Crack Initiation Mechanism Research Articles

Fatigue life prediction of film-cooling Hole specimens with initial damage

This study investigates a Nickel-based single crystal (SX) superalloy with femtosecond laser-drilled film-cooling holes (FCHs) under varying temperatures (room temperature, 850 °C, and 980 °C), employing a novel framework for predicting fatigue life based on initial manufacturing damage quantification. For all tested anisotropic SX superalloy specimens (including smooth and FCH specimens), the initial damage state is characterized as an equivalent initial flaw size (EIFS), and an EIFS calculation model considering stress concentration is established. Subsequently, the fatigue crack paths and microstructural characteristics of the FCH specimens at different temperatures are analyzed, elucidating crack initiation mechanisms and propagation patterns. A novel incremental plasticity J-integral driving force for fatigue crack propagation is introduced. By incorporating the closure effect of small crack propagation and employing Markov Chain Monte Carlo simulations for determining crack growth rate probabilities, a more accurate expression for the crack growth rate in relation to ΔJfat − ΔJth is derived. This expression comprehensively captures crack patterns on crystallographic planes and Type I mixed mode behavior. Finally, the total fatigue life of the FCH structures, featuring a threefold dispersion zone in both room and high-temperature environments, is predicted through experimental observations and description of crack growth rates. The predicted outcomes significantly outperform those of the conventional life prediction models reliant on crystal plasticity theory.

High and very high cycle fatigue behavior of an additive manufactured hot-work tool steel

In the present study, the fatigue response of an additive manufactured H13 type hot-work tool steel is investigated across the High Cycle Fatigue (HCF) and Very High Cycle (VHCF) regimes. The primary focus encompasses the interpretation of fatigue strength models, the defect type analysis along with a detailed examination of crack initiation and growth mechanisms. Despite the tremendous development in AM technology, experimental data regarding advanced mechanical properties, and particularly fatigue behavior, are still limited. Here, microstructural analysis of a modified AMed H13 hot-work tool steel, a combination of HCF and VHCF testing methodologies implemented for the characterization of the fatigue behavior, as well as a thorough fractographic analysis of the fractured surfaces were performed. Results are compared with historical data of a conventionally ingot cast and forged grade to assess the influence of the AM process on the fatigue response of H13 hot-work tool steels. It proves to be comparable to the conventionally manufactured grade, showcasing the potential utilization of AM in the production of components used in high-demanding applications, and in hot work tooling applications. However, the type of critical defects identified in the AM grade was found to be process-induced, emphasizing the need to optimize process parameters to reduce both the number and size of defects and also to ensure component reliability and high performance in various industrial applications.

Crystal plasticity-driven evaluation of notch fatigue behavior in IN718

The aim of this study was to establish a method for evaluating notch fatigue behavior through crystal plasticity finite element (CPFE) simulations based on the actual microstructure of the nickel-based alloy Inconel 718 (IN718). Initially, the equivalent plastic strain, εeps, which reflects the comprehensive slip at the grain scale, was employed to analyze the fatigue crack initiation mechanism of IN718, revealing that twinning and triple junctions of grain boundaries were high-risk locations for fatigue crack initiation. Next, fatigue simulations were performed on notched specimens using the CPFE model, with a material-level CPFE model particularly employed at the notch root. The increment of εeps, Δεeps, in a stable cycle was used as the fatigue damage control parameter and correlated with the fatigue life, Nf, revealing that the Δεeps-Nf relationship at material-level satisfied the form of the Mason-Coffin model. Finally, fatigue life prediction of IN718 notched specimens was carried out based on the Δεeps-Nf relationship, with the predicted results falling within the 2-fold scatter band, demonstrating good prediction accuracy.

TiC in-situ strengthening mechanism and crack initiation mechanism of SiC/TC4 composite coatings by laser cladding

SiC/TC4 composite coatings were fabricated successfully on the TC4 surface by varying the laser power, and the effect of TiC in-situ strengthening on the microhardness and wear resistance of coatings was investigated. The results show that SiC is continuously decomposed to generate TiC in situ, and α martensite in the coating is refined at 1000 W, with less TiCm. α martensite in the coating is roughened at 1900 W, with the highest content of TiC dominated by dendritic TiCd and petal-like TiCf, longitudinal cracks emerged from the bonding zone and penetrating through the coating. While the appropriate laser power well balanced the relationship between α-martensite and in situ precipitated phases. The C16 coating has the best performance, with an average microhardness 2.1 times higher than that of the substrate (351.8 HV0.2) and a wear rate of 38.1 % of the substrate, respectively. The wear mechanism of the substrate is abrasive, oxidative and fatigue wear, and the wear mechanism of C16 is mainly abrasive wear. The change of the mechanism is due to the fact that TiC particles play the role of skeleton and support in the coating, which are uniformly distributed around α-martensite, thus inhibiting the plastic deformation of the coating.

Effect of over-ageing on the tensile and torsional fatigue properties of the AlSi7Cu0.5 Mg0.3 precipitation-hardened cast aluminium alloy

The objective of this work is to evaluate the influence of over-ageing on the high cycle fatigue behaviour of the AlSi7Cu0.5Mg0.3 cast aluminium alloy. It is generally accepted that over-ageing has a large influence on the behaviour of these materials, however its effect on the fatigue strength is less understood. This work provides an experimental investigation of the effect of over-ageing on high cycle fatigue strength in both tensile and torsional loading conditions. It is shown that the torsional fatigue strength is more sensitive to over-ageing when compared to the tensile fatigue strength and that the fatigue defect sensitivity is negligible for torsional loads, in contrast to tensile loading conditions. The experimental results indicate that this is due to a change in the crack initiation mechanism, going from initiation in the matrix for torsion loads to initiation from casting defects for tensile loads. An original two-steps approach is proposed to rationalise the effect of over-ageing on the fatigue strength, with particular emphasis on decoupling the respective contributions from defects and the mechanical properties. This approach is used to build normalised Kitagawa-Takahashi diagrams that highlights the reduced defect sensitivity under tensile loads for the most severe over-ageing condition.

Effect of chemical etching time on the fatigue behavior of Ti‐6Al‐4V produced by laser powder bed fusion

AbstractThis study focuses on the evolution of the fatigue strength of Laser Powder Bed Fusion (L‐PBF) produced Ti‐6Al‐4V as a function of the chemical etching finishing process. The aim is to identify the critical fatigue crack initiation mechanisms and the transitions between them in terms of the evolution of the surface micro‐geometry. This is done using three different geometries and six different surface states. The evolution of the crack initiation mechanisms is then used to explain the evolutions of the fatigue strength and the fatigue scatter. Chemical etching affects the fatigue life via a polishing effect, which directly influences both the finite and the high cycle fatigue domains. It is shown that chemical etching makes it possible to obtain fatigue strengths that are almost similar to those of the machined surface. However, it is also observed that etching cannot fully counteract the effects of large surface cavities caused by surface connected porosities.

Hybrid finite element modeling of subsurface-originated spalling in flexible bearings with hoop stresses

The flexible bearing in a harmonic reducer undergoes structural deformation after being mounted on the cam, causing the bearing to operate under a complex stress state. A hybrid finite element model is developed to investigate crack initiation and propagation in flexible bearings with hoop stress under rolling contact fatigue loading. The model is coupled with continuum damage mechanics, and the damage evolution equation takes the maximum shear stress amplitude as the damage-causing stress since the hoop stress inevitably affects the fatigue life. The model is verified by comparison with the fatigue life of the inner ring without hoop stress. The crack initiation and spalling formation mechanisms in the inner ring assembled with the cam are analyzed in detail. Moreover, the effects of contact load and equivalent interference on the inner ring’s spalling morphology and fatigue life are studied.

Fatigue and fracture in dual-material specimens of nickel-based alloys fabricated by hybrid additive manufacturing

The integration of additive manufacturing with traditional processes, termed hybrid additive manufacturing, has expanded its application domain, particularly in the repair of gas turbine blade tips. However, process-related defects in additively manufactured materials, interface formation, and material property mismatches in dual-material structures can significantly impact the fatigue performance of components. This investigation examines the low cycle fatigue and fatigue crack growth behaviors in dual-material specimens of nickel-based alloys, specifically the additively manufactured STAL15 and the cast alloy 247DS, at elevated temperatures. Low cycle fatigue experiments were conducted at temperatures of 950 °C and 1000 °C under a range of strain levels (0.3%–0.8%) and fatigue crack growth tests were conducted at 950 °C with stress ratios of 0.1 and −1. Fractographic and microscopic analyses were performed to comprehend fatigue crack initiation and crack growth mechanisms in the dual-material structure. The results consistently indicated crack initiation and fatigue fracture in the additively manufactured STAL15 material. Notably, fatigue crack growth retardation was observed near the interface when the crack extended from the additively manufactured STAL15 material to the perpendicularly positioned interface. This study highlights the importance of considering yield strength mismatch, as well as the potential effects of residual stresses and grain structure differences, in the interpretation of fatigue crack growth behavior at the interface.

The crack initiation mechanism of steel disc when paired with Fe-PM pad for high-speed train braking

In this study, the Fe-based powder metallurgy (Fe-PM) brake pad was paired with a cast steel brake disc to conduct braking tests on a full-scale flywheel braking dynamometer. We systematically analyzed the morphologies of the worn surfaces and the disc temperatures during braking, uncovering the friction and wear characteristics of the friction pair. As well as highlighted the changes in contact status between the friction pair throughout the braking process, which further affected the pad wear rate and thermal fatigue damage to the brake disc. The wear rate of the pad was 0.16 cm3/MJ during the braking tests at an initial brake speed (IBS) of 250 km/h. However, it rapidly increased to 0.66 cm3/MJ as the IBS rose to 380 km/h, indicating a severe decline in wear resistance as the speed increased. The curves of the instantaneous coefficient of friction (COF) displayed significant fluctuations throughout the single braking process and got more pronounced with the increase in the IBS, similar phenomena also occurred on the measured temperature during each braking test. These were caused by the constant changing of the contact status arose by dynamic equilibrium of the formation, spalling, and regeneration for the third body layer (TBL) on the contact surfaces. Additionally, the changing of the contact status also resulted in an uneven distribution of temperature on the disc surface, which in turn generated a temperature gradient and thermal stress. Concurrently, as the braking continued, high frequency alternating thermal stress (HFATS) on the disc surface was induced by the continuously changing contact status, which was confirmed by finite element method (FEM) simulation. As a result, the brake disc would undergo thermal fatigue after fewer braking cycles, and thermal cracks would appear on the disc surface.

Influences of Pre-Existing Fissure Angles and Bridge Angles on Concrete Tensile Failure Characteristics: Insights from Meshless Numerical Simulations.

The existence of cracks is a key factor affecting the strength of concrete. However, traditional numerical methods still have some limitations in the simulation of crack growth in fissured concrete structures. Based on this background, the numerical treatment method of particle failure in smoothed particle hydrodynamics (SPH) is proposed, and the generation method for concrete meso-structures under the smoothed particle hydrodynamics (SPH) framework is developed. The concrete meso-models under different pre-existing micro-fissure inclinations and bridge angles (the inner tip line of the double pre-existing micro-fissure is defined as a bridge, and the angle between the bridge and the horizontal direction is defined as the bridge angle) were established, and numerical simulations of the crack propagation processes of concrete structures under tensile stress were carried out. The main findings were as follows: The concrete meso-structures and the pre-existing micro-fissures all have great impacts on the final failure modes of concrete. The stress-strain curve of the concrete model presents four typical stages. Finally, the crack initiation and propagation mechanisms of fissured concrete are discussed, and the application of smoothed particle hydrodynamics (SPH) in crack simulations of fissured concrete is prospected.

Effects of fissure locations on the crack propagation morphologies of 3D printing tunnel models: Experiments and numerical simulations

Hidden fissures widely exist in the surrounding rock of tunnels, and the propagations and interactions of the fissures will directly affect the safety and stability of tunnels. However, experimental and numerical simulation studies are scarce on the tunnel-fissure interactions under complex stress conditions. Based on this background, circular tunnel specimens with different prefabricated fissure locations are prepared by three-dimensional (3D) printing technology. Uniaxial compression fracture tests are conducted utilizing Digital Image Correlation (DIC) technology to obtain strain distributions. An improved Smoothed Particle Hydrodynamics (SPH) method is employed to simulate the crack propagation processes of the tunnel-fissure interactions. The results demonstrate the following: 1) Upper main cracks, upper side cracks, and lower side cracks are produced around the tunnel, and wing cracks initiate from the prefabricated fissure tips. 2) For the different intersection positions, wing crack propagation length decreases as the intersection position moves upward, while the lower side crack propagation length increases. 3) For different distances d, upper side crack does not appear, and the propagation length of upper main crack increases with the increase of the distance d. 4) For different fissure inclination angles α, upper main crack does not appear when α = 15°. The propagation length of wing crack increases with the increase of inclination angle α. 5) The peak stress increases as the intersection position moves upward, while it decreases with the increase of inclination angle α. With increasing distance d, the peak stress initially increases and then decreases. Finally, the crack initiation mechanisms under different fissure orientations and inclinations are discussed. These research findings provide valuable insights into the tunnel-fissure interaction mechanisms under complex stress conditions and the applications of the SPH method in underground engineering simulations.

Study on fatigue properties with composite waveform and variable amplitude of TC21 titanium alloy pulsed laser-arc hybrid welded joints

TC21 titanium alloy is widely used in the manufacturing of key components such as aerospace industry, its welded structure in actual service is often subjected to the cyclic loading with composite waveform and variable amplitude and leads to fatigue failure. Therefore, in this work, the composite waveform and variable amplitude fatigue properties of TC21 titanium alloy pulsed laser-arc hybrid welded joints were investigated in this paper, and the micro-deformation mechanism and crack initiation mechanism of welded joints under different initial maximum cyclic stresses were revealed. The results indicated that the micro-deformation mechanism was the competition between twinning and dislocation slip in the α′ phase at low stress. When the initial maximum cyclic stress increased, the generation and slip of dislocation dominated, and the main distribution of dislocations gradually transitioned from the α′ phase to the β phase. This caused the phase transition in the β phase to the α phase, which increased the energy at the α/β phase interface and reduced the resistance of fatigue microcrack initiation accordingly, thus promoting fatigue failure. In addition, pores were the main factor of fatigue failure for welded joints. Therefore, in this work, the influence of defect size, location and shape on the fatigue life of welded joints was considered to develop a fatigue life prediction model based on the control parameter Z-parameter and equivalent stress amplitude. The predicted composite waveform and variable amplitude fatigue life of TC21 titanium alloy welded joints was within the triple error band.

Study on crack initiation mechanism of notched TC4 titanium alloy plate based on acoustic emission information entropy

ABSTRACT Titanium alloys are widely used in high-end manufacturing fields such as aerospace and nuclear energy due to their excellent mechanical properties and corrosion resistance, but it is prone to cracking under load, seriously affecting its performance and safety. Therefore, studying the crack initiation process of titanium alloys is of great significance for improving their service life and safety. In this study, TC4 titanium alloy material is taken as the research object, and the crack emergence mechanism during its tensile fracture process is investigated by combining tensile test and AE test. The experiments were carried out under displacement-controlled conditions, and crack emergence detection was carried out by two methods: AE characterisation parameters and AE information entropy, and SEM was used to observe and analyse the specimen fracture. The results indicate that the AE characteristic parameters of different notched specimens have the same evolution pattern, and this method can be used to predict crack initiation, but there is a certain degree of uncertainty. Compared with the former, the information entropy theory can more accurately predict crack initiation. Therefore, the analysis of the entropy of AE information can be used as a highly practical real-time condition detection method to provide effective detection means for engineering applications.

Study on crack propagation mechanism and acoustic-thermal sensitivity analysis of pre-cracked weakly cemented rock

As the intensity and depth of coal mining gradually increase, environmental disturbances become more complex, and the degree of crack development in weakly cemented surrounding rocks continues to increase. In order to study the influence mechanism of crack angle on the fracture mechanism and acoustic − thermal precursor information of weakly cemented rocks, visual biaxial loading tests were conducted on pre-cracked weakly cemented rocks based on a transparent servo loading device, combined with digital speckle correlation method (DSCM), acoustic emission (AE), and infrared thermal imaging (ITI). The research results indicate that as the inclination angle of cracks increases, the initial strength, peak strength, and elastic modulus of rocks exhibit a logarithmic relationship of first decreasing and then increasing. When the inclination angle of the crack increases from < 30° to > 75°, the failure mode of weakly cemented rocks changes from shear to tension. The propagation path of deformation localization is consistent with the propagation trajectory of surface cracks, and the extension length and time of tensile cracks are longer than those of shear cracks. The acoustic − thermal sensitivity of weakly cemented rocks with crack inclination angle of > 45° is higher than that with crack inclination angle of ≤ 30°. The research results contribute to further understanding and mastering the mechanism of crack initiation and propagation in weakly cemented rocks containing joints, and provide theoretical guidance for engineering methods to control the deformation of weakly cemented surrounding rocks.

Effect of manufacturing-induced microscopic surface defects on crack initiation and fatigue mechanisms in hot-dip galvanized steel

When designing against fatigue, the surface condition of steel is of utmost importance. Since hot-dip galvanizing is a surface treatment primarily aimed at preventing corrosion, it is critical to assess its influence on the fatigue properties of steel. Given the challenges in producing large structural galvanized steel without imperfections, it is crucial to understand the influence of manufacturing-induced microscopic surface defects on crack initiation and fatigue mechanisms in hot-dip galvanized steel. In this study, to gain such insights, tension-tension fatigue testing was conducted on hot-dip galvanized steel, followed by a detailed analysis of the crack initiation sites to determine any correlation with manufacturing-induced microscopic surface defects. It was observed that under low-cycle fatigue, pre-existing surface defects did not appear to have influenced fatigue mechanisms. However, under high-cycle fatigue, crack initiation sites exhibited evidence of pre-existing manufacturing induced defects which were significantly smaller than the total crack initiation area. This indicates that the defects could not immediately penetrate the substrate but expanded within the layer and only penetrated the substrate after reaching a critical size. Therefore, it is discovered that while manufacturing-induced defects may be challenging to eradicate entirely, those below a threshold size may not immediately evolve into a stable fatigue crack. Hence, if manufacturing induced defects are kept below a critical size, they may not significantly influence the transition of stage I crack into a stable stage II crack.

Fatigue strength and fatigue crack initiation mechanism in non-combustible Mg-4%Al-1%Ca-0.2%Mn alloys and its TIG and MIG weld joints

Fatigue strength and fatigue crack initiation mechanism in non-combustible Mg-4%Al-1%Ca-0.2%Mn alloys and its TIG and MIG weld joints

The combined effect of corrosive media and its temperature on the fatigue performance of AA5086-H321 weld joints

This work investigates the fatigue behavior and damage mechanisms in the friction stir weld joints of AA-5086-H321 alloy under the combined effect of media: 3.5 % NaCl and air and its temperature: 24°C and ∼0°C. Sinusoidal loading tests were performed at different load ratios: 0.1 and 0.5, in load-controlled mode at 1 Hz in 3.5 % NaCl. The fatigue lives of the weld joints deteriorated notably under 3.5 % NaCl by selectively attacking its vulnerable nugget zone and heat-affected zone, while the effect of low temperature (∼0°C) was beneficial in both air and 3.5 % NaCl. Two types of crack initiation mechanisms were identified irrespective of the other test conditions: pit-to-pit type, favored at low-stress amplitudes, and pit-to-crack type, favored at high-stress amplitudes. A few cases of crystallographic corrosion pitting were also observed and were accredited to the inherited crystal defects within the Al-matrix. The effect of surrounding temperature was apparent on the crack growth mechanism with limited or no impact on the crack initiation mechanism. The fatigue cracks grew in the intergranular mode under 3.5 % NaCl, while its quantitative presence was decreased at ∼0°C, irrespective of the media, which was attributed as one of the key factors for the increased fatigue performance at ∼0°C.

An investigation into crack initiation and extension mechanism of laminar plasma quenched-tempered rail material with different quenched zones

Laminar Plasma Quenching Tempering (LPQT) is an innovative surface treatment technique for rails, which effectively enhances both their fatigue resistance and wear resistance. This study examines the crack initiation and propagation mechanisms in LPQT-treated rail materials with distinct quenched zones using double-disc testing and metallographic analysis. The findings indicate that the crack initiation and propagation process in LPQT rails with different quenched zones is characterized by four stages. Moreover, the grain size within the spot-quenched zone of LPQT rails is notably smaller, which results in a reduced resistance to RCF crack propagation. Consequently, the crack propagation in point-quenched LPQT rail material is more intricate, with a more severe damage scenario.

Investigation into the mechanisms of Corrosion-Induced rolling contact fatigue crack initiation and propagation in pearlitic rails

Corrosion stands as a pivotal causative agent for the initiation and propagation of rolling contact fatigue (RCF) cracks on rail surfaces. This study aims to scientifically delineate the corrosion fatigue behavior of U75V rails. The study identifies the presence of oxidative corrosion and graphitization on the rail surface. Carbides near the rail surface cause stress concentration, reducing the rail’s RCF residence. Oxide corrosion engenders internal oxide inclusions within cracks, expediting RCF crack propagation. Furthermore, grain refinement and discordant deformation between soft and hard grains near the rail surface give rise to sub-surface microporosity and microcracking. These findings advance our comprehension of rail RCF and offer insights for guiding rail maintenance and informing new rail design strategies.

Very high cycle fatigue of fiber‐reinforced polymer composites: Uniaxial ultrasonic fatigue

AbstractThis review explores uniaxial ultrasonic fatigue (USF) testing as a common and dependable method for quantifying the extended fatigue life of fiber‐reinforced polymer (FRP) composites. The objective is to explain the complexities governing the fatigue life behavior of FRPs, particularly in the realm of very high cycle fatigue (VHCF) where the number of loading cycles exceeds 107. To this end, this review encompasses the analysis of VHCF behavior, including the derivation and interpretation of stress–life (S–N) data, the evaluation of various fatigue damage mechanisms (i.e., controlling mechanisms of crack initiation and propagation) exhibited in FRP composites, and a thorough investigation of the frequency‐dependent effects on fatigue responses. Furthermore, this review tries to analyze the microscopic intricacies intrinsic to the VHCF failure of FRP composites, encompassing aspects such as fiber‐matrix de‐bonding, matrix cracking, and delamination, unveiling their modes and effects in a detailed manner. This review also underscores the pivotal integration of simulations, machine learning, and modeling techniques, emphasizing their crucial role in explaining both macroscopic and microscopic interactions governing the VHCF of FRPs.