Strain-controlled Fatigue Research Articles

Slip transfer and crack initiation at grain and twin boundaries during strain-controlled fatigue of solution-hardened Ni-based alloys

Slip transfer/blocking at grain and twin boundaries as well as preferential fatigue crack nucleation locations were studied in two solution-hardened Ni-based alloys (Inconel 600 and Hastelloy C276) deformed under strain-controlled, fully-reversed cyclic deformation in the low-cycle fatigue regime. Electron backscatter diffraction-based slip trace analysis was used to identify the active slip systems after interrupted fatigue tests. It was found that the Luster-Morris parameter m′=0.6 was an accurate geometrical criteria to discriminate between slip transfer and blocking at grain and twin boundaries. Moreover, it was found that fatigue cracks initiation was always intergranular and cracks were nucleated at grain and twin boundaries when the slip transfer across was blocked. The probability of crack nucleation increased with the misorientation angle and was independent of the grain size. This behavior was associated with the development of stress concentrations at grain and twin boundaries as well as triple junctions in which slip was blocked and is different from previous reports on fatigue crack nucleation in Ni-based superalloys deformed, in which the slip system parallel to the TB in the parent grain was suitably oriented for slip. This contrast in the fatigue crack nucleation sites between both types of Ni alloys were attributed to the differences in the degree of strain localization and show how this factor controls damage nucleation in polycrystals.

Cyclic deformation behavior of an overaged high-pressure die-cast aluminum alloy

The aim of this study is to identify the deformation behavior of a high-pressure die-cast Silafont®-36 aluminum alloy in an overaged T7 condition in relation to the significant microstructural changes caused by the overaging heat treatment. The T7 aluminum alloy exhibited a distinctive composite-like microstructure, consisting of coarser α-Al grains and larger spherical Si particles embedded in the matrix, in contrast to its as-cast and T4 counterparts. The softer α-Al matrix of the T7 alloy as revealed by the nanohardness and microhardness led to improved ductility and longer strain-controlled fatigue life at higher strain amplitudes, despite the lower strength. Cyclic stabilization was observed to be a salient feature of the T7 alloy, stemming from the equilibrium between cyclic hardening and cyclic softening. Strain-energy density-based model, by incorporating a material parameter called ‘intrinsic fatigue toughness’, could be used to predict the fatigue life of the alloy.

Study on low cycle fatigue properties of Cr-Mo steel in 50 MPa gaseous hydrogen

At present, a lack of fatigue design curves for Cr-Mo steel in high-pressure gaseous hydrogen worldwide impedes the use of the design fatigue curve (S-N curve) evaluation for vessel fatigue design, necessitating reliance on fracture mechanics methods related to the initial crack size. In this study, strain-controlled fatigue tests with a strain ratio of −1 were carried out in 50 MPa gaseous hydrogen to study the low cycle fatigue properties of Cr-Mo steel. Results indicate that hydrogen reduces the fatigue life of 4130X under high strain amplitudes. Under 0.5 % strain amplitude, different from characteristics of ductile fracture in air, the fracture in 50 MPa gaseous hydrogen showed quasi-cleavage and intergranular fracture characteristics. Based on the test results, the S-N curve in 50 MPa gaseous hydrogen was obtained with fatigue life safety factor 20 and stress amplitude safety factor 2. The S-N curve in 50 MPa gaseous hydrogen is under the curve in KD-320.2 M of the 2023 ASME Boiler & Pressure Vessel Code VIII-3, which does not consider the effect of hydrogen, when the number of cycles to failure is less than 1×106. This indicates that the fatigue life calculated by the S-N curve in KD-320.2 M cannot ensure that 50 MPa high-pressure hydrogen storage vessels avoid fatigue failure under high stress amplitudes.

Influence of friction and back stresses evolution on cyclic softening of laser powder bed fusion Ti-6Al-4V ELI alloy

Laser Powder Bed Fusion (LPBF) of Ti-6Al-4V ELI enables the fabrication of complex and individualized load-bearing patient-specific implants (PSI). These PSI are subjected to cyclic loading, which necessitates their fatigue performance evaluation. In this work, the fatigue properties of LPBF Ti-6Al-4V ELI in heat-treated conditions were characterized by studying the low cycle fatigue (LCF) behavior and underlying deformation mechanism. The fully reversed strain-controlled fatigue tests were performed at various strain amplitudes at room temperature. The ratio of fatigue life of conventional wrought alloy and LPBF Ti-6Al-4V ELI at the lowest (0.8 %) and the highest (1.8 %) strain amplitudes were found to be approximately 2.7 and 4.5, respectively. Further, the softening response during fatigue loading was correlated to the variation in the back and friction stresses. The TEM observations revealed that the dislocation pileup along α/β interfaces caused an increase in dislocation density, which drives the increase in back stress. However, the ease of slip transmission at high strain amplitude (1.8 %) reduced the heterogeneity between α and β phases, causing a decrease in the back stress. The TEM observations further suggested that the dislocation annihilation and subsequent rise in dislocation-free zones in α-phase reduced the friction stress at all strain amplitudes, which resulted in cyclic softening of LPBF Ti-6Al-4V ELI.

Analysis of viscoelastic behaviour in asphalt pavement through four-point beam bending tests

This study, conducted in accordance with ASTM T321-14 standards, offers crucial insights into the behaviour of asphalt materials subjected to cyclic loading. For proper maintenance and pavement design, it is essential to understand the material response under different loading conditions. This study focuses on the four-point beam bending test to investigate the viscoelastic behaviour of asphalt pavement. The four-point beam bending test is a useful method for determining the material's ability to withstand cyclic loading and deformation, which the material experiences during field traffic conditions. The experimental setup involves subjecting asphalt samples to cyclic loading using a four-point bending apparatus. The imposed load causes the specimen to experience bending strains, representing the actual loading conditions that pavements endure. The data gathered during testing include stress, strain, and deformation properties under various loading conditions. The stress-strain response demonstrates the material's resilience to fatigue, with a gradual decrease in stiffness beyond 10,300 cycles. Fatigue failure criteria include a 50% reduction in initial stiffness for strain-controlled fatigue tests and cracking in stress-controlled tests. The dynamic modulus in a compressive-type, repeated load test follows a three-phase pattern, highlighting the impact of temperature and binder characterization methods on sample performance. The results provide information about the material's resilience to rutting and fatigue cracking, the most significant distresses indicated in asphalt pavements. The findings from this study contribute to an in-depth understanding of the viscoelastic behaviour of asphalt pavement and can aid in the development of improved design guidelines and maintenance strategies characterizing the material response to cyclic loading. Engineers and researchers can make better decisions on the durability and performance of asphalt pavements, resulting in more cost-effective and sustainable road infrastructure.

Peridynamic numerical investigation of asymmetric strain-controlled fatigue behaviour using the kinetic theory of fracture

Numerical fatigue process modelling is complex and still an open task. Discontinuity caused by fatigue cracks requires special finite element techniques based on additional parameters, the selection of which has a strong effect on the simulation results. Moreover, the calculation of fatigue life according to empirical material coefficients (e.g., Paris law) does not explain the process, and coefficients should be set from experimental testing, which is not always possible. A new nonlocal continuum mechanics formulation without spatial derivative of coordinates, namely, peridynamics (PD), which was created 20 y ago, provides new opportunities for modelling discontinuities, such as fatigue cracks. The fatigue process can be better described by using the atomistic approach-based kinetic theory of fracture (KTF), which includes the process temperature, maximum and minimum stresses, and loading frequency in its differential fatigue damage equation. Standard 316L stainless steel specimens are tested, and then the KTF-PD fatigue simulation is run in this study. In-house MATLAB code, calibrated from the material S‒N curve, is used for the KTF-PD simulation. A novel KTF equation based on the cycle stress‒strain hysteresis loop is proposed and applied to predict fatigue life. The simulation results are compared with the experimental results, and good agreement is observed for both symmetric and asymmetric cyclic loading.

Molecular dynamics simulation of fatigue damage formation in single-crystal/polycrystalline aluminum

The fatigue plasticity mechanisms and local defect characteristics of engineering materials are critical for addressing fatigue damage. This study aims to identify the formation mechanisms of fatigue damage and delineate the microstructural characteristics that resisted or facilitated fatigue-induced plastic accumulation. The fatigue mechanical properties and microstructural evolution processes of single-crystal/polycrystalline aluminum were investigated through strain-controlled fatigue testing, considering three distinct strain amplitudes. The initiation and cumulative occurrence of local plasticity in single-crystal aluminum occur at the intersections of slip planes, which serve as sources of dislocations. The cumulative formation of irreversible surface steps results in local stress concentration, ultimately leading to fatigue damage at the free surface. Polycrystalline aluminum undergoes grain rotation and merging during cyclic loading, leading to a gradual increase in grain size during plastic deformation. The initiation and cumulative occurrence of local plasticity occur at grain boundaries, ultimately leading to fatigue damage at the grain boundaries.

Synergistic effect of fatigue and hydrogen-induced damage under asymmetric loading of TRIP steel

This study investigates the synergistic assessment of cyclic plasticity damage and hydrogen-induced cracking of transformation-induced plasticity (TRIP) steel subjected to asymmetric strain-controlled fatigue loading. The presence of hydrogen in TRIP steel results in cyclic softening throughout its life, suppressing the hardening behavior induced by martensitic transformation. The mild hardening observed in hydrogen-free specimens is attributed to the predominance of hardening induced by martensitic transformation over cyclic softening. The increase in mean strain leads to higher mean stress relaxation, suppressing the compressive stress developed during the deformation-induced martensitic transformation phenomenon. Geometrically necessary dislocation (GND) density map and fractographic images substantiate the hydrogen-enhanced decohesion failure mechanism, decreasing fatigue resistance for hydrogen-induced TRIP steel. The failure mechanisms of the fatigue damage due to the ingress of hydrogen atoms in the material are proposed for further insights.

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.

Nanostructure and damage characterisation of bitumen under a low cycle strain-controlled fatigue load based on molecular simulations and rheological measurements

Bitumen fatigue resistance is critical to determine the overall fatigue performance and service life of asphalt pavements. However, the mechanisms responsible for fatigue damage of bitumen have previously not been well understood. Molecular dynamics (MD) simulation has recently emerged as a powerful computer-aided numerical technique to model the microscopic failure behaviours in materials. This study aims to use the MD method to investigate the molecular origin of bitumen fatigue damage. The molecular models of the virgin and aged PEN70/100 bitumen were firstly constructed based on their saturate, aromatic, resin and asphaltene (SARA) four fractions. An MD equilibrium was run on the developed bitumen models with the assigned interatomic potentials. Following an MD-based tensile simulation, a strain-controlled fatigue simulation was performed to study the nanostructure and damage behaviours of the virgin and aged bitumen under fatigue loading by calculating the stress-strain response, potential energy, molecular structure and nanovoid volumes. Furthermore, a rheometer measurement was also conducted to characterise the fatigue damage of the bitumen directly by a crack length at the macroscale. Results indicate that the bitumen molecules become unfolded and tend to align along the loading direction when fatigue loading was applied. The change in the molecular configuration helped the molecular chains move closer together and thus contributed to the reduction of the intermolecular interactions including the van der Waals and Coulombic energies. With the increasing load cycles, nanovoids were formed and grew in the bitumen through molecular rearrangement and movement, leading to microscopic fatigue damage of the bitumen. It was found that the aged bitumen produced more severe fatigue damage than the virgin bitumen, which was indicated by the MD-based nanovoid volume at the molecular scale and the DSR-based crack length at the macroscale. The findings from MD simulation provide a fundamental understanding of the molecular origin of fatigue damage, that cannot be experimentally detected for bitumen materials.

Creep-Fatigue Life Evaluation for Grade 91 Steels with Various Origins and Service Histories

Grade 91 steel is widely used in the boilers and piping of thermal power plants. There has been significant research interest in understanding the variations in creep characteristics among different heats of this steel for effective plant management. In recent years, thermal power plants have been subjected to frequent load changes and startup/shutdown to adjust power supply and demand and stabilize frequencies. These operational shifts have raised concerns regarding the potential for creep-fatigue damage in high-temperature components. Therefore, this research focuses on creep-fatigue properties of Grade 91 steel and their predictability. Tensile, creep, strain-controlled fatigue, and strain-controlled creep-fatigue tests were performed on six Grade 91 steels with different heats and/or histories, and the characteristics in each test were compared. As a result, the variations in creep-fatigue life among the materials were found to be correlated with the difference in creep characteristics and stress level during stress relaxation. Furthermore, the study involved a comparative assessment of the predictive performance of creep-fatigue life using five different approaches: time fraction, classical ductility exhaustion, modified ductility exhaustion, energy-based, and hybrid approaches. Among these approaches, the hybrid approach, based on inelastic strain energy density at fracture formulated as a function of inelastic strain rate, exhibited the most accurate predictive performance.

Effect of Post-Deposition Heat Treatment on the Mechanical Behavior and Deformation Mechanisms of a Solid-State Additively Manufactured Al–Mg–Si Alloy

Abstract The effects of post-deposition heat treatment on the fatigue behavior of AA6061 processed by additive friction stir deposition (AFSD) were investigated for the first time in this work. A heat treatment to recover the T6 temper was performed on AFSD AA6061 is then subjected to strain-controlled fatigue and monotonic tension testing. Microstructural analysis revealed abnormal grain growth resulting in bimodal grain size distribution. Mechanical testing indicated a full recovery of the strength of the AA6061-T6 temper with comparable fatigue performance to the as-deposited AFSD AA6061. Fractography revealed deformation mechanisms in the post-deposition heat treatment not observed in the as-deposited samples, however, the fatigue resistance remained unchanged. A microstructure-sensitive fatigue model was implemented to capture the effects of the heat treatment process on the fatigue performance of the post-deposition heat-treated AFSD AA6061.

Qualification of thermal barrier coating for semi-cryogenic engine thrust chamber through strain-controlled fatigue tests

The combustion chamber of semi-cryogenic engines experiences elevated temperatures which are beyond the capability of most structural materials. To solve this issue, an effective cooling mechanism to be implemented. In one of the developmental launch vehicles of Indian Space Research Organisation, the wall temperature in the combustion chamber is reduced by means of employing regenerative cooling along with thermal barrier coating applied on the inner wall made of special grade copper alloy. This special coating made of layers of Nickel and Nickel-Chromium also protect the thrust chamber from oxidation. The coating forms an integral part of the inner wall and are subject to a complex pattern of loads involving both thermal and pressure loads. This paper presents details about the qualification process used to evaluate integrity of the coating. Firstly, the stresses and strains on the inner wall during the engine operating conditions are arrived at based on detailed finite element analysis. Test specimens are fabricated from copper alloy and the thermal barrier coating as in the actual thrust chamber is applied on it. The specimens are tested under tensile and compressive loading that will induce the expected strains obtained from finite element analysis. The tests are done by means of strain-controlled fatigue tests at elevated temperature in tensile and compressive strain conditions. The integrity of the coating is assessed by means of Non-Destructive Test after each cycle of test and based on these, modifications were made for better performance. The modified coating was again tested for the same loading conditions and evaluated the coating integrity.

Fatigue behavior of a nodular cast iron subjected to a variable amplitude strain-based load spectrum applied in bench tests of an Off-highway axle

Nodular cast irons are commonly adopted in off-highway applications, owing to the possibility to shape complex components and to guarantee good mechanical properties. In the fatigue strength assessment of axles made of nodular cast irons, engineers have to deal with external loads that turn into local strain spectra at the fatigue crack initiation zones, which are usually located in areas weakened by notched geometrical details. Moreover, off-highway axles are subjected to variable amplitude load histories during their service life; during the design phase, the field load histories are usually applied to the axles in the form of simplified bench load spectra. In this paper, the mechanical properties of EN-GJS-500-7 have been investigated through static tensile tests and strain-controlled fatigue tests performed on specimens with machined surface extracted from an axle. Furthermore, a local strain-based spectrum has been derived by means of strain gauges which have been applied at the failure location of the axle during the bench tests. Finally, the damage index to failure relevant to the simplified bench load spectrum has been calculated by adopting Miner's linear damage rule and the Smith, Watson and Topper mean stress corrected life equation.

Research on fatigue life prediction model for 2A70-T6 aluminum alloy at different strain ratios

PurposeIn practical engineering, oil filters often work under asymmetric cyclic loading. In order to improve the prediction accuracy of fatigue life of the oil filters under asymmetric cyclic loading, the effect of strain ratio and low cycle fatigue plastic deformation on fatigue life need to be considered. This paper aims to discuss the aforementioned objective.Design/methodology/approachFirst, strain-controlled fatigue tests with strain ratios of 0, 0.5 and −1 were carried out on the oil filter material 2A70-T6 aluminum alloy, and the test data were used to obtain strain fatigue life curves at three strain ratios. Then, based on the idea of the constant life curve method, the average value of the ratio of the strain amplitude corresponding to different strain ratios under the same partial life was defined as the strain ratio factor. Finally, the elastic-plastic factor was modified by the strain ratio factor, and a new fatigue life prediction model considering the effect of strain ratio was proposed.FindingsThe proposed model was validated, respectively, by fatigue test data of 2A70-T6 aluminum alloy, 2124-T851 aluminum alloy and oil filter and the results of the proposed model were compared with the Coffin–Manson equation, Morrow model and Smith–Watson–Topper (SWT) model, showing that the proposed model had higher applicability and accuracy.Originality/valueIn this work, a strain ratio factor is established based on the idea of the constant life curve method, and the strain ratio factor is used to modify the introduced elastic-plastic factor, and then a new fatigue life prediction model considering the influence of strain ratio and low cycle fatigue plastic deformation on material fatigue damage accumulation is proposed. The results show that the prediction results of the proposed model are in good agreement with the experimental data, and the proposed model has good fatigue life prediction ability considering the influence of strain ratio and lays a foundation for the fatigue life prediction of the oil filter.

Research on multi-scale failure mechanism of gradient nanostructured 316L steel under strain-controlled fatigue at 650 °C

Gradient nanostructured materials have excellent fatigue resistance. At present, there are few research on the fatigue properties of gradient nanostructured (GNS) materials at high temperature. Herein, the multi-scale failure mechanism of GNS 316L steel at 650 °C is studied, and the high temperature fatigue tests under different strain amplitudes are conducted. Then, post-test microstructure observations were carried out to reveal the damage mechanisms, and the fatigue behavior was numerically simulated by crystal plasticity model. The experimental results show that the strength of the GNS 316L steel is still higher than that of the coarse-grained (CG) 316L steel at 650 °C, and the fatigue life of the GNS 316L steel is also higher than that of the CG one under strain fatigue loadings. The fatigue fracture results show that the fatigue crack presents a mixed propagation mode, and the crack source of GNS 316L transfers from surface to subsurface under low strain amplitude. The numerical results directly reflect the influence of the GNS surface layer on the plastic slip behavior. The fatigue failure mechanism of GNS 316L steel under strain-controlled cyclic loading at 650 °C was explained from a multi-scale perspective. This study provides data and method support for the application of GNS 316L steel at high temperature.

Influence of grain size on fatigue strength of austenitic stainless steel (Investigation of ultimate strength dependency of fatigue strength)

Grain size dependency of the fatigue strength was investigated using Type 316 stainless steel. The main interest of this study was to clarify the root cause of the ultimate strength dependency of fatigue strength, particularly in the high-cycle fatigue regime. Four kinds of heat treatment were applied to obtain different grain sizes. The increase in the grain size caused smaller ultimate strength. The strain-controlled fatigue test and the crack growth test were conducted at room temperature. It was shown that the materials of larger grain size tended to have a shorter fatigue life, although the grain size had little influence on the crack growth rate. The reduced fatigue life due to large grain size was deduced to have been brought about by an increase in initial crack size after an incubation period before crack initiation. It was concluded that the grain size was not the dominant factor which caused the ultimate strength dependency of the fatigue strength, although the grain size surely affected both the fatigue strength and the ultimate strength.

Multiaxial non-proportional fatigue behaviour and microstructural deformation mechanisms of 9%Cr steel at elevated temperature

High-temperature components utilised in practical service are often subjected to multiaxial non-proportional loading due to their complex geometry. In the present study, a set of strain-controlled fatigue tests were conducted on P92 steel at 600 °C, including uniaxial, multiaxial proportional, and multiaxial non-proportional loading conditions. Results reveal that the axial and shear stresses exhibit varied responses to the different non-proportionalities, with proportional loading resulting in the shortest fatigue life when the strain ratio is small. The non-proportional loading induces accelerated cyclic softening at axial direction while the shear stress is enhanced. Electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) analysis indicate that the increased role of shear stress promotes the dislocation motion from the planar slip to cross-slip under non-proportional loading, which in turn facilitates the microstructure evolution. It is also important to note that the evident development of microstructure and the combined effect of more crack initiations and more secondary cracks contribute to the lowest fatigue life under proportional loading.

Cyclic deformation behavior of an equiatomic CrFeNi multi-principal element alloy

For multi-principal element alloys (MPEAs) potential engineering applications, understanding their low-cycle fatigue (LCF) behavior is of decisive importance. Recently, an equiatomic face-centered cubic (FCC) CrFeNi has been shown to offer an excellent combination of monotonic properties. In the present study, we report on its LCF behavior at room temperature. Fully reversed strain-controlled fatigue tests were conducted in air under three different strain amplitudes (±0.3 %, ± 0.5 % and ± 0.7 %). The measured cyclic stress response reveals a rapid increase (i.e., cyclic hardening) followed by a relatively gradual decrease of peak stresses (i.e., cyclic softening) until failure. Electron microscopy investigations on post-fatigue samples revealed strain amplitude dependent dislocations slip-mode and resulting substructures evolution. These observations are linked to the observed cyclic stress response and lifetime. Furthermore, the origin of CrFeNi’s cyclic stress response is analyzed by partitioning hysteresis loops. Lastly, a comparison with similar grain-sized (60–67 µm) equiatomic CoCrFeMnNi, and 316L alloys pinpoints the peculiarities of CrFeNi LCF response, which is discussed in terms of the difference in their solid solution strengthening, grain boundary strengthening and stacking fault energy.

Generalized strain energy density-based fatigue indicator parameter

In the history of fatigue study, the potentialities of strain energy density (SED) based approaches were extensively discovered; however, there was limited usage in engineering practice, largely due to the lacking of a widely accepted fatigue model and operating instruction. Accordingly, referring to previous studies, a normative form of total strain energy density (TSED) based fatigue life equation with two power function terms is given, together with a standard flow to determine the corresponding SED-related material fatigue parameters, intending to popularize its application in engineering practice. In particular, the positive elastic and plastic SEDs play the dominant role in high and low cycle fatigue domains, respectively. Strain-controlled fatigue tests of virgin Al 7075-T6511 alloy and an in-service puddle iron are conducted to check the effectiveness of the TSED as the fatigue indicator parameter to correlate fatigue life. Results show that the TSED formula works better than the strain-based Coffin–Manson–Basquin equation.