Fatigue Crack Growth Threshold Research Articles

On the role of flat-top beam in pore elimination and fatigue performance of Ti-6Al-4V fabricated by laser powder bed fusion

It's unavoidable to produce defects in the repeated layer-by-layer manufacturing process of laser powder bed fusion (LPBF). This limits the application of LPBF for safety–critical parts. The formation of defects is closely related to the interaction between the laser beam and material in the molten pool. In this paper, beam shaping was used to improve the building quality of LPBF. Process parameter optimization was performed to obtain samples with the fewest defects. Heat treatment was also employed to further improve the mechanical properties. The results showed that the obtained flat-top beam significantly reduced the propensity for keyhole pore formation and enlarged the process windows. In-situ heat treatment induced by high heat input led to the decomposition of martensite and improved the fatigue crack growth (FCG) threshold (∼3.7 MPa m0.5) of the as-built samples. After heat treatment (annealed and solution/aged), the FCG threshold further increased to 5.5/6.3 MPa m0.5, respectively. Reduced defects and high FCG resistance resulted in a fatigue limit above 600 MPa (N = 1e7, R = 0.1), which is comparable to wrought and aged Ti-6Al-4V parts. This study demonstrates the feasibility of improving molten pool stability and reducing defects through beam shaping, providing a new approach to manufacturing high-quality LPBF parts.

Fatigue growth behavior of mode II crack in headed stud steel used in steel–concrete composite structures

The fracture mechanics method has been employed for fatigue performance evaluation of stud used in steel–concrete composite structures while the fatigue crack growth behavior in headed stud steel has not been systematically studied. The present work is proposed to investigate the fatigue growth behavior of mode II crack in headed stud steel and its welded joint. Compact tensile shear (CTS) specimens extracted from the base material (BM) and weld metal (WM) of stud are tested under mode II loading to investigate the fatigue crack growth (FCG) trajectories and rates with different stress ratio. The crack closure level and FCG threshold are determined and discussed. Results show that the crack deflection in BM meets both the MTS criterion and S-criterion, while crack deflection in WM does not meet the two criterions. The 2% compliance offset criterion in the origin ASTM method is suitable to determine the crack opening force both for BM and WM of stud. The low crack closure level in WM indicates the tensile residual stress in welded joint, resulting a more quickly fatigue crack growth rate (FCGR) in WM than that in BM. The calculation formulation of equivalent SIF range proposed by Borrego et al. is verified with the best normalization effects and is recommended to fit the FCGR model both for headed stud steel and its welded joint under mode II loading.

Mixed mode fatigue crack growth and fatigue threshold analysis in polyurethane adhesives at elevated temperatures

The paper investigates mixed-mode fatigue crack growth in ductile polyurethane adhesives, emphasizing mode decoupling to distinguish the impact of each loading mode component on crack propagation. It also explores the temperature sensitivity of fatigue crack growth rates for each loading mode. Individual scrutiny of the role of each loading mode in tests is accompanied by an analysis of fatigue fracture surfaces to clarify failure mechanisms. The findings indicate differential sensitivity to ambient temperature between the mode I and mode II components in a mixed mode fatigue test. Notably, the fatigue response of the mode I component exhibited higher sensitivity to temperature than the mode II component in mixed mode fatigue fracture of the tested polyurethanes. The polyurethane adhesives' composition, particularly the hard segment ratio, emerged as a pivotal factor influencing their sensitivity to fatigue loading at elevated temperatures. Temperature effects led to a significant reduction (63%) in the mode I component of mixed mode fatigue for one of the tested adhesives, while the other exhibited a noteworthy increase (154%). This trend which was attributed to the hard segment ratio of the adhesives was also persisted in the shear mode of the mixed mode fatigue results.

Assessing fatigue crack growth thresholds for a Ti-6Al-4V (STOA) alloy using two experimental methods

Fatigue crack growth rate behavior in the threshold and near-threshold regimes for a Ti-6Al-4V solution-treated and over-aged (STOA) alloy was investigated using two test procedures: i) accelerated load reduction (ALR) utilizing faster load-shed rates than recommended in the ASTM standard E647 load-reduction (LR) test procedure, and ii) compression pre-cracking constant-amplitude (CPCA) or load-increasing (CPLI) and load-reduction (CPLR). Fatigue crack growth tests were conducted on compact, C(T), specimens (B = 6.35 mm) with two different widths (W = 51 and 76 mm) at two stress ratios (R = 0.1 and 0.7). The crack-growth-rate test data were compared to previous test data produced from the same batch of material using the ASTM LR and CPCA test procedures that were tested on C(T) specimens (W = 25, 51 and 76 mm) over a wide range in stress ratios (R = 0.1, 0.4, and 0.7).Although none of the load-reduction test procedures provided a good representation of the threshold value (ΔKth) at low R, the CPCA test procedure was the most promising. The LR, ALR, and CPLR test procedures were influenced by prior loading history, leading to higher ΔKth values and slower crack growth rates in the threshold regime due to a rise in the crack-opening loads. The LR and ALR tests at R = 0.1 and shed rates of −0.08, −0.32, and −0.95 mm−1 yielded ΔKth values that were 15 to 38 % higher than the estimated threshold stress-intensity factor range (ΔK*th)R=0.1 based on the crack-closure model (FASTRAN). The compression pre–cracking test procedures are more accurate alternatives for developing threshold and near-threshold fatigue crack growth rates. Specifically, the CPLR test procedure produced a ΔKth value that was 8–18 % higher than (ΔK*th)R=0.1. Additionally, LR and ALR tests produced different ΔKth values as a function of the specimen width for a given load ratio, which violates classical fracture mechanics principles. In addition, the spread in the ΔK-rate data in the low-rate regime was larger than the spread in the mid-rate regime as a function of R, a term referred to as “fanning”. In contrast, the CPCA test procedure produced consistent crack growth rates over the same range of ΔK values examined, independent of the specimen width and these data did not exhibit “fanning” with R. Further research is necessary to develop standard test procedures capable of providing a more definitive representation of the ΔKth value in the threshold regime. However, FASTRAN can serve as a crucial tool in aligning the actual ΔKth values with those obtained through CP testing, thereby bridging the gap and enhancing the reliability of the results.

Study on the Influence of Hydrogen Blended Transportation on the Safety of Existing X70 Steel in Gas Distribution Pipeline Network

Coal to gas is one of the natural gas sources utilized in Beijing, with a hydrogen blend concentration range from 1% to 3% and reaching up to 5% in specific cases. In order to evaluate the safety of transporting hydrogen blended natural gas with X70 pipeline steel in distribution pipelines, this study first conducted the slow strain rate tensile tests under a total pressure of 4 MPa in hydrogen environment. The results show that X70 steel exhibits highly sensitive to a hydrogen blending ratio of 5%. Subsequently, four types of hydrogen compatibility tests were conducted in the above sensitive hydrogen partial pressure include the impact toughness test, fracture toughness test, fatigue crack growth test, and fastening disk pressure test. The findings demonstrated that hydrogen blended natural gas has virtual no effect on the impact and fracture toughness, with only 10% reduction in fatigue crack growth threshold. Finally, based on fatigue life analysis by fracture mechanics evaluation, it can be concluded that the existing natural gas pipe of X70 steel is capable to operate safely over 40 years under a total pressure of 4 MPa with a hydrogen blend concentration of 5%.

On Cyclic-Fatigue Crack Growth in Carbon-Fibre-Reinforced Epoxy-Polymer Composites.

The growth of cracks between plies, i.e., delamination, in continuous fibre polymer matrix composites under cyclic-fatigue loading in operational aircraft structures has always been a very important factor, which has the potential to significantly decrease the service life of such structures. Whilst current designs are based on a 'no growth' design philosophy, delamination growth can nevertheless arise in operational aircraft and compromise structural integrity. To this end, the present paper outlines experimental and data reduction procedures for continuous fibre polymer matrix composites, based on a linear elastic fracture mechanics approach, which are capable of (a) determining and computing the fatigue crack growth (FCG) rate, da/dN, curve; (b) providing two different methods for determining the mandated worst-case FCG rate curve; and (c) calculating the fatigue threshold limit, below which no significant FCG occurs. Two data reduction procedures are proposed, which are based upon the Hartman-Schijve approach and a novel simple-scaling approach. These two different methodologies provide similar worst-case curves, and both provide an upper bound for all the experimental data. The calculated FCG threshold values as determined from both methodologies are also in very good agreement.

In-situ investigation of fatigue crack growth behavior of 34CrNi3Mo high-strength steel

In this study, the short fatigue crack growth behavior of 34CrNi3Mo high-strength steel was investigated through in-situ fatigue testing under scanning electron microscopy. An innovative method was proposed to determine the fatigue crack growth threshold by a changing load strategy, which shows high consistency with the standard test for compact tensile specimens. The difference in misorientation along distinct directions at the crack tip has been identified as a factor controlling crack deflection regardless of slip system types.

Fatigue reliability assessment of load‐carrying cruciform welded joints with undercuts and misalignments

AbstractThe additional local stress concentration caused by undercut and misaligned defects could lead to lower fatigue strength of welded joints. The paper aims to investigate the effects of undercuts and misalignments on fatigue performance and reliability of Load‐carrying Cruciform Welded Joint (LCWJ) quantitatively by probabilistic statistics theory and fracture mechanics theory. Firstly, the geometrical characteristics of undercut and misalignment are summarized from the literature and our experiments. Subsequently, the probabilistic distributions of material fracture properties, the configurations of geometries, and flaws were evaluated under specific loading conditions. The fatigue strengths are further estimated by the probabilistic reliability theory by combining the actual fatigue data. The results demonstrate a clear disparity of fatigue crack growth threshold and resistances for the tested data of base metal and weldment. The level of defects determines the interval of fatigue life, and the larger the dispersion accompanying earlier fatigue failure occurs.

Application of the theory of critical distances for fatigue life assessment of spur gears

This study evaluates the effectiveness of the theory of critical distances (TCD) method in determining the fatigue lifetime of a spur gear. A comprehensive characterization of the material parameters necessary for critical distance calculation was performed, including the fatigue limit and crack growth threshold, as well as σ-N and ε-N curves for 16MnCr5 steel. A variety of TCD methods were applied to analyse the component, including the point method, line method, volume method, and mesh control. The results indicate that overall, the TCD method is a reliable and accurate way to predict the fatigue lifetime of spur gears. The study reveals a strong correlation between predicted and experimental crack locations and fatigue lifetime, suggesting accurate prediction using TCD and the Smith-Watson-Topper parameter. Although all TCD methods, when applied correctly, yield similar results, mesh control is the faster method and is therefore more attractive from an industrial perspective. The results of this study provide valuable insight for engineers and researchers in the field of fatigue analysis of spur gears and similar mechanical components.

Roles of microstructures in high-cycle fatigue behaviors of 42CrMo high-strength steel under near-yield mean stress

In this study, high-cycle S-N characteristics and fatigue cracking behaviors under near-yield mean stress of 42CrMo steel with two different fine/coarse-grain tempered sorbite/bainite microstructures (FGM/CGM) were investigated. The results show that fatigue strength is greater for FGM than for CGM as expected, but fatigue crack growth (FCG) threshold is higher for the latter. Compared to FGM with a single crack source, CGM has multiple fatigue sources together with higher-degree ratchetting-fatigue damage, i.e., plastic-strain, dislocation cells and sub-grains, thus accelerating fatigue crack initiation. In the near-threshold regime, roughness-induced crack closure in coarse-microstructures of CGM leads to FCG retardation behavior, which increases FCG threshold. In the Paris regime, CGM presents a similar FCG rate to FGM. Microstructure barriers (i.e., crystal interfaces, carbides and interfaces with different orientations), secondary cracks, crack-path fluctuations, ratchetting and plastic strain jointly result in severer crack-tip stress shielding effects in CGM than in FGM. However, fatigue crack tends to propagate through the high Schmid factor region with {110}<111> slip system with lower slip resistance in FGM but not in CGM, which facilitates fatigue cracking of the former. Under the combined effects of the above factors, similar FCG rates are thus exhibited in both steels with different tensile strengths.

High-Cycle Fatigue Behavior of D2 Wheel Steel under Uniaxial and Multiaxial Loading Conditions for Potential Applications in the Railway Industry

This study investigates the fatigue damage evolution mechanisms of D2 wheel steel under high-cycle uniaxial and multiaxial loading conditions, with a focus on determining the fatigue crack growth threshold (FCGT). Uniaxial and multiaxial FCGT tests were performed on pre-cracked D2 wheel steel specimens subjected to high-frequency cyclic loading at stress ratios (R) of 0.1. The results indicate that the FCGT for D2 wheel steel under uniaxial loading conditions ranges between 8–9 MPa.m0.5, while under multiaxial loading conditions, it ranges between 6–9 MPa.m0.5. Scanning electron microscopy analysis revealed differences in the crack propagation mechanisms between the uniaxial and multiaxial tests, with cracks deviating from their path and following the microstructure in the uniaxial tests, and cracks propagating along planes of weakness in the multiaxial tests. These findings provide insights into the high-cycle fatigue behavior of D2 wheel steel under different loading conditions for potential applications in the railway industry.

The cyclic R-curve method for predicting fatigue crack growth threshold based on modified strip-yield model of plasticity-induced crack closure under fully reversed loading

A strip-yield model modified to leave plastically deformed stretch in the wake of the advancing crack tip is applied to simulate the buildup of plasticity-induced crack closure with crack extension from precracks with various lengths under fully reversed loading. Two types of precracks are examined: open precracks which remain open even under cyclic compression, and closed precracks which may close under compression. The effects of precrack type and length on fatigue thresholds were systematically examined. Because of a sharp increase of crack opening stress with crack extension, the effective stress intensity range ΔKeff drops initially and then turns to increase. Assuming a constant threshold value of ΔKeff for steels, new master curve equations are proposed for the cyclic R-curve. The effect of the precrack type on fatigue thresholds is successfully derived for different precrack lengths.

Fatigue crack growth behavior of a nanocrystalline low Young's modulus β-type Ti–Nb alloy

Low Young's modulus β-type titanium alloys, such as the Ti–45Nb alloy, with elastic properties close to that of human bone containing non-toxic elements are very desirable for load bearing implants. Their relatively low hardness and strength can be significantly increased by severe plastic deformation (SPD) methods, for example high pressure torsion (HPT). To gain a better understanding of the fatigue characteristics, the fatigue crack growth (FCG) behavior of Ti–45Nb was investigated in various microstructural states (as-received, HPT-deformed, HPT + cold-rolled, HPT + heat-treated). Compact tension (CT) specimens with different crack orientations were tested at different load ratios under tension-tension loading. The microstructure of the HPT and HPT + cold-rolled material shows highly elongated grains parallel to the principal deformation direction with grain sizes in the nanocrystalline regime. Compared to the majority of studies on FCG of SPD-processed materials this titanium alloy exhibits a remarkably weak anisotropy in the FCG-behavior in all material states but especially in the HPT and the cold-rolled state. This is mainly attributed to the transcrystalline fracture mode. The threshold of fatigue crack growth was found to decrease with increasing load ratio. This is related to a lower contribution of plasticity-induced crack closure at higher load ratios.

Fatigue Crack Growth Rate Description of RF-Plasma-Sprayed Refractory Metals and Alloys

A fitting method capable of describing the fatigue crack growth rate (FCGR) data in all stages of crack propagation by a simple Forman-style analytical formula was developed. To demonstrate its robustness, this method was used to quantify the fracture behavior of RF-plasma-sprayed W, Mo, W-Mo composite, and four selected Ni-based tungsten heavy alloys (WHA). The fitted FCGR parameters categorized the studied materials into two distinct sets. W, Mo, and W-Mo composite deposits made from inherently brittle refractory metals that contained a range of defects inherent to plasma spray process represented the first class. This class was characterized by low fracture toughness and a relatively wide range of fatigue crack growth thresholds. The second class of materials was represented by WHA. Here, the deposit defects were suppressed by liquid state diffusion that formed a typical WHA structure consisting of a Ni-rich matrix and large spherical W reinforcement particles. The WHA generally showed higher fatigue crack growth thresholds, but differed in fracture toughness values based on the W particle concentrations. The obtained fracture mechanical data represent a reference dataset of plasma-sprayed refractory materials, and their classification into groups clearly demonstrates the capabilities of the developed method to capture a wide range of different types of FCGR behavior.

Fatigue crack tip corrosion processes and oxide induced closure

This paper reviews the corrosion and hydrolysis reactions that occur inside a fatigue crack at ambient temperatures and pressures in humid air and aqueous solutions. This study examines the individual reaction steps, intermediate phases formed, and the time required for the metal ions to transition into hard oxide phases. This study also finds that when a fatigue crack closes at ambient temperatures, the corrosion products inside the crack should consist of thin (≈2 nm) hard oxide films on the fracture surfaces and viscous layers of water with metal ions in various states of the transition from aqueous ions to stable end-product phases, but with insufficient strengths to resist load transfer at the crack tip. This analysis assumes that metal ion complexes form at the crack tip and transition toward the end-product phases in the wake of the crack in a manner analogous to that reported for plane surfaces exposed to humid air and aqueous solutions. It is concluded that the contribution of the viscous layers to an oxide induced crack closure (OICC) mechanism should be negligible. The impact of this finding on the interpretation of R-ratio effects on fatigue crack threshold and oxide thickness measurements is discussed. The OICC mechanism should be possible at high temperatures and in the near threshold fatigue crack growth region where hard oxides can grow to sizes relevant to the cyclic crack opening displacement (COD).

Comparison of Cast, Wrought, and LPBF Processed IN718 Concerning Crack Growth Threshold and Fatigue Crack Growth Behavior

Abstract This study focuses on the influence of microstructure and ductility on the short crack behavior and the fatigue crack growth (FCG) threshold. For this, an additively manufactured batch of the nickel-based alloy IN718, made via Laser Powder Bed Fusion (LPBF) process, is compared to both conventionally wrought and cast IN718 material. An initial characterization revealed significant differences in grain structure, from regular fine grained wrought material to large grains of several millimeters in diameter in the cast variant and a chessboard-like grain structure typical for LPBF. The ductility parameters of IN718-LPBF and wrought IN718 are comparable at room temperature, but at 650 °C the LPBF-variant shows macroscopic brittle fracture. The fatigue crack behavior both in the short and long crack regime is investigated in air at 650 °C. To produce minimal crack growth increments of about 1 μm, a compressive precracking and subsequent threshold test procedure with stepwise load increase has been adapted for high temperature testing. To assess the short crack behavior, cyclic R-curves have been generated taking the influence of three different stress ratios (R = −1, 0, and 0.5) into account. As expected, increasing crack closure mechanisms at higher stress ratios lead to higher stress intensity amplitudes ΔKI necessary to initiate crack growth. The crack growth resistance of the LPBF-processed variant is higher compared to wrought IN718. In the long crack regime, the wrought alloy yields higher crack growth rates compared to LPBF and cast IN718. An expected R-ratio dependency is observed for all material states.

Prediction of fatigue life of TC4 titanium alloy based on normalized equivalent initial flaw size model

Ti-6Al-4 V (TC4) is the primary and most widely used titanium alloy in the aerospace industry, mainly for the manufacture of engines and high temperature load-bearing elements in aircraft structural components. In this study, fatigue life and fatigue crack growth (FCG) rate tests of TC4 were carried out at different temperatures and stress ratios. The effect of temperature on the fatigue mechanical properties of TC4 titanium alloy materials was investigated analyzing the test results. The fatigue limit and FCG threshold were obtained from experiments. By the using equivalent initial flaw size method, the growth behavior of small cracks were incorporates in macroscopic FCG rate and a method to predict the fatigue life of TC4 at different temperatures was established. The parameters in the proposed model have a clear physical meaning and can be determined by experiment. Finally, the fatigue test data of TC4 titanium alloy under different test conditions are used to verify the proposed fatigue life prediction model and the prediction results have reasonable accuracy with the test results.

Investigation on the Fatigue Crack Propagation of Medium-Entropy Alloys with Heterogeneous Microstructures

The behavior and the mechanism of fatigue crack propagation in CrCoNi medium-entropy alloys (MEAs) with heterogeneous microstructures were investigated in this paper. After cold-rolling and recrystallization annealing at different temperatures and times, five sets of heterostructured specimens were acquired with different recrystallization levels. Then, the structure characterizations of these five sets of specimens were carried out by nanoindentation testing and electron back-scatter diffraction (EBSD) mapping. Finally, the fatigue crack propagation tests were conducted on single edge crack specimens of these different heterogeneous microstructures. The experimental results indicate that the crack propagation rates of specimens with partial recrystallization microstructures are higher than those with complete recrystallization microstructures, and the effect on fatigue crack thresholds of these specimens is the opposite. The fatigue cracks grow along the slip planes or twin boundaries in recrystallization grains (RGs), which induced crack deflections and the roughness-induced crack closure effect. For this reason, the area percentage of recrystallization and the grain size of RGs have a great effect on the value of the fatigue crack growth threshold.

Study of fatigue crack growth characteristics of TIG welded AZ31B magnesium alloy joint based on laser bionic treatment

AbstractIt is crucial to obtain better fatigue property for the safe application of materials, while nature provides new structural design ideas for effectively improving fatigue property. In this study, a “soft‐hard” alternating bionic structure was fabricated on the surface of TIG welded AZ31B Mg alloy joints by laser bionic treatment (LBT). Microstructure of welded joints was tailored by LBT, resulting in fine equiaxed grains with random orientations and increased microhardness. The fatigue crack growth threshold of the welded joints with bionic structure is increased by more than 40%, and crack growth rate was lower. LBT could significantly affect crack growth behavior and presented obvious crack deflection, resulting in a rougher fracture surface and more second cracks and branches. LBT significantly improved the fatigue crack growth resistance, inducing a series of strengthening mechanisms. The present work opens a new alternative to improve the fatigue properties of welded joints.

Comparison of wrought and additively manufactured IN718 concerning crack growth threshold and fatigue crack growth behaviour

Rotary components in turbine machinery such as gas turbine blades and discs or turbocharger wheels need to be designed so that high cycle fatigue (HCF) loads are well below the fatigue endurance limit to ensure safe operation. This requires an accurate measurement of the fatigue endurance limit and the related intrinsic fatigue crack growth (FCG) threshold. Furthermore, knowing the FCG threshold is crucial in order to assess the criticality of initial defects (e.g. cavities, carbide nests, etc.). In this study, the influence of the manufacturing route on the FCG threshold and the FCG behaviour at 650 °C in air of the nickel based superalloy IN718 is investigated. For this, a per Laser Powder Bed Fusion (LPBF) process manufactured version is compared to a conventionally wrought IN718 material state, both in the short and long crack regime. To measure crack growth increments of about 1 μm, an alternative pre-cracking and threshold test procedure is proposed for high temperature testing. To assess the behaviour of both material states in the short crack growth regime, cyclic R-curves have been generated taking the influence of two different R ratios into account. A further comparison of the FCG behaviour of the LPBF and the wrought material state is made on the basis of da/dN-ΔKI plots, with a focus on the Paris regime created from both classical FCG tests as well as continued threshold tests. The results observed are discussed in relation to the initial characterization of the two material states, which includes tensile tests at room temperature and at 650 °C as well as microstructural investigations.