Abstract
Damage tolerant fatigue design in MMCs relies on the assessment of initial and final damage states and on the determination of damage accumulation rates. Fibre reinforced MMCs tend to have inherent manufacturing defects in the form of micro-cracks or broken fibres due to the relaxation of matrix residual stresses and due to machining. For most materials the final outcome of damage accumulation is either crack arrest or failure. In MMCs however, another type of damage accumulation is the unstable crack growth which can be considered as an alternative failure condition. The domains of these three damage zones and the bounds for arrest, failure and unstable crack growth are established within the confines of a damage map. Within these bounds, fatigue damage accumulates at a rate dictated by the degree of fibre bridging, fibre/matrix debonding and fibre failure. A micro-mechanical model for crack propagation which incorporates explicitly these mechanisms is presented and used to estimate a practical limit of failure-safe fatigue crack growth for a SCS6/Ti-15-3 composite.
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