Professional Documents
Culture Documents
Chapter 5
Overview
Fatigue definition
A material subjected
to a repetitive or
fluctuating stress will
fail at a stress much
lower
than
that
required
to
cause
failure on a single
application of load.
Failures
occurring
under conditions of
dynamic loading are
called fatigue failures.
Characterisation of Fatigue
There are three commonly
recognized forms of fatigue:
High cycle fatigue (HCF),
Low cycle fatigue (LCF),
Thermal mechanical
fatigue (TMF)
Fatigue strength is
determined by running
multiple specimen tests at a
number of different
stresses.
The objective is to identify
the highest stress that will
produce a fatigue life
beyond ten million cycles.
This stress is also known as the material's endurance limit or fatigue limit.
Gas turbines are designed so that the stresses in engine components do not
exceed this value including an additional safety factor.
Stress amplitude
1
a = ( max min )
2
Stress Ratio
R=
min K min
=
max K max
K Range
K = K max K min
= C (K )
N
dN
A
B
Slow-growth rate Mid-growth rate
(near-threshold) (Paris regime)
C
High-growth rate
Microscopic mode
Stage I, single
shear
Stage II,
(striations)
Additional static
modes
Fracture surface
features
Faceted or
serrated
Planar with
ripples
Additional cleavage or
microvoid coalescene
Microstructural
effects
Large
Small
Large
Large
Large
Small
*
Large
Large
rc < dg
Large
rc > dg
Large
rc >> dg
9
* large influence on crack growth for certain combinations of environment, load ratio and frequency.
rc and dg refer to the cyclic plastic zone size and the grain size, respectively.
da
= C Y a
dN
ao
da
f
m m/2
m
= CY ( ) dN
m/2
0
a
11
For m > 2:
Nf =
(m 2)CY m ( )m m / 2
1
1
(m 2 )/ 2
(m 2 )/ 2
(
)
(
a
)
a
o
For m = 2:
Nf =
af
1
ln
2
CY 2 ( ) ao
or
Y max a f K C
13
af =
K C2
2
Y 2 max
FATIGUE STRIATIONS
An advancing fatigue crack leaves
characteristic markings called
striations in its wake. These can
provide evidence that a given failure
was caused by fatigue.
The striations on the fracture surface
are produced as the crack advances
over one cycle, i.e. each striation
correspond to da.
Striations are close together
indicating low stress, many cycles.
Widely spaced striations mean high
stress few cycles.
Fatigue failure is brittle in nature,
even in normally ductile materials;
there is very little plastic deformation
associated with the failure.
15
EXAMPLE 5.1
A wide thick plate, K1c = 40 ksi-in0.5, contains an
edge crack 0.1 inch long. The plate is subjected to
alternating stresses between 0 and 20 ksi. Data on
similar material under similar environmental
conditions exhibited Paris law with coefficients m =
4 and C = 7x 10-10 for K in ksi-in0.5. How many
cycles will the plate support before failure?
Solution
It is first necessary to determine the length of the
longest crack the plate can support without
failure. A suitable stress intensity factor is:
K1c = 1.12 max (ac)
40 = 1.12 (20) (ac)
ac = 1.02 inches
16
Solution
For this case, Paris Law has the form
1
2
N=
(
a
da)
10
4
4
2
7 x10 (1.12) (20) 0.1
EXAMPLE 5.2
A large aluminium alloy plate contains a
central crack of length 10 mm. The plate is
subjected to a constant amplitude tensile cyclic
loading from 6 MPa to 60 MPa. The Paris law
exponent is 3, and K at da/dN = 10-7 m/cycles
is 28 MPam. Assuming that Y is 1.02,
calculate how many loading cycles must be
applied for the crack to grow to 20 mm?
18
Solution
First calculate C in Paris law
C = 10-7/283= 4.55 x 10-11,for crack in m/cycle
Obtain stress range, = 54 MPa
Substitute into the given expression:
2
Nf =
(m 2)CY m ( ) m m / 2
Nf =
1
1
( m2) / 2
( m2) / 2
(a f )
( ao )
2
4.55 x10 111.023 (54) 3 3 / 2
1
1
(0.005)1/ 2 (0.01)1/ 2