limit of the test specimens. For each condition of the steel, resistance curves are obtained both with and without concurrent fatigue cycling.
A significant increase in the crack growth rates occurred as a result of concurrent fatigue cycling. The rates are in reasonably close agreement with the values predicted from the sum of the fatigue crack growth and stable tearing components. The J-estimation formula of Ainsworth is used to demonstrate that there is no interaction between stable tearing and fatigue in the tests for the steel in the as-received condition.     

残余应力与胶粘剂对ARALL层板疲劳裂纹扩展特性的影响

研究了粘剂性质、含量及残余应力状态对纤维－铝合金胶接层板（ＡＲＡＬＬ）疲劳裂纹扩展特性的影响，分析了裂纹扩展过程中的分层状态的变化，结果表明，ＡＲＡＬＬ层板内富胶层的剪切形变和伴随裂纹扩展的分层区越大，即这两方面耗散能量越多，则疲劳裂纺扩展速率越低；胶粘剂含量的影响不明显，给层板施加预应力极大降低了层板的疲劳裂纹扩展速率，其本质在于裂尖在同样的疲劳载荷下实际所受到的有效应力降低。     

CRACK INITIATION MECHANISMS IN TORSIONAL FATIGUE

Abstract— The development of fatigue damage in Co45Ni specimens during push—pull and reversed torsion tests, performed inside a scanning electron microscope, was observed and the different stress states compared. It appeared that transgranular crack initiation and development is delayed and intergranular crack initiation promoted under torsional loading. This was explained in terms of reduced surface distortion at the emergence of persistent slip bands (PSBs) and smaller compatibility stresses at the PSB-matrix interfaces. The influence of the mechanical strength of grain boundaries on the difference between tensile and torsional fatigue lives is discussed.     

FATIGUE CRACK GROWTH BEHAVIOUR IN MOLTEN-METAL PROCESSED Sic PARTICLE-REINFORCED ALUMINIUM ALLOYS

Fatigue crack initiation and subsequent short crack growth behaviour of 2014-5wt%SiC aluminium alloy composites has been examined in 4-point bend loading using smooth bar specimens. The growth rates of long fatigue cracks have also been measured at different stress ratios using pre-cracked specimens. The distributions of Sic particles and of coarse constituent particles in the matrix (which arise as a result of the molten-metal processing and relatively slow cooling rate) have been investigated. Preferential crack initiation sites were found to be Sic-matrix interfaces, Sic particles associated with constituent particles and the coarse constituent particles themselves. For microstructurally short cracks the dispersed SiC particles also act as temporary crack arresters. In the long crack growth tests, higher fatigue crack growth rates were obtained than for monolithic alloys. This effect is attributed to the contribution of void formation, due to the decohesion of Sic particles, to the fatigue crack growth process in the composite. Above crack depths of about 200 μm “short” crack growth rates were in good agreement with the long crack data, showing a Paris exponent, m= 4 in both cases. For the long crack and short crack growth tests little effect of specimen orientation and grain size was observed on fatigue crack growth rates, but, specimen orientation affected the toughness. No effect of stress ratio in the range R=0.2-0.5 was seen for long crack data in the Paris region.     

PREDICTING THE EFFECTS OF LOAD RATIO ON THE FATIGUE CRACK GROWTH RATE AND FATIGUE THRESHOLD

The effect of the load ratio, R, on fatigue crack growth behaviour is analysed on the basis of the recently proposed inelastic discrete asperities model. A wide range of load ratios, both positive and negative, are examined. Particular emphasis is placed on compressive excursions, i.e. negative R loadings. The inelastic discrete asperities model is a micro-mechanical analysis based on the plastic crushing of a single asperity (or multiple asperities) located on the crack face close to the crack tip and under dominantly plane strain conditions. Experimental data have indicated that the primary crack face contacts which obstruct closure are immediately adjacent to the crack tip, although segments of the crack face more distant from the crack tip are not neglected. However, the more distant asperities are a part of the past crack advance history which does not influence current behaviour. By use of this model, it is shown that the effect of the load ratio can be adequately predicted once some baseline information on mechanical material properties and surface roughness is provided. The model also provides useful trend information and explains many of the observed phenomena, e.g. the ‘saturation’ of the compressive underload effects. For a constant applied nominal stress intensity factor range, ΔK_nom , it is shown that the effective stress intensity factor range, ΔK_eff , initially decreases as the positive R decreases (corresponding to the increasing influence of closure), reaches a minimum around R = 0, and then starts increasing with negative R (corresponding to the plastic crushing of the asperities which reduces closure), eventually reaching a saturation level below ΔK_nom . Conversely, for an assumption of a constant ΔK_eff , the applied ΔK_nom increases as the positive load ratio decreases, reaching a maximum around R = 0, and then decreases with more negative R values, eventually reaching again a saturation level (above ΔK_eff ). It is also shown that the effect of material hardness can be directly analysed based on this model.