Fatigue Crack Propagation Rate Research Articles

Effect of Mode II in the mixed-mode on the fatigue crack growth behaviour for SAPH440 material

In this study, the effect of mixed-mode loading on fatigue crack growth under varying applied loads for SAPH440 material was experimentally investigated. Previous research has either examined the effect of mixed-mode loading at a fixed angle or its effect on slanted cracks. This paper uses a CTS specimen and a loading device to apply varying angles of load during Mode I loading conditions. Initially, a numerical analysis was performed to validate existing equations for the stress intensity factor, which quantifies the crack driving force in the experiments. In the crack initiation region, load shedding techniques and load increasing techniques were used to confirm fatigue cracking considering mixed-mode effects. The change in the threshold value according to the loading angle was also evaluated. In the crack propagation region, a multi-level loading technique was employed to assess the mixed-mode effects under varying loading angles. This process verified the mixed-mode effect under conditions where the applied load angle varies. The fatigue crack fracture surfaces were examined using digital camera capture and SEM. It was found that when mixed-mode loading occurs during Mode I loading, the fatigue crack propagation rate varies depending on the mixed-mode loading angle.

Effect of trace element arsenic on the high cycle fatigue properties and the carbide uniformity in high carbon chromium bearing steel

AbstractIn this paper, the mechanical properties and microstructures of bearing steels with arsenic contents of 30, 40, and 120 ppm have been investigated. The results show that As‐40 steel has the highest tensile strength but lower fatigue strength than As‐120 steel. The fatigue crack propagation rate of As‐120 steel is relatively low, mainly due to the increase in ΔKth. After quenching and tempering, As‐120 steel has larger prior austenite grains and more undecomposed, elongated carbides appear, reducing the uniformity of the steel. For carbides with an aspect ratio greater than 2, they cannot grow by the Oswald mechanism of spontaneous migration but are spheroidized by self‐cracking. The undissolved elongated carbides have a lower chemical potential, which increases the diffusion tendency of arsenic in the matrix. SIMS and EPMA analyses show that there is no significant distortion of the trace element arsenic.

Tensile and Fatigue Strength, Fatigue Crack Propagation Rate, and Fracture Behavior of CaO-Added AM30 Alloy

Tensile and Fatigue Strength, Fatigue Crack Propagation Rate, and Fracture Behavior of CaO-Added AM30 Alloy

Enhanced fatigue crack propagation resistance of a new Al–Cu–Li alloy via different aging processes

The fatigue crack propagation (FCP) behavior of a new Al–Cu–Li alloy under different aging treatments including T3, T8, and non-isothermal aging (NIA) was investigated. It was detected that the T8-24h sample exhibited the highest FCP resistance and the best mechanical performance. Compared with the T3-40D sample, the crack paths of the T8-24h sample and the C150 (non-isothermal peak-aged) sample were more tortuous and the crack width was narrower. Furthermore, the T8-24 sample had the lowest decreased FCP rate by an order of magnitude at the stress intensity factor (ΔK) of 30 MPa·m1/2. A large number of nano-scale T1 phases were precipitated in the T8-24h sample and their number density was also increased compared with the other sample. The presence of the tiny T1 phase plays a crucial role in impeding crack propagation as it can be sheared by dislocations without accumulating damage. This resulted in a substantial improvement both in the mechanical and fatigue properties of the alloy. Moreover, in the Paris stage of FCP, factors such as the size and concentration of precipitates within the grain and grain boundary play a vital role in determining the extent of crack growth. The results of transmission electron microscopy (TEM) bright field images on grain boundaries (GBs) analysis show that the variations in strength between the grain boundary and intragranular regions have a direct influence on the alloy's susceptibility to fatigue and corrosion resistance.

Experimental Study on the Fatigue Crack Propagation Rate of 925A Steel for a Ship Rudder System.

The low-temperature fatigue crack propagation rate of 925A steel, as a rudder steel for polar special ships, has a crucial impact on the evaluation of the fatigue strength of polar ships. The purpose of this article is to study the fatigue crack propagation rate of 925A steel under different low-temperature conditions from room temperature (RT) to -60 °C. The material was subjected to fatigue crack propagation tests and stress intensity factor tests. The experimental tests were conducted according to the Chinese Standard of GB/T6398-2017. The results show that as the temperature decreases, the lifespan of 925A increases. Within a certain stress intensity factor, as the temperature decreases, the fatigue crack propagation rate decreases. At -60 °C, it exhibits ductile fracture; within normal polar temperatures, it can be determined that 925A meets the requirements for low-temperature fatigue crack propagation rates in polar regions. However, in some extreme polar temperatures below -60 °C, preventing brittle failure becomes a key focus of fatigue design. Finally, the fatigue crack propagation behavior at the microscale of 925A steel at low temperatures was described using fracture morphology. The experimental data can provide reference for the design of polar ships to further resist low-temperature fatigue and cold brittle fracture.

Experimental Study on Low-Cycle Fatigue Characteristics of Marine Structural Steel

This research focuses on the experimental investigation of the low-cycle fatigue characteristics of marine structural steel. The study aimed to explore the behavior of marine-grade steel under low-cycle fatigue conditions. The experimental parameters include the fatigue life of the material, crack propagation behavior, and a comprehensive analysis of mechanical properties associated with various loading conditions. Based on the experimental results, a low-cycle fatigue crack propagation rate model for marine structural steel plates was established using CTOD as a characterization parameter. The primary objective of this research is likely to enhance the durability and safety of maritime structures, providing valuable technical insights for the field of naval engineering.

A multi-scale experimental investigation on fatigue crack propagation rate behavior of powder bed fusion-laser beam 316L stainless steel subjected to various heat treatments

In this study, three heat treatments referred to as heat treatment 1 (HT1), HT2, and HT3 were applied to tune the microstructure of powder bed fusion-laser beam (PBF-LB) 316L stainless steel. Furthermore, the fatigue crack propagation rate (FCPR) of as-built PBF-LB 316L specimens and specimens subjected to the three aforementioned heat treatments was thoroughly investigated. To this end, the FCPR was evaluated by a fatigue testing machine combined with an infrared thermal camera, and the Paris law was established to quantitatively assess the FCPR of PBF-LB 316L. In addition, a systematic investigation of microstructural evolution, residual stress, tensile properties, and fatigue crack propagation (FCP) fracture surfaces as well as their effect on the FCPR in function of various heat treatments were carried out. The results indicate that the release of residual stresses, the annihilation of the cellular structure, and the occurrence of recrystallization are obtained through the application of HT1, HT2, and HT3 respectively. Furthermore, it is shown that although all three heat treatments can improve the FCPR behavior of PBF-LB 316L to some extent, HT3 PBF-LB 316L presents the lowest FCPR mainly due to its most pronounced plasticity-induced crack closure effect, indicating its highest resistance to FCP even though the recrystallization obtained by HT3 results in the lowest yield strength (YS). Finally, some recommendations about adequate heat treatments concerning fatigue life are suggested.

Investigation of high-cycle fatigue property and fatigue crack propagation behavior of a die-forged 2014 aluminum alloy aircraft wheel

The high-cycle fatigue (HCF) property and fatigue crack propagation (FCP) behavior of aircraft wheels manufactured by die forging were investigated from two sampling directions (rims and discs). The results indicate that the HCF anisotropy of the rim and disc specimens increases with decreasing stress amplitude, and the fatigue strengths are 181 MPa and 157 MPa, respectively. Based on the quantitative analysis of the fatigue fractures, a fatigue life prediction model considering the Fe/Mn-containing particles quantity factor S has been established, and the predicted values are reasonably accurate to the test values. The crack path microstructure indicates that Fe/Mn-containing particles can cause crack deflection while acting as bridges for FCP; Crack closure induced by oxides and plastic zones significantly decelerated the FCP rate. Additionally, fatigue cracks tend to propagate toward grains with smaller twist angles and higher Schmid factors (SF).

Minimizing residual stress and fatigue crack propagation rate of FSW joints of AA2024-T3 by transient thermal tensioning: Effect of heater distance

Friction stir welding (FSW) is a solid-state welding process that is suitable for joining hardly weldable metals such as aircraft AA2024-T3 aluminum alloy. Despite FSW owns many advantages, however, some problems still arise, especially welding residual stress which influences the weld fatigue performance. In the present work, in-process transient thermal tensioning (TTT) treatment was applied to the FSW process of AA2024-T3 aluminum alloy by putting two symmetrical heaters at the sides of the weld line at distances of 25 mm, 40 mm, and 55 mm. The FSW was conducted at the tool rotational speed of 1500 rpm and tool traveling speed of 30 mm/min whereas the heating temperature was set at 200 °C. Subsequently, changes in microstructure, strength, hardness, residual stress, and fatigue crack propagation rate under TTT treatment were evaluated. The results showed that the use of TTT generated peaks of tensile residual stress along the heater passage which changed the residual stress distributions. It was found that the best fatigue crack propagation resistance of the weld occurred at the heater distance of 25 mm which was attributable to the compressive residual stresses present in the weld region induced by thermal tensioning combined with re-precipitation during welding.

Multi-scale characterization of fatigue crack tip deformation and propagation in QP steel

A novel measurement method for multi-scale characterization of fatigue crack tip deformation and propagation behaviors in high strength and plasticity, multi-phase, fine-grain Quenching and Partitioning (QP) steel was proposed. The fatigue crack propagation (FCP) test system with the macro/micro images acquisition devices was built to measure the FCP rate and crack tip deformation simultaneously. First, at the mesoscale, the evolution characteristics of the crack tip deformation fields, plasticity induced crack closure (PICC) behaviors and plastic zone during the FCP process were analyzed using the sub-image stitching and matching digital image correlation (DIC) method. Then, the FCP models were established with special emphasis on the model considering the PICC effect based on the obtained crack opening load at the mesoscale. Moreover, the corresponding microscale surface crack and fracture morphologies, microstructure phase transformation and deformations were observed and analyzed by electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) techniques.

Resistance of fatigue crack propagation induced by large α colony in a Ti‐Al‐V‐Mo‐Zr alloy

AbstractFor Ti alloys used in oil drilling pipe, the fatigue crack propagation (FCP) resistance is one of the key properties for petroleum industrial applications. In this work, the fatigue crack propagation behaviors of bimodal, equiaxed, lamellar, and Widmanstatten microstructures have been systematically investigated and characterized by SEM and EBSD. The results show that the Widmanstatten microstructure containing α colonies has higher yield strength (877 MPa), moderate elongation (9.3%), and better FCP resistance compared to other specimens. During the process of crack propagation, the large α colonies can effectively deflect the cracks and induce secondary cracks, which significantly impedes the main crack propagation. Additionally, tensile twinning can occasionally occur within the large α colony along the crack, improving the plasticity of the crack tip and resulting in a decrease in fatigue crack propagation rate (FCPR).

Prediction on residual flexural fatigue life of rock-concrete interface based on a deformation-controlled fatigue crack propagation criterion

To assess the cracking resistance of rock-concrete interface, three-point bending tests were carried on composite rock-concrete specimens under the monotonic and high flexural fatigue loading. The crack opening displacements along the ligament of the beam were continuously recorded in the whole test process. According to the measured crack mouth opening displacements (CMODs), the correlation between the monotonic and fatigue deformations at different cracking statuses was discussed. It has been shown that the deformation development of composite specimens under flexural fatigue loading was mainly caused by the propagation of interfacial crack. The P-CMOD curve under monotonic loading was the envelope curve of those under the different maximum fatigue loads. There were three CMOD control points in the monotonic deformation response to indicate the fatigue crack propagation states, which corresponded to the initial cracking load, the ultimate load and the applied maximum fatigue load in the post-peak part of the monotonic response, respectively. Correspondingly, they manifested the fatigue crack initiation, the inflection point of the fatigue crack propagation rate from deceleration to acceleration and the fatigue failure of the rock-concrete interface. Based on the three CMOD control points, a deformation-controlled fatigue crack propagation criterion was proposed to assess the cracking state of the rock-concrete interface under fatigue loading. Accordingly, a theoretical prediction model, termed as fatigue deformation evolution law, was established to predict its residual flexural fatigue life. This method was verified by the reasonable agreements between experimental and predicted results in the residual fatigue life.

Effect of Residual Stress and Microstructure on the Fatigue Crack Growth Behavior of Aluminum Friction Stir Welded Joints.

Friction stir welding (FSW) has been adopted in the aerospace industry for fabricating structural alloys due to the low melting point and high thermal conductivity of aviation aluminum alloys. However, welding residual stresses can lead to secondary deformation in friction stir welded (FSWed) structures. Additionally, microstructural characteristics impact the crack growth rates and directions in these structures. Therefore, it is necessary to investigate the effects of residual stress and microstructure on the fatigue responses of FSWed joints. In this paper, we studied the fatigue crack growth behavior of two homogeneous and dissimilar FSWed joints with varying welding parameters, namely 2024-T3 and 7075-T6. The residual stresses were measured with the X-ray diffraction method. The dislocations and precipitates in different zones of the FSWed joints were analyzed via transmission electron microscopy (TEM). The results demonstrated that the residual stress significantly affected the fatigue crack growth rate and direction; the tensile residual stress promoted fatigue crack growth and offset the decrease in the fatigue crack growth rate that occurred due to grain refinement. The results of the microstructural analysis indicated that dislocation density and sliding resistance increased with the decrease in rotational speed and led to a decreased rate of fatigue crack propagation.

The influence of crack and interface oxidation on dwell fatigue crack propagation behavior of the nickel-base superalloy ATI A718Plus

The crack propagation properties are an important and often limiting factor for the commercial application of superalloys in aerospace applications where the oxidation ahead of the crack tip plays an important role. Previous research on the Ni-base superalloy A718Plus revealed that the orientation and the volume fraction of the high temperature grain boundary phases δ and η have a major influence on the dwell fatigue crack propagation rate at 650 °C in ambient air but not in vacuum. In this work, the effect of internal oxidation at the η/δ–matrix interface and its effect on dwell fatigue crack propagation and mechanical properties are examined by advanced microscopic methods and micro-cantilever testing. During crack propagation, the crack tip is exposed to air where a Nb-rich oxide layer forms and embrittles the η/δ–matrix interface causing the cracks to deflect and propagate along the oxidized interfaces. Micro-cantilever tests on the oxidized interface show that these oxide layers also significantly reduce the local strength and fracture toughness of the material. This proves that interfacial oxide layers are the underlying reason for the reduction of the dwell fatigue crack growth resistance at 650 °C, particularly in microstructures whose η/δ–matrix interfaces are oriented parallel to the crack growth direction.Graphical

Factors Affecting the Cracking Resistances of a Spring Steel Tempered at Different Temperatures

Cracking resistance is vital to the practical application of spring steels, which consists of fracture toughness (KIC) under the quasistatic loading condition and fatigue crack propagation (FCP) resistance under the cyclic loading condition. In the present study, the relation between the KIC/FCP resistance and microstructure of the 50CrMnSiVNb spring steel tempered at various temperatures is studied. In the results, it is shown that the dislocation density is the main factor influencing the KIC and FCP resistances, and the carbide size/quantity and morphology can also affect the KIC and FCP resistances. Thus, reducing the dislocation density is the most effective method to enhance the cracking resistance of the investigated steel. Moreover, decreasing the aspect ratio and obtaining a moderate size of tempered carbides are also beneficial to the cracking resistance. In addition, free hydrogen atoms can cause intergranular fracture on the fracture surface, worsening the FCP rate. To enhance the FCP resistance, smelting processes need to be improved to reduce the hydrogen content of the investigated steel.

Damage Tolerance Behaviour of Stiffened Crown Panel of a Transport Aircraft Fuselage

Ever since the introduction of damage tolerance requirements in the aviation regulations, efforts continue to be made to prevent catastrophic failures due to damages present in the structure. It has also been realized that damage detection is the weakest link in the whole process of damage tolerance design to maintain continued airworthiness. The major components of the aircraft structure consist of both integral and riveted panels of sheets and stringers which are employed in fuselage skin panels, spar webs and stiffeners. In spite of all precautions, cracks or damages may arise in many of these primary structural members. These cracks cause stiffness degradation and reduce the total load-carrying capacity of the structure. In this paper, the damage tolerance behaviour of fuselage crown panel both integral and riveted stiffened panel configurations of Aluminium alloy 2024-T351 are studied using finite element based tools using crack growth analysis methods. The crack growth behaviour of both integral and riveted stiffened panels of aircraft fuselage having same geometrical configuration and subjected to uniformly distributed tensile loads is investigated. For this, a metallic stiffened panel with eight stringers, representative of crown panel of a transport aircraft fuselage is analysed with a centre skin crack propagating through the stringers. Stress intensity factors and fatigue crack propagation rates at the progressive crack tip of both types of the stiffened panels are computed by using Modified Virtual Crack Closure Integral (MVCCI) method. The stiffened panels fatigue crack growth rate was computed by using Paris law under constant amplitude fatigue loads. The analysis results show that integral stiffened panel causes higher stress intensity factor and less load bearing capability than riveted stiffened panel which has better damage tolerant capability in comparison to the integrally stiffened panel.

Fatigue crack growth rate and propagation mechanisms of SiC particle reinforced Al alloy matrix composites

PurposeThis study aims to investigate the fatigue crack propagation behavior of SiC particle-reinforced 2124 Al alloy composites under constant amplitude axial loading at a stress ratio of R = 0.1. For this purpose, it is performed experiments and comparatively analyze the results by producing 5, 10, 15 Vol.% SiCp-reinforced composites and unreinforced 2124 Al alloy billets with powder metallurgy (PM) production technique.Design/methodology/approachWith the PM production technique, SiCp-reinforced composite and unreinforced 2124 Al alloy billets were produced at 5%, 10%, 15% volume ratios. After the produced billets were extruded and 5 mm thick plates were formed, tensile and fatigue crack propagation compact tensile (CT) samples were prepared. Optical microscope examinations were carried out to determine the microstructural properties of billet and samples. To determine the SiC particle–matrix interactions due to the composite microstructure, unlike the Al alloy, which affects the crack initiation life and crack propagation rate, detailed scanning electron microscopy (SEM) studies have been carried out.FindingsOptical microscope examinations for the determination of the microstructural properties of billet and samples showed that although SiC particles were rarely clustered in the Al alloy matrix, they were generally homogeneously dispersed. Fatigue crack propagation rates were determined experimentally. While the highest crack initiation resistance was achieved at 5% SiC volume ratio, the slowest crack propagation rate in the stable crack propagation region was found in the unreinforced 2124 Al alloy. At volume ratios greater than 5%, the number of crack initiation cycles decreases and the propagation rate increases.Originality/valueAs a requirement of damage tolerance design, the fatigue crack propagation rate and fatigue behavior of materials to be used in high-tech vehicles such as aircraft structural parts should be well characterized. Therefore, safer use of these materials in critical structural parts becomes widespread. In this study, besides measuring fatigue crack propagation rates, the mechanisms causing crack acceleration or deceleration were determined by applying detailed SEM examinations.

Influence of solution heating rate on grain structures and fatigue crack propagation behaviors of an aviation Al-Li alloy sheet

In this study, the effects of grain structure on the fatigue crack propagation (FCP) behaviors in the aviation Al-Li alloy sheets prepared by varying solution heating rates are discussed systematically. The results reveal that both the intensity of Goss texture and grain dimensions are improved with the decreased solution heating rates. Upon an identical stress intensity factor range (ΔK), the increased Goss texture of the sample with a solution heating rate of 2 ℃/min (2HR) promotes crack deflection, causing a decrease in FCP rates compared to that of the sample with a solution heating rate of about 100 ℃/min (FHR). The dislocations clustered near grain boundaries are more significant with increasing grain size during cyclic loading, which intensifies the strain localization. The accumulation of dislocations increases the possibility of micro-voids formation and creates the conditions for crack deflection, which results in a decrease in FCP rate. Besides, based on the calculation of the reversible plastic zone (RPZ) size, the initial ΔK entering the rapid propagation region increases with decreasing solution heating rates and exhibits a strong linear relationship with grain size.

Fatigue response of open hole plates: A finite element simulation investigating the influence of dynamic and static cold expansion processes

Cold Expansion (CE) techniques are extensively used in the aeronautical industry to enhance the fatigue life of open-hole plates. However, the availability of accurate Finite Element (FE) models to simulate the fatigue behavior of this process, particularly Dynamic Cold Expansion (DCE), is limited. This study introduces two novel methods for predicting the fatigue response of DCE and Static Cold Expansion (SCE) open-hole plates. The first method directly estimates the total fatigue life using Continuum Damage Mechanics (CDM) and the Theory of Critical Distance (TCD). The second method separates the prediction of fatigue crack initiation life and propagation life, incorporating CDM, TCD, and the Extended Finite Element Method (XFEM). Moreover, FE models are developed to simulate residual stress, stress under external cyclic loads, and fatigue crack propagation behavior for both DCE and SCE specimens. The proposed methods are evaluated, compared, and the mechanisms behind fatigue life enhancement and fatigue crack propagation modes in CE specimens are discussed. It is found that the prediction accuracy is enhanced by considering stress distributions along the thickness direction and improving the Line Method (LM) in TCD through the introduction of a novel CE parameter. The results demonstrate that both methods achieve good predictive performance, with an average error index within ±30%. Furthermore, it is observed that both DCE and SCE processes primarily improve the fatigue crack initiation life of open-hole plates, with the percentage of crack initiation fatigue life increasing as the expansion size increases. The majority of the fatigue crack propagation life in CE specimens is concentrated in the initial stages of crack propagation. In addition, the effects of DCE and SCE processes on reducing the fatigue crack propagation rate are more pronounced along the thickness direction compared to the width direction, leading to distinct crack propagation modes between CE and non-cold expansion (NCE) specimens.

Hydrogen-assisted fatigue crack propagation behavior of a C–N co-doped interstitial high-entropy alloy

The hydrogen-assisted fatigue crack propagation behavior of a C–N co-doped interstitial high-entropy alloy (iHEA) was investigated under in-situ electrochemical hydrogen charging. The cracking path, deformation microstructure, and fractography were characterized via multiple methods. Results suggest that hydrogen uptake shows a certain acceleration on the fatigue crack propagation rate (FCGR) of the iHEA, and such acceleration increases are intensified when increasing the hydrogen-charging current density. Crack propagation along grain boundaries and a remarkable decrease in the extent of plastic deformation immediately near to the crack surface have also been observed. This decrement of critical plastic strain for fatigue crack propagation primarily accelerates the FCGR.