Fatigue Crack Initiation Sites Research Articles

Strengthening mechanism of abnormally enhanced fatigue ductility of gradient nanostructured 316L stainless steel

Structural materials with a good combination of high fatigue strength and high fatigue ductility are highly desirable in engineering applications. However, it remains a challenge to “break” the exclusive relationship between fatigue strength and fatigue ductility. The cylindrical 316L stainless steel specimens with a gradient nanostructured surface layer were prepared using surface mechanical rolling treatment (SMRT). Fully reversed strain-controlled tension–compression fatigue experiments indicated that the SMRT processed 316L specimens achieved simultaneous improvement of fatigue strength and fatigue ductility. The abnormal increase in fatigue ductility is attributed to the significant secondary cyclic hardening caused by the martensitic phase transformation and the transition in fatigue crack initiation mode. The martensitic phase transformation enhances the fatigue strength while reducing the proportion of plastic deformation in the controlled strain amplitude. The competition between the driving force and resistance of fatigue nucleation in different structural units results in the migration of fatigue crack initiation sites from the surface to subsurface, thereby prolonging the fatigue crack initiation life. This work reveals the synergistic strengthening mechanism of fatigue strength and fatigue ductility of a gradient nanostructured 316L stainless steel.

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.

Uniaxial deformation behaviors and mechanism of Ti–6Al–4V alloy with bi-oriented grains

It is of great importance to investigate the deformation and damage mechanisms of polycrystalline materials with soft crystal orientations, considering the soft grains are usually the fatigue crack initiation sites. In this study, a Ti–6Al–4V alloy fully consisted of <01 1‾ 0> and <1‾ 21‾ 0> α (soft) grains was prepared and its uniaxial deformation behavior was investigated. Interestingly, no significant asymmetry on the tension-compression yield strength was found in this alloy with bi-grain orientations, though mechanical asymmetry was generally found in the traditional Ti alloys with strong texture. After high temperature solution treatment, the preferred bi-orientations were retained and the asymmetry degree of yield strength did not change, showing an excellent stability in texture and mechanical performance. Deformation mechanisms during tension and compression were studied and discussed. This work provides a new understanding on the deformation and damage mechanisms in the grains with soft crystal orientations, and may guide the microstructural design of Ti alloy for pursuing high mechanical and fatigue performances in the future.

Understanding the influence of environmental conditions on the low cycle fatigue behaviour of high strength low alloy (HSLA) steel under air and corrosive (3.5% NaCl) conditions

Offshore structures which are made up of high-strength low alloy (HSLA) steel experience fatigue load due to sea waves and corrosion. In the present work, the influence of environmental conditions (air and 3.5 % NaCl solution) on the strain-controlled fatigue life of High Strength Low Alloy (HSLA) steel has been determined. Low cycle fatigue experiments were conducted on HSLA steel specimens of 12 mm diameter which were prepared parallel to the rolling direction. The strain amplitude was varied in the range of 0.4 to 0.7 % for a constant test frequency of 0.3 Hz. For all the total strain amplitudes (Δεt/2), a significant reduction in fatigue life was observed while testing the specimens under the presence of 3.5 % NaCl solution compared to the air environment. Microscopic investigation indicates that rigorous grain boundary oxidation has happened, and it has created the grain boundary cracking and several sites for fatigue crack initiation and propagation. The presence of corrosive compounds (Fe2O3, FeOOH) was also confirmed by the X-ray diffraction patterns. In addition, mixed modes (transannular and intergranular) of fractures were observed due to the presence of 3.5 % NaCl solution.

Effects of aging and shot peening on surface quality and fatigue properties of material extrusion additive manufactured 17-4PH stainless steel

Material extrusion additive manufacturing (MEX) gains increasing interest due to its cost-effectiveness. However, concerns arise regarding inherent MEX characteristics potentially affecting mechanical properties. This study investigates the effects of shot peening and heat treatment on MEX 17-4PH stainless steel. After shot peening, surface nanocrystalline and compressive residual stress are induced. Aging results in higher hardness and tensile strength with lower elongation, while shot peening results in higher surface hardness with minimal change in elongation. For fatigue properties of as-sintered specimens, Al2O3 particle contamination dominates at high cycle regimes, while other MEX surface inhomogeneities dominate at low cycle regimes. Furthermore, as-aged properties are dominated by all surface inhomogeneities, resulting in the non-improvement of fatigue performance compared to the as-sintered specimens. However, shot peening on the as-sintered specimens significantly enhances fatigue properties through the formation of surface nanocrystalline structures and the induction of compressive residual stress, albeit with the occurrence of wrapped corners acting as fatigue crack initiation sites. Remarkably, the combination of aging and shot peening yields the most improvement in fatigue performance, exhibiting behaviours akin to as-sintered specimens with shot peening but without the generation of wrapped corners. Instead, fatigue crack initiation sites shift to subsurface region’s inhomogeneities.

Key role of surface defects in the multiaxial fatigue life of additively manufactured unmachined 18Ni300 maraging steel

The study aims to estimate the role of surface defects in the fatigue life of age-hardened and unmachined additively manufactured 18Ni300 maraging steel and to verify the effectiveness of stress-based life prediction models. Axial-torsional cyclic loading paths involving in-phase and out-of-phase cases are applied. Scanning electron microscopy and micro-computed tomography are performed to detect the fatigue crack initiation sites and paths. The effectiveness of the classic models and a physics-constrained Gaussian process for regression in fatigue life prediction is estimated. Results show that the intrinsic orientation of the surface defects affects the fatigue mechanism by increasing the material sensitivity to axial stress. Additionally, the steel is insensitive to the phase shift between the axial and torsional loading components. The hydrostatic stress and the integrated shear stress amplitudes over the critical plane are pointed as the most effective load-related quantities for life prediction.

Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity

Fatigue properties are crucial for critical aero-engine components in extreme service environments, which are significantly affected by surface integrity (SI) indexes (especially surface topography, residual stress σ res, and microhardness) after machining processes. Normal-direction ultrasonic vibration-assisted face grinding (ND-UVAFG) has advantages in improving the machinability of Inconel 718, but there is a competitive relationship between higher compressive σ res and higher surface roughness R a in affecting fatigue strength. The lack of a quantitative relationship between multiple SI indexes and fatigue strength makes the indeterminacy of a regulatory strategy for improving fatigue properties. In this work, a model of fatigue strength (σ f)sur considering multiple SI indexes was developed. Then, high-cycle fatigue tests were carried out on Inconel 718 samples with different SI characteristics, and the influence of ND-UVAFG process parameters on SI was analyzed. Based on SI indexes data, the (σ f)sur distribution in the grinding surface layer for ND-UVAFG Inconel 718 samples was determined using the developed model, and then the fatigue crack initiation (FCI) sites were further predicted. The predicted FCI sites corresponded well with the experimental results, thereby verifying this model. A strategy for improving the fatigue life was proposed in this work, which was to transfer the fatigue source from the machined surface to the bulk material by controlling the SI indexes. Finally, a critical condition of SI indexes that FCI sites appeared on the surface or in bulk material was given by fitting the predicted results. According to the critical condition, an SI field where FCI sites appeared in the bulk material could be obtained. In this field, the fatigue life of Inconel 718 samples could be improved by approximately 140%.

Finite Element Analysis and Fatigue Test of INTEGRA Dental Implant System.

The study involved numerical FEA (finite element analysis) of dental implants. Based on this, fatigue tests were conducted according to the PN-EN 14801 standard required for the certification of dental products. Thanks to the research methodology developed by the authors, it was possible to conduct a thorough analysis of the impact of external and internal factors such as material, geometry, loading, and assembly of the dental system on the achieved value of fatigue strength limit in the examined object. For this purpose, FEM studies were based on identifying potential sites of fatigue crack initiation in reference to the results of the test conducted on a real model. The actions described in the study helped in the final evaluation of the dental system design process named by the manufacturer as INTEGRA OPTIMA 3.35. The objective of the research was to identify potential sites for fatigue crack initiation in a selected dental system built on the INTEGRA OPTIMA 3.35 set. The material used in the research was titanium grade 4. A map of reduced von Mises stresses was used to search for potential fatigue crack areas. The research [loading] was conducted on two mutually perpendicular planes positioned in such a way that the edge intersecting the planes coincided with the axis of the system. The research indicated that the connecting screw showed the least sensitivity (stress change) to the change in the loading plane, while the value of preload has a significant impact on the achieved fatigue strength of the system. In contrast, the endosteal implant (root) and the prosthetic connector showed the greatest sensitivity to the change in the loading plane. The method of mounting [securing] the endosteal implant using a holder, despite meeting the standards, may contribute to generating excessive stress concentration in the threaded part. Observation of the prosthetic connector in the Optima 3.35 system, cyclically loaded with a force of F ≈ 300 N in the area of the upper hexagonal peg, revealed a fatigue fracture. The observed change in stress peak in the dental connector for two different force application surfaces shows that the positioning of the dental system (setting of the socket in relation to the force action plane) is significantly decisive in estimating the limited fatigue strength.

Estimation of the fatigue crack initiation site and life of Ti-6Al-4V alloy for two types of circle and slender crystal grains

In this study, the fatigue crack initiation behaviour and fatigue crack initiation life of the Ti-6Al-4 V alloy, which had circular and slender grains, were quantitatively evaluated based on slip line length and out-of-plane component of Schmidt factor. As the results, in crystal grains where fatigue cracks initiated, the slip system that contributes to crack initiation could be identified by considering the out-of-plane component of the Schmidt factor (SFsinΩ), and the fatigue cracks were initiated by the basal slip of the primally α phase in all specimens. Furthermore, regarding the prediction of the location of fatigue crack initiation, it is clear that the grains that are candidates for fatigue crack initiation could be estimated based on the relationship between the slip line length of the basal slip system that contributes to crack initiation in each grain and SFsinΩ. Finally, the macro fatigue crack initiation life could be estimated using a parameter of P that combines micro crack initiation driving force Pi and micro crack propagation driving force Pp.

Study on high cycle fatigue performance at elevated temperature for a selective laser melted Ti6Al4V alloy

Selective laser melted Ti6Al4V alloy has broad application prospects in aeroengine field. In this study, high cycle fatigue tests were carried out systematically using hourglass shaped specimen (K t=1) at 400 °C. The S-N curves were acquired and compared with data of the casting and the forging. The anisotropy and the defect effects of the fatigue performance were analysed. The LOF defects on the surface and subsurface preferentially act as the fatigue crack initiation site for almost all the tested HCF specimens. The position and irregularity of defect have greater influence on elevated temperature fatigue life than the defect size. The fatigue strength of horizontal orientation is lower than that of vertical orientation, because of the characteristics of larger size, more irregular shape and higher density for the crack source defects of horizontal specimens. The fatigue performance of the SLM Ti6Al4V alloy in this study is better than that of the casting and even the forging, but the dispersion of fatigue data of the SLM alloy is much greater than that of the both traditional process alloys.

LCF life prediction of turbine disc alloy using crystal plasticity and 3D representative volume element containing twin boundaries

The traditional LCF life prediction method based on macroscopic behavior is difficult to reveal the microscopic fatigue failure mechanism. Therefore, the crystal plasticity finite element method and the representative volume elements considering the real microstructure were used to simulate the cyclic deformation of a nickel-based superalloy FGH4098, and a fatigue failure criterion is established to predict the LCF life. The influence of twin boundary on the prediction accuracy is particularly discussed. Meanwhile, the hotspots which are potential sites for fatigue crack initiation were analyzed. The results show that the consideration of twin boundary can improve the accuracy of life prediction, with a scatter factor of ±1.3 only.

Numerical Simulation on Crack–Inclusion Interaction for Rib-to-Deck Welded Joints in Orthotropic Steel Deck

Weld defects such as porosity, inclusion, burn-through, and lack of penetration are difficult to detect and control effectively in an orthotropic steel deck (OSD), which will be a fatigue crack initiation site and lead to several fatigue cracking. The crack growth behavior in defective welded joints is different from that of defect-free joints. This study investigates crack–inclusion interaction for rib-to-deck welded joints in OSDs based on numerical simulation and linear elastic fracture mechanics (LEFM). A refined finite element model of a half U-rib with cracks and inclusions was established by using the FRANC3D-ABAQUS interactive technology. The full processes of the crack–inclusion interaction from approaching and penetrating were accurately simulated. Critical parameters, including the stress intensity factor (SIF), the shape factor, the growth rate, and the growth direction were analyzed. The stiff and soft inclusions amplify and shield the SIF of cracks when the crack grows to the local area of inclusions. During the entire process of crack growth, the soft and stiff inclusion accelerate and inhibit the crack growth, respectively. The stiff inclusion will lead to asymmetric growth of the crack shape, where the portion of the crack away from the inclusions has a higher growth rate. The soft and stiff inclusions will attract and repel the direction of crack growth at the proximal point, respectively.

Revealing the relationship between the shot type and fatigue performance of laser powder bed fused 304L steel following shot peening

Shot peening (SP) is gaining popularity as a post-processing method for improving fatigue properties of laser powder bed fused (LPBF) metallic materials. This work investigated the influence of shot type on the surface strengthening and life improvement of LPBF 304L stainless steel (SS) with a rough as-built surface using ASH 110 steel shot, AZB 300 ceramic shot, and CW 35 strengthened steel shot. The shot characteristics (size, shape factor, and hardness), SP surface characteristics (morphology, roughness, residual stress, and hardness), and SP subsurface characteristics (grain refinement, deformation twinning, martensitic transformation, and defect distribution) were fully characterized and quantified. Particularly, the foldings with rolled-up edges that affected surface finish appeared on the SP surface, and their formation was ascribed to the as-built surface morphology containing incompletely melted powder particles and agglomerations, as well as the shot properties such as size, hardness, and sharpness. The irregular LoF defects between the contour region and infill region could not be entirely eliminated/healed utilizing SP procedures, and these defects were always the fatigue crack initiation sites for AB and SP samples. Therefore, the critical role of “penetration depth” of the kinetic energy on irregular LoF defects and fatigue performance was highlighted. A larger penetration depth can be achieved by employing small-sized ceramic shots with high hardness, deformation resistance, and kinetic energy, inducing refined structures and compressive residual stress around the irregular LoF defects, thereby constricting the fatigue crack initiation and propagation. This work provides a valuable reference for SP process design and optimization of LPBF metallic materials.

On the Effect of Testing Frequency on High and Very High Cycle Fatigue Behavior of AA2024-T3, Ti-6Al-4V, and Inconel 718

An increase of testing frequency to reduce the testing time could affect the fatigue behavior of metallic materials. The current paper investigates the effect of testing frequency on the high and very high cycle fatigue behavior of AA2024, Ti-6Al-4V, and Inconel 718 alloys tested at 20, 90, and 1000 Hz. To quantify the effect of testing frequency a two-parameter Weibull distribution and Basquin’s equation were utilized as well as the threshold stress intensity factor range was determined. Fatigue crack initiation sites were evaluated on the fracture surface with respect to different testing frequencies. The results showed that changes in the testing frequency significantly influence the mechanical response of the Ti-6Al-4V alloy, while no substantial impact on the fatigue properties of AA2024 and Inconel 718 alloys was identified. The findings of the study contribute to a more complete knowledge of the frequency sensitivity of the alloys and provide valuable insights for the design and evaluation of materials used in high-frequency applications.

Effect of Nitrogen Content on the High Cycle Fatigue Properties of Titanium Microalloyed Steel

The high cycle fatigue properties of three industrial 0.12% Ti microalloyed steels with different nitrogen contents (56, 40, and 30 ppm in molten steel of tundish) are investigated. The results show that &lt;20% of the fatigue crack initiation sites are oxide inclusions of size in 16.8 μm ≈ 55.9 μm, while the rest 80% are surface defects. No TiN inclusions cause fatigue failure and the fatigue limit strength slightly decreases with increasing N contents as the yield strength decreases with a coarser ferrite grain. Inclusions characterization in the section near the fracture shows that the average sizes of TiN inclusions in H56, M40, and L30 steels are 3.50, 3.22, and 2.89 μm, and the maximum sizes are 6.92, 6.67, and 6.23 μm, respectively. Calculating for a cooling rate of 0.2 K s−1 using ChemAppPy precipitation model, the size of TiN inclusions will increase from 6.1 to 7.1 μm, when increasing N content from 30 to 60 ppm. The relationships between nitrogen content, TiN inclusions, and fatigue failure quantified by experimental test and modeling show that the nitrogen content in steel can be relaxed up to 60 ppm when considering economical denitrogenization and fatigue safety.

3D characterization of internal defects for fatigue performance of welded SA192 steel water walls

Weld defects in SA192 steel water walls have been characterized using 3D nano-tomography. The fatigue test specimens were extracted from different weld locations of the water walls. The internal welding defects number, size, shape, and location were measured before low-cycle fatigue tests. The weld defect size and shape were found to be the most prominent factors influencing fatigue crack initiation and fatigue life. Sharper defects significantly reduce the fatigue life of the specimen as compared to the rounder defects. The stress intensity factor for each type of defects was calculated using linear-elastic fracture mechanics and the Murakami methods. In the defect-free specimens, the weld fusion zone was the most preferential sites for fatigue crack initiation due to a higher hardness of the as-solidified microstructure.

Stored energy density research on the fatigue crack initiation at twin boundary and life prediction of Inconel718 superalloy

The fatigue crack initiation at twin boundary (TB) and the life prediction of IN718 alloys in the high cycle fatigue (HCF) regime and very high cycle fatigue (VHCF) regime were investigated through crystal plasticity finite element (CPFE) simulations and experiments. The fatigue damage parameter, considering the evolution of geometrically necessary dislocation (GND) density, slip and back stress, known as the back-stress-based stored energy density in this study, Gba, was proposed to precisely characterize the plastic strain distribution and localization, which in turn was engaged in locating fatigue crack initiation site and predicting the fatigue life. The element analysis around TB and the CPFE simulations indicated the coupling of slip activation parallel to the TB and the absence of primarily strengthening phase (γ'') on the both side near the TB was responsible for crack initiation. To predict fatigue life, the varying pattern of the Gba at fracture with fatigue life was studied based on the experimental results in the HCF and VHCF regimes, and the life prediction method was obtained accordingly. Finally, the fatigue life evaluations of the IN718 alloy at three load ratios (R = −0.1, 0.1, and 0.5) were conducted and results showed that the life estimates were basically within ±3 scatted bands.

Local weld geometry-based characterization of fatigue strength in laser-MAG hybrid welded joints

Thisresearch studies the influence of local weld notch parameters on fatigue crack initiation sites in laser-hybrid butt welds, utilizing high-resolution 3D scans and fatigue tests to failure. The suitability of different local geometric weld notch parameters for fatigue strength characterization is investigated, and the current challenges associated with their measurements are highlighted. The weld notch shapes were found to fluctuate significantly, resulting in considerable variation in notch parameters over short intervals. Undercut depth was found to determine the critical location for crack initiation. There were several instances where the fatigue crack initiated from notches with large radii despite the presence of sharper notches, contrary to what is expected on the basis of previous investigations. The results of the present study indicate that the undercut depth is a suitable fatigue strength indicator for high-quality laser-MAG hybrid welds, overcoming the practical limitations of notch radius measurement.

Very High Cycle Fatigue Damage of TC21 Titanium Alloy under High/Low Two-Step Stress Loading

Very high cycle fatigue (VHCF) tests were carried out under variable amplitude loading for TC21 titanium alloy. The first level of high amplitude loading was set as 950 MPa close to yield strength, and the second level of low amplitude loading was determined between 435 MPa and 500 MPa where fatigue cracks initiated at the specimen subsurface under constant amplitude. The results indicate that the high/low stress block significantly reduced the cumulative fatigue life of low stress amplitude, and the fatigue crack initiation site changed from the specimen subsurface under constant loading to the specimen surface under stress block. Based on continuum damage mechanics, the fatigue damage model of two-step stress block was established to estimate the fatigue damage process. The prediction of cumulative fatigue life generally agreed with the experimental data. The cumulative fatigue damage of the stress block was related to the stress amplitude and the cycle ratio, which determined the stress fatigue damage and its interaction damage. The surface crack initiation in the stress block accelerated fatigue damage of low stress amplitude, reducing the cumulative life.

A numerical study on tensile stress concentration in semi-ellipsoidal corrosion pits

Pitting corrosion is a common cause of concern for steel structures in an offshore environment. As geometric stressconcentrating features, corrosion pits can potentially act as fatigue crack initiation sites. The severity of a pit can be analyzed based on its geometric characteristics, and the loading and boundary conditions of the component. In this study, the stress distribution in and around a semi-ellipsoidal pit in a plate subjected to (remote) uniaxial tension is investigated using finite element analysis. The investigated characteristics include the width, length and depth of semi-ellipsoidal pits (2b, 2c and a, respectively); the remote load acts parallel to the pit length. A parametric study was conducted with a focus on normalized parameters b/c, a/t and a/2c, and their effect on the stress concentration factor (SCF). The considered value ranges for b/c, a/t and a/2c were 0.1 to 1, 0.01 to 0.2 and 0.125 to 1.5, respectively. Within the range of values for each parameter, SCF did not vary significantly with changes in a/t and increases for increasing a/2c and b/c values. The maximum value of SCF is obtained for the sharpest pit with a circular mouth (a/2c = 1.5 and b/c = 1).