Increase In Crack Growth Rate Research Articles

Fatigue Crack Growth Mechanisms for Nickel-based Superalloy Haynes 282 at 550-750 °C

The fatigue crack growth rates for nickel-based superalloy Haynes 282 were measured at 550, 650, and 750 C using compact tension specimens with a load ratio of 0.1 and cyclic loading frequencies of 25 and 0.25 Hz. The crack path was observed to be primarily transgranular for all temperatures, and the observed effect of increasing temperature was to increase the fatigue crack growth rates. The activation energy associated with the increasing crack growth rates over these three temperatures was calculated less than 60 kJ/mol, which is significantly lower than typical creep or oxidation mechanisms; therefore, creep and oxidation cannot explain the increase in fatigue crack growth rates. Transmission electron microscopy was done on selected samples removed from the cyclic plastic zone, and a trend of decreasing dislocation density was observed with increasing temperature. Accordingly, the trend of increasing crack growth rates with increasing temperature was attributed to softening associated with thermally assisted cross slip and dislocation annihilation.

Fatigue crack growth in a nickel-based superalloy at elevated temperature - experimental studies, viscoplasticity modelling and XFEM predictions

Abstract Background Nickel-based superalloys are typically used as blades and discs in the hot section of gas turbine engines, which are subjected to cyclic loading at high temperature during service. Understanding fatigue crack deformation and growth in these alloys at high temperature is crucial for ensuring structural integrity of gas turbines. Methods Experimental studies of crack growth were carried out for a three-point bending specimen subjected to fatigue at 725°C. In order to remove the influence of oxidation which can be considerable at elevated temperature, crack growth was particularly tested in a vacuum environment with a focus on dwell effects. For simulation, the material behaviour was described by a cyclic viscoplastic model with nonlinear kinematic and isotropic hardening rules, calibrated against test data. In combination with the extended finite element method (XFEM), the viscoplasticity model was further applied to predict crack growth under dwell fatigue. The crack was assumed to grow when the accumulated plastic strain ahead of the crack tip reached a critical value which was back calculated from crack growth test data in vacuum. Results Computational analyses of a stationary crack showed the progressive accumulation of strain near the crack tip under fatigue, which justified the strain accumulation criterion used in XFEM prediction of fatigue crack growth. During simulation, the crack length was recorded against the number of loading cycles, and the results were in good agreement with the experimental data. It was also shown, both experimentally and numerically, that an increase of dwell period leads to an increase of crack growth rate due to the increased creep deformation near the crack tip, but this effect is marginal when compared to the dwell effects under fatigue-oxidation conditions. Conclusion The strain accumulation criterion was successful in predicting both the path and the rate of crack growth under dwell fatigue. This work proved the capability of XFEM, in conjunction with advanced cyclic viscoplasticity model, for predicting crack growth in nickel alloys at elevated temperature, which has significant implication to gas turbine industries in terms of “damage tolerance” assessment of critical turbine discs and blades.

Effects of microstructure on high temperature dwell fatigue crack growth in a coarse grain PM nickel based superalloy

The influence of microstructure on the dwell fatigue crack growth behaviour of an advanced nickel-based superalloy was investigated at a temperature of 700°C. Microstructural variations were induced by heat treatment variables: different cooling rates of quenching from super-solvus solution heat treatment, 0.7 and 1.8°Cs−1, and an addition of a high temperature stabilisation heat treatment (2h at 857°C) between the solution treatment and the final ageing treatment. With a one hour dwell introduced at the peak load of the fatigue cycle, such different microstructural conditions can lead to a difference of up to two orders of magnitude in crack growth rates in air, when compared to those obtained under baseline fatigue loading. By performing such dwell fatigue and baseline fatigue tests in vacuum, it is confirmed that such increases in crack growth rates under dwell fatigue loading in air are mainly environmentally related. Transmission electron microscopy (TEM) was utilised to analyse both crack tip oxides and associated deformation mechanisms in the matrix. A novel mechanism taking into account competing interactions of crack tip oxidation (leading to increases in crack growth rates) and stress relaxation (leading to decreases in crack growth rates) is outlined.

Unique Appearance of Lamellar Cleavage Patterns on Fracture Surfaces of Ti-Based Amorphous Matrix Composite

In order to improve mechanical properties of Ti-based amorphous matrix composites basically composed of ductile β-Ti dendrites and brittle amorphous matrix by overcoming their inherent brittle nature, their fracture mechanisms should be verified in relation with microstructure, stress intensity factor level, and crack growth rate. In this study, thus, detailed fractographic observations including the unique appearance of lamellar cleavage patterns, which has not been reported in previous studies on conventional metals and alloys, were conducted. According to fractographic results, lamellar cleavage patterns were formed by repeated interruptions of crack propagation on {100} cleavage planes by difference between dendrite orientation and loading direction. Ductile-to-brittle transition phenomenon (ductile dimpled fracture → lamellar cleavage fracture → ordinary cleavage fracture in dendrite areas, and vein pattern → smooth pattern in amorphous matrix areas) occurred with increasing crack growth rate was also plausibly explained by the concept of time required for crack growth as well as dendrite orientation.

Experimental investigation and numerical simulation on fatigue crack behavior of bridge steel WNQ570 base metal and butt weld

The experimental study on the fatigue crack growth rate and the threshold of high strength bridge steel WNQ570 base metal and butt weld has been performed. Two data processing methods are conducted to derive fatigue crack growth parameters of 95% survival probability. It turns out that the fatigue crack growth rate based on each specimen data is larger than that based on group method of data processing in terms of normal stress intensity range (10–70MPam0.5). The fatigue crack growth rates increase and the fatigue crack growth thresholds decrease with increasing stress ratios. For WNQ570 of the batch utilized in this research, the fatigue crack growth rate of base metal is lower than butt weld. The fatigue crack performance of WNQ570 base metal is also better than other common bridge steels including HPS485W, 14MnNbq, Q345qD and the universal steel performance provided by BS7910 and IIW-1823-07. Based on the measured FCGR parameters, numerical simulation by Franc3D and ABAQUS can precisely predict the fatigue life of compact tension specimens, which demonstrates that simulation method is appropriate to be applied to fatigue assessment practice of whole steel bridges based on linear elastic fracture mechanics (LEFM).

Underload‐induced crack growth behaviour of minor cycles of pipeline steel in near‐neutral pH environment

AbstractDespite decades of research, the mechanisms of near‐neutral pH stress corrosion cracking of pipeline steel are still not fully understood. This investigation was aimed to understand the effect of minor cycles with very high R ratios (minimum stress/maximum stress) on crack growth in air and in near‐neutral pH environments. It has been demonstrated that the minor cycle, even with an R ratio as high as 0.9, could significantly contribute to the crack growth of pipeline steels in the presence of a large underload cycle with a low R ratio of 0.5 in near‐neutral pH environment. Comparing with constant amplitude tests, an increase of crack growth rate by a factor of 3 and 5 was observed when some non‐propagating minor cycles were combined with an underload cycle for tests in air and in near‐neutral pH solution, respectively. Based on the test results, the crack growth mechanisms during minor cycle loading in near‐neutral pH environments were discussed and practical strategies aimed to minimise crack growth during pipeline operation were also proposed.

Influence of overloads on dwell time fatigue crack growth in Inconel 718

Inconel 718 is one of the most commonly used superalloys for high temperature applications in gasturbines and aeroengines and is for example used for components such as turbine discs. Turbine discs can be subjected to temperatures up to ~700°C towards the outer radius of the disc. During service, the discs might start to develop cracks due to fatigue and long dwell times. Additionally, temperature variations during use can lead to large thermal transients during start-up and shutdown which can lead to overload peaks in the normal dwell time cycle. In this study, tests at 550°C with an overload prior to the start of each dwell time, have been performed. The aim of the investigation was to get a better understanding of the effects of overloads on the microstructure and crack mechanisms. The microstructure was studied using electron channelling contrast imaging (ECCI). The image analysis toolbox in Matlab was used on cross sections of the cracks to quantify: crack length, branch length, and the number of branches in each crack. It was found that the amount of crack branching increases with an increasing overload and that the branch length decreases with an increasing overload. When the higher overloads were applied, the dwell time effect was almost cancelled out. There is a strong tendency for an increased roughness of the crack path with an increasing crack growth rate.

Crystallographic orientation and temperature effects on the fatigue crack growth rate and resulting fracture surface morphology in PWA1484 single crystal superalloy

ABSTRACTThis research looked at the effect of crystallographic orientation and temperature on the fatigue crack growth rate and the resulting fracture surface morphology in PWA1484 single crystal superalloy. Two groups of single edge notch tension specimens, one group with controlled secondary orientations and one group with uncontrolled secondary orientation, were tested at temperatures from 649°C to 982°C at R‐ratios of 0.1 and 0.7. It was found that the effect of temperature on the crack growth rate becomes more pronounced as the crack driving force increases while the secondary orientation and R‐ratio effects on the crack growth rate increase with increasing temperature. Two types of crack surface morphology were seen during fractography. The first was a precipitate avoidance (γ′ avoidance) morphology that was rolling but still predominantly flat when observed on a larger scale. In <001> primary oriented specimens, this fracture mode tended to follow the precipitate/matrix faces (microscopically cubic) while macroscopically staying essentially normal to the applied loads. The second mode was a form of cleavage (γ′ shearing) and occurred predominantly on octahedral crystallographic planes.

Reduced Dwell-Fatigue Resistance in a Ni-Base Superalloy After Short-Term Thermal Exposure

The effect of short-term thermal exposure on microstructure and dwell-fatigue resistance of Ni-base superalloy 718Plus was investigated. Contrary to previous studies performed after long-term exposure, an increase in the dwell-fatigue crack growth rate was observed, which was connected to a small increase in the size of the hardening precipitates. The proposed controlling mechanism was the stress relaxation rate at the crack tip, and based on this a schematic model for the development of the properties during exposure is presented.

Thresholds of time dependent intergranular crack growth in a nickel disc alloy Alloy 720Li

At high temperatures in air, introducing a dwell period at the peak stress of fatigue cycles promotes time dependent intergranular crack growth which can increase crack growth rates by upto a few orders of magnitude from the rates of transgranular fatigue crack growth in superalloys. It is expected that time dependent intergranular crack growth in nickel-based superalloys may not occur below a critical mechanical driving force, Δ K th−IG , analogous to a fatigue threshold (Δ K th ) and a critical temperature, T th . In this study, dwell fatigue crack growth tests have been carefully designed and conducted on Alloy 720Li to examine such thresholds. Unlike a fatigue threshold, the threshold stress intensity factor range for intergranular crack growth is observed to be highly sensitive to microstructure, dwell time and test procedure. The near threshold crack growth behaviour is made complex by the interactions between grain boundary oxidation embrittlement and crack tip stress relaxation. In general, lower Δ K th−IG values are associated with finer grain size and/or shorter dwell times. Often a load increasing procedure promotes stress relaxation and tends to lead to higher Δ K th−IG . When there is limited stress relaxation at the crack tip, similar Δ K th−IG values are measured with load increasing and load shedding procedures. They are generally higher than the fatigue threshold (Δ K th ) despite faster crack growth rates (d a /d N ) in the stable crack growth regime. Time dependent intergranular crack growth cannot be activated below a temperature of 500 ∘ C.

Fatigue Crack Initiation and Growth of Aluminum Alloy with Stress Ratio Effects

Fatigue crack initiation and growth of aluminum alloys with stress ratio were investigated due to it was widely used in aircraft production parts. Various types of aluminium alloy have been selected (6063-T6, 7075-T6, and 2024-T351). Compact design standard based on ASTM standard E647-11 was used for specimen. Cyclic loading experiment was conducted using Instron 8801 Hydraulic Server Machine with da/dN software for setup and parameter setting. Investigations on crack propagation and fracture surface were done by using Scanning Electron Microscope (SEM) to obtain the image of the specimen surface. Further analysis was done on the image to study on the crack initiation and propagation. Various stress ratio effects were set for the compact specimens having thickness 12.7 mm. Relationship between crack growth rate and the stress intensity factor range were further identified with the stress ratio effects. The gradients of crack growth rate increase while the stress ratio, R increase. Higher R-ratio results in higher value range of minimum load applied. Paris law and Modified Forman law were used as comparison with the experimental data for validation purposes and to provide the level of precision.

Corrosion fatigue crack growth behavior of 7075-T6 under biaxial tension–tension cyclic loading condition

Biaxial and uniaxial fatigue crack growth of aluminum alloy 7075-T6 was characterized under air and salt water (3.5%) environments. Biaxial fatigue increased crack growth rate in region I relative to uniaxial fatigue under both environments. Biaxial fatigue increased crack growth rate in region II relative to uniaxial fatigue under salt environment. Crack growth rates in region I were comparable in air and salt environments, while they were faster in salt water than air environment in region II. Biaxial fatigue in salt environment exhibited intergranular cracks along with main transgranular fracture. A mechanism for biaxial corrosion fatigue crack growth is proposed.

Normalizing effect on fatigue crack propagation at the heat-affected zone of AISI 4140 steel shielded metal arc weldings

The fractography and mechanical behaviour of fatigue crack propagation in the heat-affected zone (HAZ) of AISI 4140 steel welded using the shielded metal arc process was analysed. Different austenitic grain size was obtained by normalizing performed at 1200 °C for 5 and 10 hours after welding. Three point bending fatigue tests on pre-cracked specimens along the HAZ revealed that coarse grains promoted an increase in fatigue crack growth rate, hence causing a reduction in both fracture toughness and critical crack length, and a transgranular brittle final fracture with an area fraction of dimple zones connecting cleavage facets. A fractographic analysis proved that as the normalizing time increased the crack length decreased. The increase in the river patterns on the fatigue crack propagation in zone II was also evidenced and final brittle fracture because of transgranular quasicleavage was observed. Larger grains induced a deterioration of the fatigue resistance of the HAZ.

Modelling of high temperature fatigue crack growth in Inconel 718 under hold time conditions

Inconel 718 is a frequently used material for gas turbine applications at temperatures up to 650°C. The main load cycle for such components is typically defined by the start-up and shut-down of the engine. It generally includes hold times at high temperatures, which have been found to have a potential for greatly increasing the fatigue crack growth rate with respect to the number of load cycles. However, these effects may be totally or partly cancelled by other load features, such as overloads or blocks of continuous cyclic loading, and the actual crack propagation rate will therefore depend on the totality of features encompassed by the load cycle. It has previously been shown that the increased crack growth rate found in hold time experiments can be associated with a damage evolution, where the latter is not only responsible for the rapid intergranular crack propagation during the actual hold times, but also for the increased crack growth during the load reversals. In this paper, modelling of the hold time fatigue crack growth behaviour of Inconel 718 has been carried out, using the concept of a damaged zone as the basis for the treatment. With this conceptually simple and partly novel approach, it is shown that good agreement with experimental results can be found.

Effect and mechanism of out-of-plane constraint on creep crack growth behavior of a Cr–Mo–V steel

The effect and mechanism of out-of-plane constraint on creep crack growth rates were experimentally investigated. The results show that the out-of-plane constraint effect on creep crack growth rates is related to C∗-integral levels. In low C∗-integral region, with increasing out-of-constraint, there is a change in creep fracture mode from ductile to brittle intergranular fracture, which leads to the increase in creep crack growth rates. In middle and high C∗-integral regions, the constraint basically has no effect or slight effect on the creep crack growth rates. In creep life assessments, the effects of constraints and C∗-integral levels on the creep crack growth rates should be considered.

Effect of frequency on high-temperature fatigue crack growth in a silicon carbide reinforced silicon nitride composite

A detailed study on a silicon nitride reinforced with silicon carbide whiskers, Si3N4SiCW, has been undertaken at elevated temperature during static and dynamic loading at increasing K and ΔK respectively. It is shown that cyclic sub-critical crack growth rates are lower than static crack growth rates. The increased crack growth rate during static far field loading is attributed to the stress relaxation of the inter-granular glass phase which allows time-dependent processes to occur ahead of the crack tip which lead to enhanced sub-critical crack growth rates. During cyclic fatigue the glass phase has insufficient time to relax and glassy ligaments are able to bridge the crack wake thereby shielding the crack tip from the full force of the applied load. Also, at particular temperatures, bridging between the surfaces of the crack wake by the inter-granular glass phase results in increased strength and fatigue retardation. The extent of ‘crack wake healing’ is shown to be time and temperature dependent. The viscosity of the glass phase is directly related to the temperature and the bonding force associated with glass phase bridging is observed to reduce with increasing temperature. The results from a previous study at room temperature are compared to those found during this investigation.

Micromechanics of brittle creep in rocks

In the upper crust, the chemical influence of pore water promotes time dependent brittle deformation through sub‐critical crack growth. Sub‐critical crack growth allows rocks to deform and fail at stresses well below their short‐term failure strength, and even at constant applied stress (“brittle creep”). Here we provide a micromechanical model describing time dependent brittle creep of water‐saturated rocks under triaxial stress conditions. Macroscopic brittle creep is modeled on the basis of microcrack extension under compressive stresses due to sub‐critical crack growth. The incremental strains due to the growth of cracks in compression are derived from the sliding wing crack model ofAshby and Sammis(1990), and the crack length evolution is computed from Charles' law. The macroscopic strains and strain rates computed from the model are non linear, and compare well with experimental results obtained on granite, low porosity sandstone and basalt rock samples. Primary creep (decelerating strain) corresponds to decelerating crack growth, due to an initial decrease in stress intensity factor with increasing crack length in compression. Tertiary creep (accelerating strain as failure is approached) corresponds to an increase in crack growth rate due to crack interactions. Secondary creep with apparently constant strain rate arises as an inflexion between those two end‐member phases. The minimum strain rate at the inflexion point can be estimated analytically as a function of model parameters, effective confining pressure and temperature, which provides an approximate creep law for the process. The creep law is used to infer the long term strain rate as a function of depth in the upper crust due to the action of the applied stresses: in this way, sub‐critical cracking reduces the failure stress in a manner equivalent to a decrease in cohesion. We also investigate the competition with pressure solution in porous rocks, and show that the transition from sub‐critical cracking to pressure solution dominated creep occurs with increasing depth and decreasing strain rates.

Fatigue reliability analysis of the jacket support structure for offshore wind turbine considering the effect of corrosion and inspection

Due to the high level of fatigue loads as well as a large number of load cycles caused by wind and wave loads together, fatigue performance of welded connections is a design driving criterion for offshore wind turbine support structures. In this paper prediction of fatigue reliability of welded multi-planar tubular joints of the support structure of a fixed jacket offshore wind turbine designed for a northern North Sea site in a water depth of 70m is performed. Dynamic response of the jacket support structure due to wind and wave loads is calculated by using a decoupled procedure with good accuracy. Hot-spot stresses at failure-critical location of the relative reference brace of the selected tubular joint are derived by summation of the single stress components from axial, in-plane and out-of-plane action, the effects of planar and non-planar braces are also considered. A two-parameter Weibull function is used to fit the long-term statistical distribution of hot-spot stress ranges by combination of time domain simulation for representative environmental conditions (wind/sea states) in operational condition. The main uncertainties associated with the whole procedure of reliability analysis are identified and quantified. The load histories are normalized to ensure that fatigue design criteria based on the SN-Miner-Palmgren approach is satisfied. Hence the reliability estimates obtained refer to fatigue design of tubular joints that satisfy design criteria. The reliability analysis is based on fracture mechanics (FM) analysis of crack growth. The corrosion-induced increased crack growth rate is taken into account by considering the increased hot-spot stress range due to changes of nominal stress and stress concentration factors (SCFs) produced by the thickness thinning (wastage) effects of all braces and chord of the selected tubular joint with a general uniform corrosion model. The geometry function effect and the material degradation effect due to corrosion on the reliability analysis are also investigated. The effects of inspection and repair with and without consideration of corrosion are quantified based on the quality of inspection in terms of probability of crack detection curves. The sensitivity of the reliability index on important random variables is estimated.

Contributions of aging to the fatigue crack growth resistance of human dentin

An evaluation of the fatigue crack resistance of human dentin was conducted to identify the degree of degradation that arises with aging and the dependency on tubule orientation. Fatigue crack growth was achieved in specimens of coronal dentin through application of Mode I cyclic loading and over clinically relevant lengths (0⩽a⩽2mm). The study considered two directions of cyclic crack growth in which the crack was either in-plane (0°) or perpendicular (90°) to the dentin tubules. Results showed that regardless of tubule orientation, aging of dentin is accompanied by a significant reduction in the resistance to the initiation of fatigue crack growth, as well as a significant increase in the rate of incremental extension. Perpendicular to the tubules, the fatigue crack exponent increased significantly (from m=14.2±1.5 to 24.1±5.0), suggesting an increase in brittleness of the tissue with age. For cracks extending in-plane with the tubules, the fatigue crack growth exponent does not change significantly with patient age (from m=25.4±3.03 to 22.9±5.3), but there is a significant increase in the incremental crack growth rate. Regardless of age, coronal dentin exhibits the lowest resistance to fatigue crack growth perpendicular to the tubules. While there are changes in the cyclic crack growth rate and mechanisms of cyclic extension with aging, this tissue maintains its anisotropy.

Fatigue crack growth in fibre metal laminates with multiple open holes

ABSTRACTThe fatigue crack growth behaviour of hybrid S2‐glass reinforced aluminium laminates (Glare) with multiple open holes was investigated experimentally and analytically. It was observed that the presence of multiple‐site fatigue damage would increase crack growth rates in the metal layers as two propagating cracks converged. An analytical crack growth model was established for predicting crack growth rates based on empirical Paris equation. The effective stress intensity factor at crack tips is a function of mode I far‐field stress intensity factor, crack opening stress intensity factor and effective non‐dimensional stress intensity factor that incorporated the crack‐bridging effect in fibre metal laminates. The predicted results under different applied stress can capture the trend of averaged crack growth rates in experiments, although deviation exists in the predictions.