While fatigue crack growth is inherently a three-dimensional challenge, it is often modelled in two dimensions for simplicity. This study explores the relationship between the two-dimensional primary plastic zone (PPZ) on the surface of specimens and the three-dimensional twisting of the crack front leading to a slanted crack front. Fatigue crack growth experiments were conducted using 2-mm-thick MT-160 AA2024-T3 sheet specimens in both L-T and T-L crack orientations. High-resolution digital image correlation (HR-DIC) was employed to capture the PPZ within the surface displacement data and correlate its morphology with the twisting angle of the slanted crack front.Further, this study investigates how the twisting of the crack front affects the crack propagation curve, represented as da/dN−ΔK, by examining its influence on the mixed-mode I/II/III loading state along the crack front. Here, we utilize finite element simulations to derive a mapping function that adjusts ΔK to ΔKeqv, accounting for the twisted crack front caused mixed-mode loading conditions. The modified da/dN−ΔKeqv curves for both L-T and T-L orientations demonstrated similar behaviour, suggesting that differences in their crack front twisting may explain the discrepancies observed in their traditional da/dN−ΔK crack propagation curves.
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