Efficient and accurate determination of crack propagation rate without unloading-induced crack closure

Abstract

The accurate delineation of the fatigue crack growth rate (da/dN) model, encompassing the short crack stage, assumes paramount importance in the operation and maintenance of transportation vehicles such as aircraft. Nonetheless, the determination of the da/dN encounters challenges, notably crack closure engendered by unloading observations on the specimen and the attendant issue of exorbitant test expenditures due to low load amplitude (ΔP), thereby impeding the precise establishment of the da/dN model, particularly in the short crack stage. Hence, this study initially posits a novel crack observation methodology employing a self-engineered stress transfer apparatus to sustain the stress (σ) on the specimen at its closure stress (σcl) level post-unloading, thus mitigating the impact of crack closure on crack observation and augmenting the accuracy of da/dN curve determination. Subsequently, building upon this innovation, a fatigue crack propagation (FCP) test protocol tailored for the short crack stage is advanced, principally by substantially augmenting ΔP to surmount the cost constraints of the test, thereby broadening the scope of da/dN curve determination to 10−8 mm/cycle. Lastly, premised on the acquisition of high precision and comprehensive da/dN curves, a da/dN model is posited by integrating with the extant da/dN model, which can comprehensively and precisely delineate the FCP behavior across the entire crack growth spectrum, particularly in the short crack stage. Illustratively demonstrated through a case study on 42CrMo steel crankshaft, a fatigue life (Nf) prediction investigation conducted based on this da/dN model substantiates its efficacy in accurately assessing the FCP behavior of crankshaft materials vis-à-vis existing models, thereby reducing the Nf prediction error by 14.64 %.