Fatigue Crack Growth Rate Tests Research Articles

Experimental Study on the Influence of Thermal Loading Caused by Shoe Braking on Microstructure and Mechanical Properties of Railway Wheels

AbstractThis study aimed to investigate the impact of thermal loading resulting from shoe braking on ER8, SUPERLOS® and ER-TEN railway wheels. To assess the effects of exposure to temperatures ranging from 700 to 970 °C, a series of tests, including hardness, tensile, toughness, fatigue crack growth rate tests and microstructural analysis, were conducted. Specimens were collected from both new wheels and wheels subjected to heat treatments to replicate the microstructural changes induced by shoe braking. The results revealed that the heat treatment at 700 °C caused a decrease in the hardness, yield strength and ultimate tensile strength of the steels due to the formation of globular pearlite. However, a reversal of this trend was observed after heat treatments at 750 and 970 °C. Nonetheless, these properties remained lower than those of the un-treated condition, primarily due to the presence of globular pearlite. Regarding fracture toughness, ER8 and SUPERLOS® generally exhibited a decrease after the heat treatments, while ER-TEN showed an increase after heat treatments at 750 and 970 °C. Additionally, a slight increase in the crack growth threshold and sub-critical crack growth rate was observed after the heat treatments in all steels.

Study on the mechanical properties of X80 pipeline steel under pre-charged high-pressure gaseous hydrogen

Hydrogen embrittlement (HE) is a significant challenge to the safe operation of hydrogen-blended natural gas pipelines. The mechanical properties of X80 steel were studied after H2 pre-charging followed by mechanical properties tests and fracture morphologies observation. Results indicated that the hydrogen saturation time of X80 steel was roughly 48 h. H2 pre-charging induced a decline in strength, plasticity, and fatigue properties, while hydrogen-assisted fatigue crack growth occurred during the early stage of fatigue crack growth rate tests. Additionally, the fracture morphologies transited from primary microvoid coalescence to a mixed mode characterized by ductile dimples and quasi-cleavage planes with increasing hydrogen. The HE susceptibility increased with increasing hydrogen partial pressure and decreasing loading frequency, but there existed a critical value (6 × 10−7 s−1) for the strain rate effect on the HE susceptibility. Under H2 pre-charging conditions, the predominant HE mechanism was the hydrogen-enhanced local plasticity (HELP) mediated hydrogen-enhanced decohesion (HEDE) mechanism.

Microstructure and fatigue crack growth behavior of heat-treated electron beam melted Ti-6Al-4V alloy

The effect of post-deposition heat treatment on microstructure and fatigue crack growth has been analyzed for electron beam melted Ti-6Al-4V plates. Samples have been heat-treated at temperatures of 950 °C and 1050 °C, and subsequently cooled at different cooling rates in the furnace and the water. The as-built sample possesses columnar prior β grains filled with exceptionally fine α+β Widmanstätten patterns and epitaxially grows in the vertical direction. Heat treatment with a slow cooling rate increases the α lath thickness, whereas fast cooling results in multiple needle-shaped α/α′ phases inside the prior β grains. The yield strength and ultimate tensile strength in as-built conditions are greater than the extruded mill annealed sample. The as-built samples show better crack growth resistance during the fatigue crack growth rate test than the heat-treated and mill-annealed samples. The lower plastic deformation of the as-built sample than the mill-annealed sample is attributed to the existence of fine α laths that restrict the motion of dislocation.

Insights into fatigue crack propagation behaviour of WAAM produced SS316 stainless steel: Molecular dynamics simulation and experimental analysis

The current work focuses on the crack growth mechanism / behavior of wire arc additively manufactured SS316L. Beside the experimental investigation, a molecular dynamics based polycrystalline model is developed to simulate the crack propagation under cyclic loading. The purpose of this work is to understand the crack growth behavior of wire arc additively manufactured SS316L, particularly the directional dependence of crack propagation. The experiments and molecular dynamics analysis are performed for the crack propagation along the build and traverse direction for the SS316L deposit. The experimental procedure involves fatigue crack growth rate tests, while the molecular dynamics simulations model the crack propagation in polycrystalline structures of different grain sizes. The ultimate tensile strength in build and traverse direction were 535±2 MPa and 495 ± 2 MPa, respectively. The experimental results reveal faster crack propagation along build direction in comparison to traverse direction. The values for Paris law material constants i.e. C and m are 7x10-15 and 6.78 along build direction while 8x10-14 and 6.02 along traverse direction, respectively. The crack growth along the build direction is primarily intergranular, which leads to high crack growth rate. The molecular dynamics simulations reveal the initiation and closure of secondary cracks for the traverse direction, which leads to slower crack growth rate along the traverse direction. The fractography of the fractured surfaces from fatigue crack growth rate test also indicate the formation of secondary cracks for the case of traverse direction. The molecular dynamics simulations performed with three grain sizes and thickness variation indicate the insensitivity of predicted crack growth mechanisms with respect to grain sizes used for simulations.

Investigation of fatigue crack growth behavior and crack tip plastic zone characteristics in welded structures based on local displacement fields

The fatigue crack growth behavior in welds is difficult to evaluate due to complex internal stresses and microstructural differences. This paper uses the CJP model based on displacement field variations to describe the fatigue crack growth behavior and the size of the crack tip plastic zone in welds. First, fatigue crack growth rate tests were conducted on base metal and as-welded specimens. The digital image correlation technique was used to capture the speckle pattern variations on the specimen surface during crack growth, obtaining the crack tip displacement field required by the CJP model. Based on this, by calculating the stress intensity factor ranges ΔK and ΔKCJP, two da/dN–ΔK(ΔKCJP) curves defined by the traditional and CJP models were obtained, proving the model’s applicability for describing fatigue crack growth behavior in welded joints. Finally, the CJP model was used to calculate and compare the crack tip plastic zones of base metal and as-welded specimens. It was found that the maximum error for the as-welded specimen was 37.84%, occurring at the initial stage of crack propagation and gradually decreasing with the fatigue process.

Microstructure and fracture toughness of laser wire deposited Ti-6Al-4V

In this paper, the microstructure, and mechanical properties of Ti-6Al-4V fabricated through Laser Directed Energy Deposition (L-DED) process are investigated and discussed. Deposited coupons were produced on Ti-6Al-4V wrought substrate using Ti-6Al-4V ELI grade wire with the laser wire deposition (LWD) process. Characterization efforts led to the evaluation of the microstructure, hardness, tensile behavior, and fatigue crack growth resistance of the build-up alloy. Microstructure of the deposit consists of columnar prior β grains and basket-weave α/β phase mixture. The size of the alpha laths is measured as 1.2 ± 0.3 µm and 0.8 ± 0.2 µm in the banded zone and band-free zone, respectively. Hardness of the deposited block is found to be uniform and ranging between 321 and 323 Hv. Tensile and fatigue crack growth properties of the deposited block were evaluated in various orientations. Tensile specimens loaded in the deposition direction exhibited 824 MPa and 930 MPa for yield and ultimate tensile strength, respectively. Tensile specimens loaded in the build direction exhibited 782 MPa and 907 MPa for yield and ultimate tensile strength, respectively. The analysis reveal that the tensile properties of the deposited material match the strength requirements for ASTM F1108 Cast Ti-6Al-4V. However, they fell just below the AMS 4911P Wrought Ti-6Al-4V standard. Fatigue Crack Growth Rate tests were conducted for three directions: parallel to the deposition direction, parallel to the build direction and at 45° of the deposition direction. No significant differences in crack growth properties were observed between the different orientations with average crack initiation near threshold (ΔKth) and the fracture toughness (Kc) value of 3.6 MPa√m and 69 MPa√m, respectively. The crack propagation properties are similar to cast & wrought materials.

Experimental investigation on the fatigue and fracture properties of a fine pearlitic rail steel

This study reports an experimental investigation of the fatigue and fracture resistance of R350HT, a heat-treated pearlitic rail steel with refined microstructure used in rails. Monotonic tensile, rotating bending, linear elastic plane strain fracture toughness, and fatigue crack growth rate tests are presented. The results are used to outline the basic properties and are corroborated by fractographic investigation. This enables the identification of the dominant type of fracture. Regarding fatigue and fracture resistance, the investigated material shows similar properties as other pearlitic rail steels, such as R260. At room temperature, the dominating fracture is of brittle cleavage type, showing some ductile regions associated with pro-eutectoid.

CO2 effect on the fatigue crack growth of X80 pipeline steel in hydrogen-enriched natural gas: Experiment vs DFT

Utilizing the existing natural gas grid presents a promising method for transporting hydrogen on a large scale. However, the effects of natural gas and its impurities on hydrogen-assisted cracking in pipeline steel have not been adequately studied. This study aims to investigate the fatigue performance of X80 pipeline steel in hydrogen-enriched natural gas (HENG) environments and in mixtures containing the impurity CO2. This is achieved through fatigue crack growth rate (FCGR) tests and density functional theory (DFT) calculations. The experimental results show that the FCGR in H2 is slightly faster than that in HENG, whereas it is slower than that in the N2/CO2/H2 mixtures. The enhanced FCGR by CO2 further increases with the increasing CO2 content. DFT computational results indicate that the adsorbed CO2 on the iron surface significantly accelerates the migration of H atoms from surface to subsurface. This promotes the entry of hydrogen into the steel.

Study of cyclic plastic zone ahead of the fatigue crack tip using Digital Image Correlation system

Structural components are susceptible to cyclic loadings during their operation. They are more prone to failure due to localized plastic deformation. The plastically deformed region ahead of the crack tip due to fatigue loading is the important factor responsible for fatigue crack propagation. The plastically deformed region is separated into monotonic and cyclic plastic zones. The cyclic plastic zone (CPZ) is approximately 1/3rd to 1/4th of the monotonic plastic zone (MPZ). The existing analytical expressions to calculate the size of the CPZ are based on elastic perfectly plastic analysis. In this paper, an experimental technique, namely 3D-Digital image correlation (DIC), is used to evaluate the size of the CPZ during the fatigue crack growth rate (FCGR) tests on CT specimens. The DIC system having two cameras is used to capture high-resolution images of crack region of CT specimen surface during the FCGR tests. The FCGR tests are carried out on nuclear piping material steel SA333Gr6 under constant load range and constant load ratio. The post-processing of DIC images revealed an asymmetric butterfly-type shape of the cyclic plastic zone. The DIC evaluated CPZ was compared with the CPZ obtained by a calibrated cyclic plasticity material model-based finite element (FE) analysis. It was observed that the average difference between DIC evaluated experimental CPZ and CPZ calculated by plane stress-based FE analysis is about 5%.

Fatigue Crack Growth Rate Prediction in Nickle based Super-alloys using Machine Learning Algorithm

The state-of-the-art research in any field is inclined towards the use of artificial intelligence (AI) and machine learning (ML) techniques due to their versatility and ease of application without compromise in the results. Predicting the service life of structural members subjected to fatigue loading, is a daunting task and is currently dependent on experimental, finite element (FE) and/or numerical approaches. Damage tolerant (DT) design incorporates fatigue crack growth rate (FCGR) test data to avoid catastrophic structural failure and is proven to be successful in predicting the life of a component. Such predictions also prove beneficial in applications such as structural health monitoring (SHM) and planning non-destructive inspection. Prediction methods and models, currently used, are application specific or inconsistent across different applications. Hence in the present work, an ML algorithm is proposed to predict the Paris region of the FCGR curve for nickel based super alloys, viz. GTM 720 and GTM 718. Experimental dataset for various stress ratios (R) of the alloys were used to train the back propagation neural network (BPNN) algorithm. The algorithm was appropriately tuned and evaluated so as to fit the training data well and achieve good generalization. Using this trained ML algorithm, the FCGR was predicted for a different stress ratio and compared with experimental results of GTM 720 and GTM 718, available in literature. The results obtained are quite comparable indicating promising applications for ML based algorithms in FCGR prediction.

A nonlinear kinetic rate model for unifying fatigue crack growth rates of nickel-based superalloys at room and elevated temperatures

This study presents a nonlinear kinetic rate model to describe the temperature-dependence of fatigue crack growth rate (FCGR) of nickel-based superalloys across a wide range (20 to 650 °C). FCGR testing was performed using compact tension specimens of GH4742 superalloy. Metallography analysis on crack growth paths of two tested specimens suggests there is a local resistance to pure model I cracking at 20 °C, which can greatly be weakened at 650 °C. Compared to the classical Arrhenius equation, the proposed model captures the nonlinear temperature-dependence, and yields more accurate results by reducing the scatter factor from 5 to 3.

Crack growth in high strength mooring line steel under variable amplitude loading

Mooring lines are of key importance for the safe and reliable operation of numerous floating offshore structures. Due to the constantly changing wind and wave conditions acting on such structures, any fatigue crack growth in a mooring line will occur under cyclic loading of distinctly variable amplitude. This paper considers a long-term load history for mooring lines on a North Sea offshore platform. For fatigue testing purposes, a characteristic load sequence representing the actual load history in a condensed and simplified form is developed and presented. Fatigue crack growth rate test results for a grade R4 high strength mooring chain steel subjected to this variable amplitude load sequence is furthermore presented, including tests performed in air as well as under free corrosion conditions in artificial seawater. Based on comparison testing performed under variable- and constant amplitude conditions, the validity of a linear damage rule hypothesis for stable crack growth under the characteristic load sequence is investigated. This damage rule converts the load spectrum to an equivalent constant load range, making it a potentially useful tool for estimating fatigue crack growth in mooring chains when test data for a representative characteristic load sequence are unavailable. Results from the comparison testing are used to show that under stable fatigue crack growth conditions, while subjected to the characteristic load sequence developed for this offshore platform, the linear damage rule can be a reasonable assumption.

Correlation between microstructure and fatigue properties of hot-rolled thick-plate complex-phase steel

Complex-phase (CP) steels, with a multiphase microstructure, offer an excellent combination of high strength, ductility, and formability, making them an attractive alternative to conventional high-strength low-alloy (HSLA) steels in the automotive industry. However, the microstructure and fatigue property relation in CP steels is complex. This limits the full exploitation of CP steels in applications, such as heavy-vehicles, where excellent fatigue performance of thick-plates after punching holes is the critical parameter. In this work, we initiate the study of the relation between microstructure and fatigue properties of a commercial CP steel (800CP) and compare it with a conventional HSLA (500MC) steel. Fatigue property, tensile property, and fatigue crack growth rate (FCGR) testing are conducted and the performance of the two steels is rationalized using detailed microstructure characterization, before and after fatigue testing. FCGR testing shows that, despite a higher yield strength of the 800CP, both steels have a similar propagation rate due to a more tortuous crack propagation path and a higher quantity of secondary crack formation in the 800CP microstructure. The high cycle fatigue (HCF) testing shows that the fatigue limit in the 800CP is 25% higher. This increase in fatigue limit is attributed to the improved resistance to fatigue crack initiation in the 800CP due to its larger fraction of bainite.

Enhanced hydrogen embrittlement of steel by the premature hydrogen dissociation with the increasing inert gas pressure in hydrogen-containing mixtures

Regarding hydrogen embrittlement (HE) in the mixtures of hydrogen and inert gas, the results were understood mainly based on the partial hydrogen gas pressure. On the other hand, the effect of the total gas pressure has not been fully investigated. In this study, fatigue crack growth rate (FCGR) tests were conducted in high-purity hydrogen gas at different gas pressures. Also, the FCGR tests were conducted in hydrogen and nitrogen mixtures at different total gas pressures. The hydrogen partial pressure in the mixture was the same as the high-purity hydrogen. This was the first time that acceleration of the FCGR in the mixtures compared to that in the high-purity hydrogen was observed. To elucidate the mechanism of the enhanced HE in the mixtures, hydrogen permeation and hydrogen desorption experiments were carried out. Based on the results of these tests, the acceleration of the FCGR in the mixtures could be interpreted by the fast hydrogen entry rate, which may result in a higher local hydrogen concentration near the crack tip during a limited time. Density functional theory (DFT) calculations were performed to consider the total gas pressure effect on an atomic scale. The thrust force of other gas molecules in the mixtures made the hydrogen molecules enter the potential field of the iron surface sooner, advancing the dissociation of the hydrogen. This will increase the surface concentration of the hydrogen atoms.

Fatigue crack growth behavior of SS316L deposition from wire arc additive manufacturing

Wire arc additive manufacturing has shown the potential to build large metal parts with high deposition rates and low cost of production compared to other additive manufacturing techniques. Austenitic stainless steel 316L is known for corrosion resistance and weldability, which makes it a strong candidate for building and repairing marine and offshore parts, with wire arc additive manufacturing. These parts experience fluctuating loads during service, which necessitates the fatigue performance study of wire arc additively build stainless steel. This work investigates the fatigue crack propagation behavior of stainless steel 316L depositions from wire arc additive manufacturing. Single beads of stainless steel 316L were deposited layer by layer to fabricate the wall structures. From the wall structures, the specimens were prepared for the tensile and fatigue crack growth rate tests along the traverse and build directions. In conjunction with mechanical testing, electron back-scattered diffraction and scanning electron microscopy techniques were employed to characterize the microstructure. Microstructural observations showed the presence of columnar dendrites along the build direction. The electron dispersive spectroscopy revealed the elemental diffusion at the layer interfaces due to the remelting of the layers. Differences in mechanical properties were observed across the two directions. Along build directions, the ultimate tensile strength was 8 % higher and yield strength was 7 % lower than the respective strengths along the traverse direction. The build direction also exhibited 46 % higher fatigue life cycle than the traverse direction. The difference in properties across different orientations was closely associated with the microstructural variations. Overall, the mechanical performance of the wire arc additively deposited SS316L is better than the previously reported selective laser melted SS316L.

The influence of printing strategies on fatigue crack growth behavior of an additively manufactured AISI 316L stainless steel

AbstractSelective laser melting (SLM) is an additive manufacturing powder‐bed fusion process that allows producing complex metallic parts with a relative density of up to 99.9%. Nevertheless, the mechanical properties of these components depend on numerous process variables, and there is a lack of systematic studies focused on SLM stainless steels. In the work herein presented, three specific printing strategies were X‐Y patterned to manufacture Compact Tension specimens transversally, longitudinally, or chess‐oriented, without any post‐processing heat treatment. The specimens were made of AISI 316L austenitic stainless steel. Thereafter, fatigue crack growth rate (FCGR) tests were carried out at room temperature, at constant amplitude loading (R = 0.2), to determine the fatigue crack propagation constants of the Paris Law associated with each print strategy. It was possible to conclude that transversal additively manufactured specimens showed the lowest FCGRs, and all results were well below the fatigue design curve given in ASME BPVC, Section XI.

Fatigue crack growth behavior for gas tungsten arc welded joint of TC2 titanium alloys sheets

Gas tungsten arc welding (GTAW) is a most preferred welding method for titanium alloys. Due to severe inhomogeneity of welded joints resulting from welding heat input and stress concentration, the joints are prone to fatigue crack initiation, and the fatigue crack growth rate (FCGR) and direction have great variability. Thus, it is of great significance to master the fatigue crack growth (FCG) behavior for the evaluation of remaining life. The FCGR tests were performed in different zones of the TC2 titanium alloy joints welded by the GTAW, and the acceleration behavior of the FCG was investigated. The results show that the crack growth is accelerated prematurely at stable crack growth stage (stage II). The precracks in the weld zone (WZ) and heat affected zone (HAZ) present cross-regional growth during the acceleration process. The regions before and after the critical acceleration point correspond to stage IIa and stage IIb, respectively. The FCG life at the stage IIa accounts for 90% of the total life, and the stress intensity factor range at the critical acceleration point is much lower than that at the instability point. It is proposed that the critical acceleration point is taken as the remaining life evaluation point of the TC2 titanium alloy gas tungsten arc welded joint, and the crack should be limited to the stage IIa, where the FCGR decreases according to the base metal, WZ and HAZ. In addition, the control parameters and the critical criterion of the accelerated growth were proposed, which laid a foundation for the remaining life prediction of the TC2 titanium alloy structures welded by the GTAW.

Experimental study on the fatigue crack growth rates of welded ultra-high strength steel plates

The assessment of the fatigue crack growth rate behavior of welded structural components made of ultra-high strength steels (UHHS) is very important to gain a comprehensive understanding of these materials under high-cycle fatigue loadings and to enhance their applications in the construction industry. The literature on the fatigue crack growth rates of welded ultra-high strength steel plates with nominal yield strengths higher than 690 MPa is very scarce and only very limited research has been done thus far to provide the Paris’ Law fatigue material constants for welded UHSS components in terms of the base metal (BM), the weld metal (WM), and the heat-affected zone (HAZ) regions, which are essential for fatigue life prediction. Hence, the fatigue crack growth rates of butt-welded UHSS plates with three grades (S700, S960, and S1100) are experimentally investigated in this study using Paris’ Law for these three different regions of the welded components. Gas metal arc welding (GMAW) and laser welding (LW) methods are adopted to analyze the influence of welding methods on each steel grade with respect to their static and fatigue strength, microstructural changes, and hardness. In the fatigue crack growth rate test, it was observed that the S700 base material shows the lowest fatigue crack propagation resistance amongst these three grades. In welded components, laser welding outperforms gas welding in terms of the fatigue crack growth resistance. Comparisons of fatigue crack growth behaviors are made among all three tested UHSSs as well as with those from the literature.

Remaining fatigue life assessment of corroded mooring chains using crack growth modelling

Failures caused by the combined actions of fatigue, corrosion and wear are important safety concerns for mooring chains used on floating structures in the oil and gas industry. Prediction of remaining corrosion fatigue life based on surface condition could therefore be a useful tool for the continued safe operation of corroded chains. This paper investigates the use of crack growth modelling for estimating the remaining corrosion fatigue life of mooring chains that exhibit significant pitting corrosion damage. A crack growth modelling approach is used to produce remaining fatigue life estimates for a selection of severely pitted mooring chains. Using fatigue crack growth rate test results for grade R4 high strength mooring chain steel, empirical crack growth laws are presented for free corrosion and cathodic protection conditions at load ratio R = 0.1. Two different methods for establishing equivalent cracks from surface scans of corrosion damage are presented. The mooring chains are proof loaded as part of their manufacturing process. Residual stresses introduced during this process have therefore been determined by finite element analysis and accounted for in the fatigue crack growth predictions. One of the equivalent crack models, accounting for the single dominant corrosion pit, provided quite accurate fatigue life predictions when compared with full scale test results.

Effect of Mg on Inclusion and High Cycle Fatigue Behavior in Titanium Microalloyed Beam Steel

In this paper, the fatigue behavior of titanium microalloyed beam steels were studied by high cycle fatigue test and fatigue crack growth rate test. The effect of Mg addition on the fatigue behavior in titanium microalloyed beam steel was systematically analyzed. According to the experimental results, the addition of magnesium can effectively modify the inclusions by reducing the size of Al2O3 and TiN and promoting the formation of finer complex inclusions with a MgO·Al2O3 core in titanium microalloyed high-strength beam steel. The number of inclusions in the experimental steels had far less of an impact on the fatigue characteristic than inclusion size. With the heterogeneous nucleation effect of MgO·Al2O3, the inclusions are refined after the Mg addition. The tensile strength of Beam-2 steel decreased by approximately 54 MPa, while its fatigue strength increased by about 33 MPa, showing favorable fatigue resistance. These findings are essential for optimize the fatigue properties of titanium microalloy steel and promoting the development of automobile beam steel with excellent fatigue properties.