Fatigue Crack Growth Research Articles

Assessment of fatigue crack growth in metro cast manganese steel frogs and inspection strategy

Fatigue cracking is one of the notable failure mechanisms of railway turnout frogs due to high contact forces induced by the wheel-rail impact. However, the treatments specific to the frogs of cast high manganese steel to prevent sudden failure are rarely provided and are independent of the crack conditions, which can significantly affect the fatigue crack growth rate. To address this shortcoming, the fatigue crack growth in a cast high manganese steel frog is computationally investigated with varied wheel and crack conditions. The dynamic wheel-frog impact is first simulated to obtain the distribution of contact pressure imposed on the frog, and the propagation of the fatigue crack is then predicted using the finite element formulation in fracture mechanics. The simulation results show that the train speed and axle load can change the maximum contact stress. Nevertheless, when representing the growth rate in terms of the cumulative passing axle load, the effect of axle load and train speed on the crack growth is minimal and moderate, respectively. In contrast, the initial crack conditions, including the location and angle, have an overweighted influence. As a result, an inspection scheduling strategy for identified cracks with different conditions is proposed to consider both safety and operational efficiency.

Does hygrothermal degradation of Mode I fatigue delamination resistance in carbon fibre reinforced polymer laminates depend on the ageing conditions?

Hygrothermal ageing has detrimental effect of the fatigue delamination growth (FDG) in carbon fibre reinforced polymer laminates, and may increase the crack growth rate by a factor of ∼5. The paper examines, how this degradation for Mode I fatigue delamination is affected by the severity of the ageing conditions. Fatigue delamination tests for R = 0.1 and R = 0.5 are conducted after ageing (1) at 70 °C 85 % relative humidity (RH) and (2) immersion in 70 °C water bath (WB). Paris-type FDG characterisation is derived, in the form, which accounts for the effect of fibre bridging. It is demonstrated that parameters of FDG degradation do not differ for these two types of hygrothermal ageing. The physical reasons for this are examined using dynamic mechanical thermal analysis (DMTA) and fractographic analysis, which revealed similar irreversible degradation of the material near the fibre/matrix interface and in the matrix itself, and the similar damage mechanisms in fatigue delamination. Furthermore, this study can highlight the importance of obeying similitude principles in FDG characterisation, and provide extra information for the ISO standard development for mode I fatigue delamination in unidirectional carbon fibre reinforced polymer composites.

Automated crack extension measurement method for fracture and fatigue analysis using digital image correlation

A novel Automated Crack Extension Measurement (ACEM) method based on combining decorrelation in strain field and a threshold near maximum of full-field strain obtained from digital image correlation, is developed in this work. A manual method for measuring crack extension from images of the specimen surface and ImageJ, was utilized to validate the accuracy of the proposed method. Initially, ACEM method was validated for crack extension under mode-I fracture of single edge notch specimens with different initial notch sizes. A satisfactory agreement was obtained from this analysis along with limits on the different parameter values used in ACEM. The method was then applied to low-cycle fatigue specimens with different initial notch lengths. Comparison of crack extension between ACEM and manual method reveals satisfactory agreement reinforcing the fidelity of the developed method for fracture and fatigue analysis. Fracture resistance and fatigue crack growth rate curves were also obtained for the different specimens.

Particle filter for fatigue crack growth prediction using SH0 wave on-line monitoring

Fatigue crack is one of the main failure modes of pressure vessels. Online monitoring and predicting methods of crack growth play an important role in the operation of important pressure vessel. The SH0 wave is non-dispersive, and it is not disturbed by internal media of pressure vessel and very sensitive to cracks, therefore it is suitable for fatigue crack growth monitoring. Moreover, fatigue crack growth in industry is affected by material properties, loads, which usually shows some uncertainty. And the particle filter (PF) is well suited to deal with prediction problems affected by uncertainty. Hence, the prediction method of crack growth based on SH0 wave monitoring and PF is proposed (short for SH0-PF). The basic theory of crack monitoring method using SH0 wave is introduced, and the signal feature extraction using the damage index is studied. The state equation characterizing the fatigue crack growth is established by Paris model, and the observation equation is established based on the normalized correlation moment damage index according to monitoring signal using SH0 wave. The prediction reliability of the fatigue crack growth applying SH0-PF is verified by experiment with the single edge notched specimen. The experimental results indicate that the prediction accuracy of SH0-PF is better than that of the traditional Paris model.

Experimental study on decoupled charge blasting-induced crack propagation with parabolic shaped charge

In this study, a new parabolic shaped charge structure is proposed to realize bidirectional blasting in coal mines. To examine the fracture characteristics of rock mass induced by shaped charge structure under explosion load, a dynamic caustic experimental system is adopted. Further, the blasting-induced damage distribution characteristics of rock mass caused by different decoupling coefficients are investigated. Using polymethyl methacrylate (PMMA) as the experimental material, a two-dimensional model is established. AUTODYN, an explicit dynamics simulation program, is used to examine the initial crack generation process under shaped charge blasting. The stress wave propagation rule and the relationship between blasting damage and decoupling coefficient are explored. The results show that the parabolic shaped charge structure can control the explosion energy distribution and reduce the surrounding rock damage. When the decoupling coefficient is 2, the main crack length is optimum. During the crack propagation process, the growth rate and stress intensity factor of the main crack of the specimen show an oscillatory downward trend. Two stress concentration points are generated on either side near the main crack, forming the initial crack. When the decoupling coefficient is less than 2, long cracks exist in both the shaped and non-shaped charged directions, and the energy gathering effect is poor. When the decoupling coefficient is greater than 2, the energy gathering effect is obvious, but the main crack length is shorter.

Review on Environmentally Assisted Static and Fatigue Cracking of Al-Mg-Si-(Cu) Alloys

This paper reviews the relevant literature and covers the main aspects of the environmentally assisted cracking of Al-Mg-Si-(Cu) alloys. Apart from a brief overview of the major microstructural and mechanical properties, it presents research results on the corrosion sensitivity and stress corrosion susceptibility of Al-Mg-Si alloys. Possible mechanisms of stress corrosion cracking and corrosion fatigue in aluminum alloys, such as anodic dissolution and/or interaction with hydrogen, are considered. A number of factors, including atmospheric or solution conditions, applied stress, and material properties, can affect these mechanisms, leading to environmentally assisted cracking. Specific attention is given to Al-Mg-Si alloys with copper, which may increase the sensitivity to intergranular corrosion. The susceptibility to both intergranular corrosion and stress corrosion cracking of Cu-containing Al-Mg-Si alloys is mostly associated with a very thin layer (segregation) of Cu on the grain boundaries. However, the effect of Cu on the corrosion fatigue and fatigue crack growth rate of Al-Mg-Si alloys has received limited attention in the literature. At the current state of the research, it has not yet been holistically assessed, although a few studies have shown that a certain content of copper can improve the resistance of aluminum alloys to the environment with regard to corrosion fatigue. Furthermore, considerations of the synergistic actions of various factors remain essential for further studying environmentally assisted cracking phenomena in aluminum alloys.

Effect of different regions on fatigue crack growth behavior of 6005-T6 aluminum alloy metal inert gas (MIG) butt welded joint: experimental and numerical study

Effect of different regions on fatigue crack growth behavior of 6005-T6 aluminum alloy metal inert gas (MIG) butt welded joint: experimental and numerical study

Atomic force microscopy monitoring of subcritical slow crack growth in soda lime silicate glass

Prediction of brittle fracture in silicate glasses requires a fundamental understanding of slow crack growth rates, far below the critical stress intensity (KIC) of the material. Here, atomic force microscopy (AFM) was used to characterize slow crack propagation in soda lime silicate glasses. Using large-sample AFM systems with specialized tips and scanners, fractures less than 20 nm wide were measured as a function of relative humidity (RH). The results were found to be sensitive to the type of AFM tip used and to the dryness of the surface. Continuous scanning and image capture over several days allowed the determination of the crack tip velocity. The dependance of crack tip velocity on RH was measured by enclosing the sample and AFM head in a humidity-controlled chamber. The crack tip velocity was measured as low 4.0×10-12 m/s at 15 % RH and as high as 3.7×10-10 m/s at 40 % RH. Overall crack growth was smooth during the AFM scan. Additionally, recession of the crack tip was noted as the sample dried, indicating crack tip closure may be occurring. Further studies on alternative compositions will provide details on subcritical fracture processes in a range of different environmental conditions.

Thermo-mechanical fatigue crack growth in a nickel-based powder metallurgy superalloy

Fatigue crack growth is studied in a nickel-based powder metallurgy (PM) superalloy (FGH4099) subjected to in-phase (IP) and out-of-phase (OP) thermo-mechanical fatigue (TMF), as well as isothermal fatigue (IF) at peak temperature. The crack growth rate and path are evaluated for both coarse grain (CG) and fine grain (FG) FGH4099, especially the effects of phase angle and polycrystalline microstructure. The results show that the TMF crack propagation is mainly transgranular in OP condition; while in IP condition, fatigue crack propagates intergranularly at low ΔK and transforms to transgranular after passing the transition region. The crack propagation resistance for FG microstructure is lower than that for CG microstructure at elevated temperature, as a result of secondary cracks and grain boundary weakening effect. Crystallographic slip controls the crack propagation process, while the twin boundaries (TB) and special grain boundaries also exert a significant influence on crack deflection. The formation of secondary cracks is closely related to local misorientation and crystallographic deformation during TMF crack propagation. The crack deflection in a single grain reveals a competition mechanism between crystallographic slip and grain boundary effect, which explains the lower crack growth rate for OP when compared to IP or IF.

Experimental evaluation of the short and long fatigue crack growth rate of S355 structural steel offshore monopile weldments in air and synthetic seawater

Welded steel structures used in the offshore wind industry are exposed to harsh marine environments, which can result in corrosion-induced fatigue damage. Of particular concern is the heat affected zone (HAZ) of welded joints, a region known for its altered microstructure and mechanical properties, which can significantly influence the initiation and propagation of fatigue cracks. This study investigates the short and long fatigue crack growth rates, and the effect of seawater exposure, for the HAZ in S355 steel weldments. Single-edge notch bend (SENB) specimens are used, with a shallow notch in the HAZ. A series of specimens is immersed in synthetic seawater that is continuously circulated at a controlled temperature to assess the synergistic effects of corrosion and fatigue. The experimental method integrates a novel application of front face strain compliance for monitoring short cracks, alongside an extended back-face strain compliance approach for monitoring long crack propagation. It is concluded that the short fatigue crack growth rate of the HAZ is 2.7 to 3.5 times higher in seawater as compared to air. As the crack propagates and enters into the long crack regime, the ratio decreases to 2.2 times at the transition point of the two-stage crack growth curve and further decreases to 1.5 times when the notch advances towards fracture. The findings indicate that the fatigue crack growth rates documented in standards tend to be on the conservative side. This study significantly enriches the fatigue crack growth data available in literature, which will contribute to a more accurate lifetime assessment offshore wind turbine structures.

A nonparametric degradation modeling method for remaining useful life prediction with fragment data

Condition-based maintenance (CBM) is an effective way to keep the safety of industrial equipment by predicting the remaining useful life (RUL) and scheduling the maintenance plan before failure. Condition monitoring data is the basis of health state evaluation and RUL prediction. In ideal cases, the monitoring data are collected consecutively starting from the healthy stage until the end of the lifetime. In real industrial cases, however, fragment data often exist due to the interruption of monitoring and/or the loss of sensor readings. The major characteristic of fragment data is that they only record a random period of degradation process. The initial degradation time information is generally lost. Therefore, it is unable to be modeled using the common time-dependent modeling framework. To deal with the above issue, this paper proposes a nonparametric degradation modeling method for RUL prediction with fragment data. In this method, a new state-dependent degradation modeling framework is constructed via two-step axis transform. It formulates the RUL using a function depending on the health state. Based on functional principle component analysis (FPCA), a principal analysis via maximum likelihood estimation (PAMLE) algorithm is developed to recover the missing data of failed units. In addition, a RUL prediction-oriented optimization (POO) algorithm is proposed to predict the RUL of in-service units based on a piece of fragment data. Consequently, the proposed method is capable of dealing with the issues of both data recovery and RUL prediction. The effectiveness of the method is demonstrated using a fatigue crack growth dataset and a lithium-ion (Li-ion) battery degradation dataset.

In-situ studies on environmental degradation in Al 7075 in saltwater environment under tensile loading

Abstract We report the crack growth on peak aged Al 7075 under tensile loading in a saltwater environment to investigate whether hydrogen plays a role in the initiation and the subsequent growth of the crack. As the hydrostatic stress is at a maximum ahead of the notch, it has been speculated that hydrogen would diffuse to region of maximum hydrostatic stress and initiate the crack. An elastic-plastic finite element (FE) model is developed to determine the stress distribution around the circular notch at the edge of the plate. The crack growth was monitored using a camera attached with an optical microscope, and various regimes corresponding to hydrogen evolution, pit formation and growth, crack nucleation and initial growth and rapid crack growth leading to failure have been identified. We observe the crack was nucleated in a region associated with the highest hoop stress instead of the maximum hydrostatic stress from the base of a pit at the circular notch. We demonstrated the crack growth rate in a salt water environment is governed mostly by the dissolution of grain boundary MgZn2 precipitate, rather than the hydrogen induced decohesion mechanism.

Modeling of crack tip fields and fatigue crack growth in fcc crystals

Predicting the mechanical behavior of polycrystalline materials containing a crack under both monotonic and cyclic loading conditions is crucial for accurately assessing the integrity of engineering materials. This study focuses on the deformation characteristics of face-centered cubic (fcc) grains within the crack tip field and their significant role in governing the driving force for fatigue crack growth during cyclic loading. We employ a cyclic crystal plasticity finite element (CPFE) model to analyze the mechanical response of austenitic 316L stainless steel polycrystals by accounting for nonlinear kinematic hardening effects. Through CPFE simulations, we investigate the deformation fields in 316L grains at the crack tip, considering two different grain orientations under plane strain conditions. Our CPFE results under monotonic loading align consistently with previous theoretical and experimental findings, particularly in comparing CPFE-simulated and experimentally observed plastic sectors consisting of different slip traces on the specimen surface near the crack tip. Based on a critical plastic work criterion for crack advancement, cyclic CPFE simulations are used to determine the fatigue crack growth rate as a function of stress intensity factor range for the two crack tip grain orientations in stainless steel. The simulated Paris law exponent matches experimental values. Furthermore, we compare cyclic CPFE results with those from cyclic J2 plasticity finite element simulations. This study demonstrates a cyclic CPFE approach for determining crack tip fields, accounting for crystallographic effects on plastic deformation of crack tip grains. Our approach can be applied to effectively evaluate fatigue crack growth rates in fcc polycrystalline metals.

Comparison of fatigue crack growth design curves on GMAW and EBW joints of high strength steels

There is a growing demand in the industrial sector for the use of high-strength structural steels (HSSSs), which can achieve a significant weight reduction in structures. These structural steels are usually produced by quenching and tempering (Q + T) or thermomechanical treatment (TM), and their applications in welded structures pose several challenges for the users. In industrial practice, gas metal arc welding (GMAW) is basically the most commonly used fusion welding process, which has a relatively high heat input. However, at HSSSs, there is a need for low heat input but, at the same time, productive welding processes. High-energy density welding processes, e.g., electron beam welding (EBW), offer a unique opportunity to weld these steels. The widespread use of HSSSs is also hampered by the fact that the benefits of high strength can be exploited primarily under static loading. At the same time, different welded structures made of HSSSs are often subjected to cyclic loading, and possible weld defects and material discontinuities are major risks in this case. During our experiments, GMAW and autogenous EBW processes were applied to make welded joints from S960 Q + T and TM structural steels. The fatigue resistance of the welded joints was characterized by fatigue crack growth (FCG) tests, considering the increased crack sensitivity of HSSSs. A statistical approach was followed both in the design of the experiments and in the evaluation of their results. Based on the test results fatigue crack propagation design curves were determined for the investigated GMAW and EBW welded joints. The design curves were compared with each other, with design curves of lower strength material (S690QL) and with the recommended fatigue crack growth laws of BS 7910.

Fatigue prediction through quantification of critical defects and crack growth behaviour in additively manufactured Ti-6Al-4V alloy

The study presents a methodology for predicting the fatigue life and identifying critical defects in additively manufactured (AM) Ti-6Al-4V alloy processed via laser powder bed fusion (L-PBF). Predictions were made on L-PBF Ti-6Al-4V alloy in two conditions: as-built and heat-treated by using X-ray μ-Computed Tomography (μ-CT) for the quantification of the defects and fatigue crack growth (FCG) data. For validation, fatigue life predictions were made on the same specimens on which μ-CT was conducted prior to fatigue testing. FCG and fatigue tests (S-N) highlighted differences in the performance between the as-built and heat-treated conditions: the as-built condition had a lower threshold stress intensity factor range (ΔKth) of 2.16 MPa m1/2 than that of the heat-treated condition, 4.96 MPa m1/2. Differences in fatigue limit were attributed to differences in ΔKth in as-built and heat-treated specimens. To gain mechanistic understanding of these differences near ΔKth cracks were examined using Electron Backscatter Diffraction - Kernel Average Misorientation (EBSD-KAM). It was found that upon heat treatment, the dislocation density increased around near threshold fatigue cracks. Increases in ΔKth are attributed to the increases in β-phase content and α-lath thickness caused by heat treatment.

Effect of PtAl coating on the HCF property of a coated third-generation single crystal superalloy with sheet specimens at 900 ℃

High-cycle fatigue (HCF) is one of the primary failure modes for turbine blades in aero-engines. Therefore, comprehending the effect of coating on the HCF property of single crystal (SX) superalloys is vital for the safe service of turbine blades. In order to mimic the degradation of the fatigue property for the turbine blades during service, this study investigated the effect of PtAl coating on the HCF property of a third-generation Ni-based SX superalloy using sheet specimens at 900 ℃ and different maximum stresses (σmax). The results indicated that both coating and σmax affected the fatigue properties and crack initiation process of SX superalloy. A transition in fatigue crack initiation site from the internal micropores to the surface cracks for both uncoated and coated alloys has been observed as the σmax decreased. However, the coating significantly increased the σmax required for the transition of the crack initiation site. Meanwhile, the HCF property of the SX superalloy was reduced with the deposition of PtAl coating at lower σmax, and the debit in HCF life was more pronounced with decreasing the σmax. The coating facilitated the rapid nucleation of surface cracks and promoted the transition of the fatigue crack initiation site under higher σmax. On the other hand, since the HCF life is controlled by the crack growth rate, grain boundaries in the interdiffusion zone (IDZ) and secondary reaction zone (SRZ) accelerated the growth of the surface crack under lower σmax, resulting in a shorter crack initiation stage and lower fatigue life compared to the uncoated alloy. This study will be helpful in accurately predicting the HCF life of the coated Ni-based SX superalloys.

Thermal Fatigue Failure of Micro-Solder Joints in Electronic Packaging Devices: A Review

In electronic packaging products in the service process, the solder joints experience thermal fatigue due to temperature cycles, which have a significant influence on the performance of electronic products and the reliability of solder joints. In this paper, the thermal fatigue failure mechanism of solder joints in microelectronic packages, the microstructure changes of the thermal fatigue process, the influence factors on the joint fatigue life, and the simulation analysis and forecasting of thermal fatigue life are reviewed. The results show that the solder joints are heterogeneously coarsened, and this leads to fatigue cracks occurring under the elevated high-temperature phase of alternating temperature cycles. However, the thickness of the solder and the hold time in the high-temperature phase do not significantly influence the thermal fatigue. The coarsened region and the IMC layer thicken with the number of cycles, and the cracks initiate and propagate along the interface between the intermetallic compound (IMC) layer and coarsened region, eventually leading to solder joint failure. For lead-containing and lead-free solders, the lead-containing solder shows a faster fatigue crack growth rate and propagates by transgranular mode. Temperature and frequency affect the thermal fatigue life of solder joints to different degrees, and the fatigue lifetime of solder joints can be predicted through a variety of methods and simulated crack trajectories, but also through the use of a unified constitutive model and finite element analysis for prediction.

Effects of crack-γ/γ' interface relative distributions on the deformation and crack growth behaviors of a nickel-based superalloy.

Using the molecular dynamics (MD) method, we investigated the effects of crack distributions on the deformation and crack growth of a nickel (Ni)-based superalloy. The results indicated that as the distance between two cracks increased, both tensile strength and plasticity decreased, while the crack growth rate significantly increased. In systems with short crack distances, strong interactions occurred between the dislocations that emitted from two cracks and the γ/γ' interface mismatched dislocation network. These interactions led to an overlap in the plastic zones ahead of the crack tips at the γ/γ' interface, which resulted in significant passivation at the front and middle regions of the cracks. Consequently, the two cracks merged in the X-direction to form a wide crack. The cracks coalescence consumed a lot of external deformation work, resulting in the highest tensile strength and plasticity. In this study, we proposed a potential approach to simultaneously enhance the strength and plasticity of multidefect systems, providing a theoretical basis for explaining deformation mechanisms and crack growth in these systems.

Optimization of cutout characteristics in AISI 1045 steel plates for high-cycle fatigue life extension

Crack growth is a pivotal concern in structural engineering, directly impacting structures’ stability, quality, and overall lifespan. This study addresses this challenge by investigating structural optimization strategies to mitigate fatigue crack growth (FCG) by strategically incorporating stop-drilled cutouts near the crack tip. The research introduces three optimization problems, focusing on determining the optimal cutout position with a fixed radius, the optimal cutout radius with a fixed position, and the optimal cutout shape with a constant position for the cutout’s center. Experimental assessments are conducted on an edge-cracked AISI 1045 steel plate to evaluate the effectiveness of these optimization strategies in enhancing fatigue life. Employing the Extended Finite Element Method (XFEM) for numerical simulations and Particle Swarm Optimization (PSO) for the optimization process, the findings reveal that strategically positioned cutouts substantially reduce the crack growth rate. Optimal cutout placement significantly improves fatigue life, demonstrating an approximate 287% increase. The analysis affirms the accuracy of the numerical model in predicting fatigue life and crack growth paths, validated through comparison with experimental data. In summary, this research underscores the effectiveness of optimization techniques in mitigating fatigue crack growth, providing valuable insights for structural integrity enhancement in structural mechanics.

The Influence of Residual Stress on Fatigue Crack Growth Rates in Stainless Steel Processed by Different Additive Manufacturing Methods

The properties and microstructure of Type 304L stainless steel produced by two additive manufacturing (AM) methods—directed energy deposition (DED) and powder bed fusion (PBF)—are evaluated and compared. Localized heating and steep temperature gradients of AM processes lead to significant residual stress and distinctive microstructures, which may be process-specific and influence mechanical behavior. Test data show that materials produced by DED and PDF have small differences in tensile strengths but clear differences in residual stress and microstructural features. Measured fatigue crack growth rates (FCGRs) for cracks propagating parallel to and perpendicular to the build directions differ between the two AM materials. To separate the influences of residual stress and microstructure, K-control test procedures with decreasing and constant stress intensity factor ranges are used to measure FCGRs in the near-threshold regime (crack growth rates ≤ 1 × 10−8 m/cycle). Residual stress is quantified by the residual stress intensity factor, Kres, measured by the online crack compliance method. Correcting the FCGR data for differences in Kres brings results for specimens of the two AM materials into agreement with each other and with results for wrought specimens, when the latter are corrected for crack closure. Differences in microstructure and tensile strength have an insignificant influence on FCGRs in these tests.