Mechanism Of Fatigue Crack Propagation Research Articles

Cyclic Deformation Behavior of Additive-Manufactured IN738LC Superalloys from Virgin and Reused Powders.

In laser powder bed fusion (L-PBF), most powders are not melted in the chamber and collected after the printing process. Powder reuse is appreciable without sacrificing the mechanical properties of target components. To understand the influences of powder reuse on mechanical performance, a nickel-based superalloy, IN738LC, was investigated. Powder morphology, microstructure and chemical compositions of virgin and reused powders were characterized. An increase in oxygen content, generally metallic oxides, was located on the surface of powders. Monotonic tensile and cyclic fatigue were tested. Negligible deterioration in strength and tensile ductility were found, while scattered fatigue performance with regard to fatigue life was shown. Deformation and fatigue crack propagation mechanisms were discussed for describing the powder degradation effects.

Effect of temperature on low cycle fatigue behavior of T91 steel in liquid lead-bismuth eutectic environment at 150–550 °C

The low cycle fatigue behavior of T91 steel in a lead–bismuth eutectic and an air environment was investigated at 150–550 °C. The temperature dependent “fatigue endurance peak and trough” was found in liquid LBE. Quasi-cleavage cracking was observed on the fracture surface at 150 °C and 350 °C, which indicates the occurrence of liquid metal embrittlement (LME). The plasticity recovery reduced LME susceptibility of T91 steel at 250 °C and 550 °C. The effects of LME, liquid LBE corrosion and dynamic strain aging on the mechanisms of fatigue crack initiation and propagation are discussed.

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.

Effect of particle morphology on fatigue crack propagation mechanism of TiB2-reinforced steel matrix composites

Fatigue crack growth mechanisms of as-cast and hot-rolled TiB2-reinforced steel matrix composites (SMCs) fabricated by eutectic solidification are systematically investigated through in-situ scanning electron microscopy (SEM) fatigue experiment system. The experiment results show that the as-cast SMC exhibits a relatively superior fatigue crack growth resistance with respect to the hot-rolled SMC. A lower FCGR at the low and intermediate stress intensity factor (ΔK) range in as-cast SMC is found, which is related to the TiB2 particle morphology. Hexagonal and rectangular primary particles have a high Young’s modulus and strong interfacial bonding, which inhibits the advancing of plastic deformation in front of the crack tip. Three-dimensional interconnected eutectic particle phases composed of dendrites can produce a hardening effect at crack tip and restrain the generation of plastic deformation in this morphology region. The stress-strain field in front of the crack tip is changed by the hard TiB2 particles, which leads to the deflection of the crack path. Hence, the tortuous crack path created by facing these particles causes reduction in the effective driving force of the crack tip and slows the FCGR. The net mismatch between the surfaces lead to premature contact and roughness-induced crack closure further reducing the FCGR. In comparison, large number of hot-rolled micro-cracks in the hot-rolled SMC are detrimental to fatigue crack growth resistance through the coalesce mechanism of micro-cracks, thereby accelerating the FCGR.

Multiaxial fatigue of Inconel 718 produced by Selective Laser Melting at room and high temperature

This work investigates the fatigue and cyclic plasticity of Inconel 718 produced by Selective Laser Melting (SLM) at room and elevated temperature. Strain-controlled axial, torsional and proportional tests with Rɛ=0 were carried out at 20 °C and 450 °C using thin-walled specimens, resulting in fatigue lives ranging from 103 to 105 cycles. SLM Inconel 718 exhibits a columnar microstructure along the build direction, and the dominant defect related to the manufacturing process was gas pores. Fatigue crack initiation occurred a carbides and/or metallic inclusions for all tests and, therefore, intrinsic defects related to the manufacturing process did not induce premature initiation of fatigue cracks. The orientation of macroscopic fatigue cracks was consistent with the plane of maximum shear stress for all loading conditions. The fatigue crack propagation mechanism of SLM Inconel 718, on the other hand, depends on the loading path and temperature. Both the equivalent strain amplitude and the Fatemi–Socie criterion could correlate fatigue life of all loading conditions at 20 °C and 450 °C within factor-of-two boundaries. As a general trend, the fatigue endurance of SLM Inconel 718 is inferior to its forged counterpart, especially at 450 °C. The cyclic plasticity behaviour of SLM and forged Inconel 718 is similar at both 20 °C and 450 °C and can be simulated by the Chaboche model.

Analysis of fatigue crack propagation mechanism of Ni3Al under supergravity at atomic size

Mechanisms of fatigue crack propagation of Ni3Al alloy under supergravity are studied by the molecular dynamics method. The initial model of the crack is a [100](010) crack in Ni3Al. Changes in the microstructure evolution, crack growth rate, and stress intensity factor of [100](010) crack are compared and analyzed without and with supergravity. The results show that the deformation mechanisms of the crack tip are slip bands along the a/6[112] direction by dislocation analysis in the absence of supergravity cyclic loading; after adding to supergravity, the mechanisms of crack propagation have changed, multiple voids are formed at the crack tip, and the dislocation lines also grow faster, which cause severe damage to the internal structure of the [100](010) crack in Ni3Al. By tracking the changes in crack length and width, it is found that the supergravity accelerates the growth of crack length and width and reduces the stress intensity factor threshold. Finally, the crack propagation rate increases under supergravity conditions.

Digital-image-correlation observation of cyclic plastic strain field during the damage-accumulation mode of fatigue crack propagation under pure cyclic mode II loading for cold-rolled SUS430 steel

Fatigue cracks propagate intermittently by the cyclic initiation and coalescence of voids in front of the fatigue crack tip during fatigue crack propagation in the damage accumulation mode. In this study, digital image correlation is used to measure the evolution of the measured plastic strain distribution near the crack tip with loading and cyclic loading during one cycle. The evolution is estimated based on strain distribution measurements results and mechanical considerations. The strain is set at the unloading point because results indicate that the crack propagated in the region where the experimental shear plastic strain is the maximum in the first quarter cycle (at the first maximum load); the measured plastic strain is almost constant in the region where the crack propagates, and the crack is initiated by a subsequent cyclic strain localization and coalescence with the main crack. This study clarified the damage accumulation mode fatigue crack propagation mechanism with the measured strain behavior, and presents a method to use continuum plastic strain at the crack tip as a mechanical driving force for this mode.

Revealing the fatigue crack propagation mechanism of a Ni-based superalloy electron beam welded joint through in-situ SEM observation

In this study, in-situ scanning electron microscope (SEM) fatigue crack propagation experiments for electron beam welded joints of GH4169 Ni-based superalloy are carried out. Based on material characterization and analysis, the corresponding fatigue crack propagation mechanism of the welded joint (WJ) is investigated. Compared to the base material (BM), the WJ has comparable static strength, but worse plasticity. Significantly, the WJ has longer fatigue crack growth life than that of the BM. The fatigue crack growth rate (FCGR) curves of the WJ and the BM intersected with each other. In particular, under low stress intensity factors (ΔK) level, the FCGR of the WJ is lower than that of the BM. Under high ΔK level, the FCGR of the WJ is higher than that of the BM. The steep FCGR curve of the WJ can be attributed to the unique weld texture and a shielding effect caused by the weld strength mismatch.

Effect of macrozones on fatigue crack initiation and propagation mechanisms in a forged ti-6Al-4V alloy under fully-reversed condition

In the present study, the mechanisms of fatigue crack initiation and propagation was investigated in a forged Ti-6Al-4V alloy with a bimodal microstructure through a combination of experiments and crystal plasticity finite element simulations. Transgranular crack initiations were observed on both basal and prismatic planes, in grains exhibiting high plastic activity. A fatigue indicator parameter based on the Tanaka-Mura model was found to correctly identify these critical grains. Intergranular crack initiations were found in pairs of grains sharing the same basal plane. An analysis of the grain boundary configuration suggested that these grains were separated by a (0001) tilt subgrain boundary as the c-axis was argued to belong to the boundary plane. Short crack propagation was found to be transgranular and crystallographic on either basal or prismatic plane depending on the microtextured regions they belong. Crack path was more serrated with high number of deflection and branching in regions favoring prismatic activity. However, no significant difference in terms of crack propagation rate was noticed between the different macrozones which was attributed to a relatively similar plastic activity in both regions. An analysis of the M-index finally suggested that the presence of a macrozone was not a necessary condition for crack initiation but appeared necessary for its propagation.

Influence of surface integrity induced by multiple machining processes upon the fatigue performance of a nickel based superalloy

Machining operations are of key importance to the fatigue performance of nickel based superalloys due to the high thermal/mechanical loadings yielded on the machined workpiece which can significantly alter the surface integrity of the components. Therefore, understanding the influence mechanisms of machining induced surface integrity upon fatigue response is vital to determine their manufacturing processes and applications. In this respect, this paper investigates the surface integrity of nickel based superalloy subject to different mechanical and thermal loadings induced by various machining processes including conventional machining (e.g. finish and rough milling) and nonconventional machining (e.g. laser assisted milling and abrasive waterjet cutting) methods, as well as their influences upon fatigue performance and failure mechanisms. In-depth surface metallurgical and crystallographic analysis has been conducted to reveal the surface damage mechanisms, which allows the description of the machining induced mechanical and thermal alterations on the machined workpiece. Furthermore, the examination of the fractography from the fatigue specimen has been conducted, which enables the understanding of the influence mechanism of the corresponding surface defects on the fatigue crack initiation and propagation, subject to a four points bending fatigue test. While the resulted S-N curves indicate that the high cycle fatigue of machined nickel based superalloy is mainly dominated by the machining induced residual stress conditions, the surface defects from different machining processes can particularly influence fatigue crack initiation and propagation mechanisms in both the low and high cycle regimes.

Mechanisms of fatigue crack initiation and propagation in auxetic meta-biomaterials

The fatigue performance of additively manufactured auxetic meta-biomaterials made from commercially pure titanium has been studied only recently. While certain assumptions have been made regarding the mechanisms underlying their fatigue failure, the exact mechanisms are not researched yet. Here, we studied the mechanisms of crack formation and propagation in cyclically loaded auxetic meta-biomaterials. Twelve different designs were subjected to compression-compression fatigue testing while performing full-field strain measurement using digital image correlation (DIC). The fatigue tests were stopped at different points before complete specimen failure to study the evolution of damage in the micro-architecture of the specimens using micro-computed tomography (micro-CT). Furthermore, finite element models were made to study the presence of stress concentrations. Structural weak spots were found in the inverted nodes and the vertical struts located along the outer rim of the specimens, matching the maximum principal strain concentrations and fracture sites in the DIC and micro-CT data. Cracks were often found to originate from internal void spaces or from sites susceptible to mode-I cracking. Many specimens maintained their structural integrity and exhibited no signs of rapid strain accumulation despite the presence of substantial crack growth. This observation underlines the importance of such microscale studies to identify accumulated damage that otherwise goes unnoticed. The potential release of powder particles from damaged lattices could elicit a foreign body response, adversely affecting the implant success. Finding the right failure criterion, therefore, requires more data than only those pertaining to macroscopic measurements and should always include damage assessment at the microscale. Statement of significanceThe negative Poisson's ratio of auxetic meta-biomaterials makes them expand laterally in response to axial tension. This extraordinary property has great potential in the field of orthopedics, where it could enhance bone-implant contact. The fatigue performance of additively manufactured auxetic meta-biomaterials has only recently been studied and was found to be superior to many other bending- and stretch-dominated micro-architectures. In this study, we go beyond these macroscopic measurements and focus on the crack initiation and propagation. Full-field strain measurements and 3D imaging are used to paint a detailed picture of the mechanisms underlying fatigue. Using these data, specific aspects of the design and/or printing process can be targeted to improve the performance of auxetic meta-biomaterials in load-bearing applications.

Fatigue Crack Growth Behaviour and Role of Roughness-Induced Crack Closure in CP Ti: Stress Amplitude Dependence

This paper investigated the fatigue crack propagation mechanism of CP Ti at various stress amplitudes (175, 200, 227 MPa). One single crack at 175 MPa and three main cracks via sub-crack coalescence at 227 MPa were found to be responsible for fatigue failure. Crack deflection and crack branching that cause roughness-induced crack closure (RICC) appeared at all studied stress amplitudes; hence, RICC at various stages of crack propagation (100, 300 and 500 µm) could be quantitatively calculated. Noticeably, a lower RICC at higher stress amplitudes (227 MPa) for fatigue cracks longer than 100 µm was found than for those at 175 MPa. This caused the variation in crack growth rates in the studied conditions.

Fatigue crack propagation in carbon steel using RVE based model

A representative volume element (RVE) based multi-scale method is proposed to investigate the mechanism of fatigue crack propagation by the molecular dynamics (MD) and the extended finite element methods(XFEM) in this study. An atomic model of carbon steel plate is built to study the behavior of fatigue crack at the micro scale by MD method. Then the RVE model for fatigue crack propagation should be built by fitting the data which was obtained from the MD result with the Paris law model. Moreover, the effect of micro-structural defects including interstitial atoms, vacancies have also been considered in this study. The results indicate that the micro-structural defects can deeply influence the values of Paris law constants and the life of the specimen can be evaluated by the proposed method.

Experimental investigation on fatigue crack initiation and propagation mechanism of friction stir lap welded dissimilar joints of magnesium and aluminum alloys

At present, the effect of the microstructure of friction stir lap welded (FSLW) dissimilar joints of Mg and Al alloys on fatigue crack initiation and propagation is not clear. In this article, the effects of the microstructure of FSLW dissimilar joints of AZ31 Mg and Al–Zn–Cu–Mg alloys are studied. The grain orientations of the crack initiation and propagation region were characterized by electron backscattering diffraction analysis. And the models for fatigue crack propagation in the different grain orientations were established. Based on the above experimental results, the initiation mechanisms of fatigue cracks were clarified, and the effects of grain orientations on crack propagation were revealed. The results showed that the crack initiation was caused by the simultaneous activation of the (0002, 21¯1¯0] basal slip and twinning in various directions by fatigue loading. The direction of crack propagation was dominated by the (0002)[2¯110] basal slip with (1¯012)[1¯011¯] twinning adjusting in the crack propagation zone. The cyclic effect of concentration and release of stress on the activation and termination of twins was the main reason for the zigzag path of crack propagation.

Fatigue damage prognosis of steel bridges under traffic loading using a time-based crack growth method

Traditionally, the fatigue damage assessment of steel bridges is conducted using cycle-based methods. Cycle-based methods require stress time history be transformed to cycle history first before fatigue analysis can be performed. However, well-defined cycle history does not exist for the traffic-induced stress time history of bridges as it contains numerous large and small cycles with random stress ranges embedded together. To address this inherent difficulty, a time-based fatigue crack growth (FCG) model is proposed for fatigue damage prognosis of steel bridges under traffic loading. The time-based FCG method describes the crack growth in the time domain through a crack growth kinetics function derived based on the physical mechanism of fatigue crack propagation. To demonstrate the proposed method, numerical simulations are first performed using full-scale coupled vehicle-bridge interaction framework to generate stress time histories of a typical steel bridge under traffic loading. Then, FCG analysis is performed using the time-based method and the effects of road surface roughness and vehicle weight on the FCG are studied. Finally, a case study on the I-10 Twin Span Bridge is presented to demonstrate the time-based FCG method for fatigue damage prognosis using in situ monitoring data. The results show that the proposed method can be used to directly predict the FCG of steel bridges in the time domain using stress time histories obtained either from stress analysis or in situ monitoring.

Cyclic Deformation Induced Residual Stress Evolution and 3D Short Fatigue Crack Growth Investigated by Advanced Synchrotron Tomography Techniques.

Diffraction and phase contrast tomography techniques were successfully applied to an austenitic–ferritic duplex stainless steel representing exemplarily a metallic material containing two phases with different crystal structures. The reconstructed volumes of both phases were discretized by finite elements. A crystal plasticity finite-element analysis was executed in order to simulate the development of the experimentally determined first and second order residual stresses, which built up due to the manufacturing process of the material. Cyclic deformation simulations showed the single-grain-resolved evolution of initial residual stresses in both phases and were found to be in good agreement with the experimental results. Solely in ferritic grains, residual stresses built up due to cyclic deformation, which promoted crack nucleation in this phase. Furthermore, phase contrast tomography was applied in order to analyze the mechanisms of fatigue crack nucleation and short fatigue crack propagation three-dimensionally and nondestructively. The results clearly showed the significance of microstructural barriers for short fatigue crack growth at the surface, as well as into the material. The investigation presented aims for a better understanding of the three-dimensional mechanisms governing short fatigue crack propagation and, in particular, the effect of residual stresses on these mechanisms. The final goal was to generate tailored microstructures for improved fatigue resistance and enhanced fatigue life.

The Mechanism of Creep during Crack Propagation of a Superalloy under Fatigue-Creep-Environment Interactions.

In this study, we examine the mechanism of fatigue-crack propagation in 718Plus superalloy at 704 °C under fatigue–creep–environment interactions, in this case, a new turbine disc material used in aero-engines at high temperatures. The effect of creep on the fatigue-crack propagation of the superalloy at high temperature was also researched. There was an unusual inhibitory effect on the propagation of fatigue cracks in 718Plus alloy, in which the propagation rate of fatigue cracks decreased with the increase of creep time through exploration of dwell-fatigue-crack growth (DFCG) test with different creep times. In particular, under lower stress intensity factor range (ΔK) conditions, the fatigue-crack growth rate with a 90 s hold-time was one order of magnitude lower than that with a 5 s hold-time. Conversely, the gap between the two DFCGs gradually decreased with the increase of ΔK and the creep effect became less apparent. The mechanism of crack propagation in 718Plus alloy under two creep conditions was investigated from a viewpoint of the microstructure, oxidation rate at high temperature and crack path morphology under different conditions.

Effect of shot peening on very high cycle fatigue of 2024-T351 aluminium alloy

To investigate the influence of shot peening (SP) on very high cycle fatigue (VHCF) performance of 2024-T351, the specimens with three surface conditions were performed under ultrasonic fatigue tests: mechanicallypolished without peening (NP), ceramic shot peening (SP1), steel and glass mixed shot peening (SP2). The roughness, microhardness, residual stress, fractography measurement and scanning electron microscopy (SEM) were applied before fatigue test to characterize the effective layer induced by the peening treatment. For the failed specimens, the fracture surface were analysed using SEM to study the mechanisms of fatigue crack propagation. In addition, the fatigue life curve in ultra-high cycle region continuously decreased in the three series of specimens. However, the experimental results revealed that fatigue strength improvement resulting from shot peening treatment was negligible in very high cycle regime. Furthermore, the stress intensity factor for the surface crack initiation (SCI) and interior crack initiation (ICI) was discussed based on quantitative analysis on the fracture surface. The average values of ΔKfish-eye for NP, SP1 and SP2 specimens are about 2.22, 1.48 and 1.61 MPa · m1/2, respectively.

Microstructure characterization and mechanism of fatigue crack propagation of 6082 aluminum alloy joints

In this research the metal inert gas (MIG)welding was applied on 8.6 mm thick 6082-T6 aluminum alloy. It was found that the hardness of the 6082 high-strength aluminum alloy weld center is the lowest, the hardness is 84 HV, and the hardness of the softened zone is 100 HV. In the fatigue crack stability propagation stage, when the crack between the fatigue strips encounters the non-deformable second phase particles, the non-deformable second phase particles continue to propagation forward under the action of dislocations, and the deformable second phase particles have an effect on the crack and the crack does not expand. The crack between the fatigue strips is mainly caused by the tear propagation and propagations in a "Z" shape.

Fatigue crack propagation behavior of fuel cell membranes after chemical degradation

The durability of fuel cells is significantly impaired by chemical and mechanical degradations of perfluorosulfonic-acid membranes. However, how the mechanical degradation, especially the fatigue crack propagation behavior, is impacted by chemical degradation is not clear. In this paper, the fatigue crack propagation behavior of Nafion 212 and Nafion XL composite membranes after chemical degradation are investigated. The fluoride release rates of Nafion 212 and Nafion XL membrane are 0.335 and 0.095 μmol cm−2 h−1, respectively. Likewise, the fatigue crack propagation rate of Nafion 212 membrane is also larger, which is attributed to two fatigue crack propagation mechanisms induced by chemical degradation, including bubble collapsing and pore interconnecting. By contrast, the fatigue crack propagation mechanism of Nafion XL membrane is not significantly changed where chemical degradation only accelerates crack growth in exterior surface layers. These findings provide new insights into the failure mechanisms under combined chemical and mechanical degradations.