Lecture 6 Fatigue Failure

28/04/2017
Lecture 6
Fatigue Failure
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Part A
Preliminary Discussion
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Basic Definition
Definition of fatigue
ASTM E1823
The process of progressive localized permanent structural

change occurring in a material subjected to conditions that
produce fluctuating stresses and strains at some point or
points and that may culminate in cracks or complete fracture
after a sufficient number of fluctuations
Basic Definition
Progressive
Fatigue process occurs over a period of time or usage
Localized
Fatigue process operates at local areas rather than throughout the
entire component or structure
Permanent
The structural change due to fatigue is an irreversible process
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Basic Definition
Fluctuating
Fatigue process involves stresses and strains that are cyclic in
nature and requires more than just a sustained load
Cracks
The ultimate cause of fatigue failure is that a crack has grown, due
to cyclic loading, to a point at which the remaining material can no
longer tolerate the stresses and strains
Fracture
The last stage of the fatigue process is separation of a component
or structure into two or more parts
Fatigue of Metals
Characteristics of fatigue failure

Can occurs at a stress level considerably lower than the
tensile or yield strength for a static load
Largest cause of failure in metals, estimated approximately
90%
Occurs frequently in moving parts, e.g. shafts, connecting
rods, gears
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Fatigue of Metals
Stress field measured using Stress field computed using

photoelasticity Finite Element Method
Physical Nature of Fatigue Failure
Beachmarks
(clamshell marks)
Fracture surface of a steel component

experiencing fatigue failure
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Process of Fatigue Failure
Stages in fatigue failure
I. Crack initiation. Small cracks forms at some point of

high stress concentration followed by the deepening of
the initial crack on plane of high shear stress
II. Crack propagation. Cracks advance incrementally with
each stress cycle in direction normal to maximum
tensile stress
III. Final failure. Occurs rapidly once the advancing cracks
reached critical size
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Slip due to external load
Slip step
Static stress
Slip band
extrusion
Cyclic stress
Slip band
intrusion
Slip due to cyclic load
1 1 1
2 2 2
3 3 3
4 4 4
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Crack path
Stage II
Crack profile of transgranular (transcrystalline) fatigue crack growth
in aluminum-lithium alloy
Cyclic Stress
Random stress cycle Asymmetrical stress cycle Symmetrical (reversed) stress cycle
Mean stress Stress amplitude Stress ratio

1 1 min
m = ( max + min ) a = ( max min ) R=
2 2 max
Stress range
Note:
r = max min R = -1 for reversed stress cycle
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Example 1
Question
A cylindrical fatigue specimen is subjected to a cyclic stress
loading on the form:
(t ) = 10 + 50 sin (t ) MPa
where is the angular velocity and t is time. Compute the mean
stress, stress amplitude, stress range and stress ratio
Approaches in Fatigue Analysis
f = I + II : Number of cycles
I
= f (stress level, loading history, residual stresses, material properties, geometry)
II
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Approaches in Fatigue Analysis
Fatigue Analysis
(Estimation of lifetime in service)
Fatigue Crack Nucleation Fatigue Crack Propagation
I >>> II I <<< II
Strength of Materials Mechanics of Cracks

(Continuum Mechanics) (Fracture Mechanics)
Part B
Fatigue Crack Nucleation
Approach
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Introduction
Fatigue crack nucleation approach

Components are assumed to be homogeneous, i.e. contain no
macroscopic flaws such as macroscopic cracks
Large majority of number of cycles to complete rupture is
expended during the crack nucleation stage
The location and orientation of potential occurring cracks are the
unknowns, thus have to be determined (predicted)
Appropriate for components that cannot sustain the presence of
macroscopic cracks
Developed using the framework of Continuum Mechanics
Fatigue Testing
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Fatigue Testing
m = 0
S-N Curve (Whler Curve)
m = 0 m = 0
(Aluminum)
(Steel)
Fatigue (endurance) limit. Stress level below which fatigue failure

will not occur
Fatigue strength. Stress level at which failure will occur for some
specified number of cycles
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S-N Curve (Whler Curve)
S-N curve for typical metals
m = 0
Fatigue Strength
Factors affecting fatigue strength

Stress concentration. Fatigue strength is reduced by stress
concentration
Surface roughness. Smoother surface increases fatigue

strength
Surface treatment. Carburizing enhances fatigue strength
Environment. Aggressive (corrosive) environment decreases
fatigue strength
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Mathematical Representation of S-N Curve
a = A ( f )B = 'f (2 f )b
f
Mathematical Representation of S-N Curve
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Safety Factors for S-N Curve
( , )

f
a
SF = SF =

(safety factors in stress) (safety factor in lifetime)
Example 2
Question
For the AISI 4340 steel, a stress amplitude of 500 MPa will be applied in service
for 2000 cycles. What are the safety factors in stress and in lifetime
a
a = A ( f )B
(500,2000)

f
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Effect of Mean Stress
S-N Curve
Asymmetrical stress cycle
Mean stress increases
Haigh Diagram
Lifetime decreases
Asymmetrical stress cycle
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u Tensile strength
~ fB True fracture strength
1 Goodman line
a m
u + =1
Tensile strength
Sf u
~ fB True fracture strength
2 2 Gerber parabola
2
a
3 + m =1
S f u
3 Morrow line
1 a
+ ~m = 1
Sf fB
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Example 3
Question
A cylindrical 4340 steel bar is subjected to a fluctuating axial load that
varies from a maximum of 330 kN tension to a minimum of 110 kN
compression. Using the Goodman line, determine the minimum bar
diameter to give infinite fatigue life. The mechanical properties of the
steel are:
u = 1090 MPa S f = 204 MPa
a m
+ =1
Sf u
Part C
Fatigue Crack Propagation
Approach
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Introduction
Fatigue crack propagation approach

Attention is focused on the behavior of components containing
pre-existing crack under mechanical or thermal loading
Large majority of number of cycles to complete rupture is
expended during the crack propagation stage
Appropriate for components that can tolerate the presence of
macroscopic cracks
Developed using the framework of Fracture Mechanics
Physical Mechanism of Fatigue Crack Growth
Beach marks
(clamshell marks) Fatigue striations
10 m
Fatigue striations in aluminum as

Fracture surface of a steel component observed using TEM
experiencing fatigue failure
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Physical Mechanism of Fatigue Crack Growth
Fatigue Testing
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Fatigue Testing
Representation of Fatigue Testing
Geometry independence
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Region I
Below a threshold value Kth, no
observable fatigue crack growth
Kth occurs at crack propagation
rates of the order of 0.25 nm/cycle
or less
Region II
Represents an essentially linear
relationship between log da/dN and
log K
da
log log(K )
d
Region III
Region of accelerated crack growth
Kmax approaches the fracture
toughness of the material KIC
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Mathematical Representation
Paris Law
da
= C (K )
m
d
K = K max K min
= Y max a Y min a
C, m: Material parameters
Example 4
Question
Show that for the Paris Law, number of cycles to failure Nf required for
crack to propagate from initial length a0 to final length af , is given by
the following relation:
(a )
m m
(a0 )
1 1
2 2
da r = max min
= C (K ) f =
f
m
m
d C
m
r
m/2
Y 1
m
Assume that the parameter Y is independent of crack length and m 2
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Lecture 6 Fatigue Failure

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28/04/2017

The process of progressive localized permanent structural

Characteristics of fatigue failure

Stress field measured using Stress field computed using

Physical Nature of Fatigue Failure

Fracture surface of a steel component

Process of Fatigue Failure

Stages in fatigue failure

I. Crack initiation. Small cracks forms at some point of

Process of Fatigue Failure

Process of Fatigue Failure

Slip due to external load

Process of Fatigue Failure

Slip due to cyclic load

Process of Fatigue Failure

Mean stress Stress amplitude Stress ratio

Approaches in Fatigue Analysis

Approaches in Fatigue Analysis

Fatigue Crack Nucleation Fatigue Crack Propagation

Strength of Materials Mechanics of Cracks

Fatigue crack nucleation approach

S-N Curve (Whler Curve)

Fatigue (endurance) limit. Stress level below which fatigue failure

S-N Curve (Whler Curve)

S-N curve for typical metals

Factors affecting fatigue strength

Surface roughness. Smoother surface increases fatigue

Mathematical Representation of S-N Curve

Mathematical Representation of S-N Curve

Safety Factors for S-N Curve

Effect of Mean Stress

Asymmetrical stress cycle

Mean stress increases

Effect of Mean Stress

Asymmetrical stress cycle

Effect of Mean Stress

~ fB True fracture strength

Effect of Mean Stress

Fatigue crack propagation approach

Physical Mechanism of Fatigue Crack Growth

Fatigue striations in aluminum as

Physical Mechanism of Fatigue Crack Growth

Representation of Fatigue Testing

Representation of Fatigue Testing

Representation of Fatigue Testing

Assume that the parameter Y is independent of crack length and m 2

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