Abstract
The increasing use of forged Al-alloy components in automotive vehicles has generated a large quantity of data which shows that a retained forged surface can have a significantly detrimental effect on fatigue performance. Extensive SEM studies of the fatigue crack initiation sites on four point bend S-N samples and the as-forged surface appearance of these and actual components have been undertaken. The results from these studies have shown common features across all the samples examined. These features, rather than the surface roughness, can be associated with multiple fatigue crack initiation sites and explain the observed reduction in fatigue properties.
Highlights
It has long been known that surface finish can have a strong influence on the fatigue performance of metals and alloys
The increasing use of forged Al-alloy components in automotive vehicles has generated a large quantity of data which shows that a retained forged surface can have a significantly detrimental effect on fatigue performance
As part of the Jaguar Land Rover fatigue characterisation process, this effect is quantified from Four Point Bending (FPB) S-N tests and the results obtained used to modify the strain-life (LCF) damage curve
Summary
It has long been known that surface finish can have a strong influence on the fatigue performance of metals and alloys. As part of the Jaguar Land Rover fatigue characterisation process, this effect is quantified from Four Point Bending (FPB) S-N tests and the results obtained used to modify the strain-life (LCF) damage curve. The increasing use of forged and cast-forged Al-alloy components in vehicles has generated a large quantity of such data, which shows that a retained forged surface finish can have a significantly detrimental effect on fatigue performance. The current work examines the surface effect on the fatigue behaviour of a 6082-T6 forged aluminium alloy
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