Professional Documents
Culture Documents
FATIGUE OF MATERIALS
TOPICS & REFERENCES
Mechanisms for Fatigue Fatigue Crack Propagation Ch. 14 in Meyers & Chawla S. Suresh, Fatigue of Materials, 2nd Ed., Cambridge (1998)
Page 793
Fatigue of Materials
Many materials, when subjected to fluctuating stresses, fail. The stresses required to cause failure are far below those needed to cause fracture on single application of load. Fatigue failure is failure under dynamic loading. Fatigue is the cause for more than 90% of all service failures in structural materials. It is something that you would like to avoid. Fatigue failures generally occur with little or no warning (with catastrophic results).
Page 794
Fatigue Fractures
They generally appear to be brittle.
Stress concentrators PSBs Inclusions Etc
[Hertzberg]
Page 796
Stress Cycles
max a STRESS = r 0 min m TIME All fluctuating stress cycles are made up of a m and a a
Stress Range: Stress Amplitude (alternating stress): Mean Stress: Stress Ratio: Amplitude Ratio:
a =
max min
r
2
min max 1 R A= a = m 1+ R
Page 797
Stress Cycles
max
max min
STRESS
m
TIME
min
Real stress cycles are far more complex and unpredictable than the ideal one showed on the prior viewgraph. Thus, fatigue failures are statistical in nature. Now we need to consider how fatigue parameters influence fatigue failure.
Page 798
S or
SL
Example: Al alloys Non-ferrous metals
a
Fatigue Limit Endurance Limit at 107 Cycles
102
104
106
108
102
104
106
108
Nf
Nf
In materials exhibiting a fatigue limit, cyclic loading at stresses below the fatigue limit cannot result in failure. In steels SL/UTS = 0.4 to 0.5). For non-ferrous materials we will generally define the fatigue strength as the stress that will cause fracture at the end of a specified number of cycles (usually 107).
Page 800
Categories of Fatigue
(1)
(2)
(3)
M.F. Ashby and D.R. Jones, Engineering Materials 1, 2nd Edition, Butterworth-Heinemann, Boston (1996), p. 146
Page 801
Categories of Fatigue
High-strain LOW CYCLE Finite life Infinite life Plastic deform. of bulk SUTS SYS Low-strain HIGH CYCLE
Stress, Sa
Elastic deform. of bulk 100 101 102
103
104
105
105
107
108
Adapted from J.E. Shigley, C.R. Mischke, and R.G. Budynas, Mechanical Engineering Design, 7th Edition, McGraw-Hill, Boston (2004), p. 314
Page 802
Stress-Life or Strain-Life?
Most data is presented on S-N curves. This is typical of the stresslife method which is most suitable for high-cycle applications [i.e., in the high-cycle fatigue (HCF) regime].
The strain-life method is more applicable where there is measurable plastic deformation [i.e., in the low-cycle fatigue (LCF) regime].
2
2
O 2
Page 803
Strain-Life Method
Its convenient to consider elastic and plastic strains separately.
= elastic + plastic
e = elastic strain amplitude 2 a = true stress amplitude f = fatigue strength coefficient b = fatigue strength exponent
Page 804
Page 805
+ f ( 2 N f
This is the Manson-Coffin relationship between fatigue life and total strain. We can use it to determine the fatigue strength.
f
Strain Amplitude /2 (log Scale)
P > e
LCF
At high temperatures, the Manson Coffin equation breaks down because Nf decreases as temperature increases. In addition, Nf depends on cyclic frequency.
P < e
HCF
f
E
ELASTIC
Total strain b
PLASTIC
Page 807
[Dowling]
p B
2
2
O 2
Page 809
Time
2 4
Cyclic Hardening
3 5
Strain
5 3 1
Time
2 4 2 4
Cyclic Softening
3 5
Strain
1 3 5
Time
2 4 4 2
Page 810
max
Effects of Mean Stress and Stress Ratio Variation of m (and R) will cause the endurance limit to change
STRESS
R = -1.0
m = 0 min max TIME
STRESS
a m min max
R = -0.3
TIME
STRESS
a m
R = 0.0
STRESS
R = 0.0
min
[Dieter]
Page 812
R = negative
Linear
R = -1
R=0
Gerber
2 m a = o 1 UTS
( (
Parabolic
R = positive
Soderberg
a = o 1 m YS
1
Linear
YS
Mean Stress
UTS
R=1
Most experimental data lies between the Goodman and Gerber values. The Goodman relation is more conservative and is safer for design purposes.
Page 813
Figure 9.43
As you can see, a certain stress amplitude (a1) is applied for a number of cycles (N1). The number of cycles to failure for a1 is Nf1. The fraction of life used is N1 /Nf1. There will be additional expressions for regions of loading with different stress amplitudes. The total life used can be expressed as:
N1 N N + 2 + 3 + N f1 N f 2 N f 3 + Ni N fi
Page 814
Figure 9.43
N N1 N + 2 + 3 + N f1 N f 2 N f 3
=
i
Ni =1 N fi
Fatigue failure is expected when the life fractions sum to unity (i.e., when 100% of the fatigue life is exhausted).
Page 815
[Dowling]
I II III
Page 817
I II III
Page 818
Page 819
Where slip fits in. Crystalline solids generally deform by slip, which leaves slip bands on the surface. In unidirectional deformation, slip occurs uniformly through a grain.
dislocations
Slip planes
In fatigue, some grains show slip lines while others will not. Additional deformation produces additional slip lines.
Fewer slip lines are produced than the actual number of fatigue cycles.
In many materials, slip rapidly reaches a saturation value, resulting in distorted regions of heavy slip.
Page 820
Page 821
CRACK INITIATION
PSBs are embryonic fatigue cracks that open when small tensile strains are applied.
[Dieter]
Once formed cracks will initially propagate along slip planes (Stage I). Later they assume directions perpendicular to the applied stress (Stage II).
Page 823
PSBs are embryonic fatigue cracks that open when small tensile strains are applied.
Figure 4.4. (a) The critical annihilation distance for screw and edge dislocations. (b) Mechanism of extrusion formation by combined glide and dislocation annihilation. (c) Irreversible slip in the PSB creating effective interfacial dislocations which put the slip band in a state of compression. (d) The combined effects of applied stresses and internal stresses. Bigger arrows indicate repulsive forces on interfacial dislocations and smaller arrows denote forces caused by the applied load (After Essman, Gsele and Mughrabi, Phil. Mag. A, v. 44, 1981, pp. 405-426).
[Suresh, p. 138]
Page 824
Page 825
Stage I
Cracks propagate via crystallographic shear modes. A few cracks nucleate along crystallographic slip planes. The rate of crack propagation is low (on the order of a few /cycle). The fracture surface in Stage I is nearly featureless.
Stage II
Stage II crack propagation shows ripples/striations.
From R.M.N. Pelloux, Fractography, in Atomistics of Fracture, edited by R.M. Latanision and J.R. Pickens, Plenum Press (1981) pp. 241-251
Each striation represents the position of the advancing crack. The crack propagation rate is high (on the order of a m/cycle). Striations are the result of a combination of crack propagation and blunting.
[Dieter]
Page 827
Stage III
The fatigue crack becomes too large. The Kc of the material is exceeded resulting in fast fracture.
Fatigue Life
a (crack length)
ac
Incr.
da ao dN Nf
N (# cycles)
Page 828
Stage III
The fatigue crack becomes too large. The Kc of the material is exceeded resulting in fast fracture.
ac
Fatigue Life
a (crack length)
Incr.
da ao dN Nf
N (# cycles)
a = alternating stress
a = crack length m = a constant ranging from 2 to 4 n = a constant ranging from 1 to 2
C1 = constant
= total strain
m1 = a constant ranging from 2 to 4
This is known as the Paris equation. It predicts the crack growth rate in the region of stable crack growth (Stage II).
Page 830
ij x
a w
Applied Stress
ij =
K Fij ( ) + ... 2 r
Page 831
The K is the stress intensity factor that we defined previously as fracture toughness.
K = F ( a, ) = a F ( a w) = a Y
Shape factor; depends on specimen shape and crack geometry
Values of K have been tabulated for materials with different crack geometries. Of course, we are interested in the critical K values (i.e., Kc) .
Page 832
= max min
K = Y a K = K max K min = Y a
For constant , K correlates with the fatigue crack growth rate. This is illustrated on the next page.
Page 833
a ao dN
da
N (# cycles)
Obviously
da = F (K ) dN
The variation of the fatigue crack growth rate with K is shown on the next page.
Page 834
II
K max K c
III
p 1
K th
No crack growth
da p = A ( K ) dN
I.
II. Crack propagation Paris law region III. Unstable crack growth accelerated crack growth
Page 835
da p = A ( K ) dN
where A and p are constants that depend upon material, environment, and test conditions. The influence of the mean stress, written in terms of the stress ratio R, is given by:
A ( K ) da = dN (1 R ) K c K
p
An increase tends to increase crack growth rates in all portions of the crack growth curve.
Page 836
II.
III.
Page 837
(a) dc/dN vs. K for several Ti, Al, and steel alloys. (b) The same data replotted as dc/dN vs. K/E. Normalizing K by dividing by the modulus (E) produces a curve (with some scatter about it) in which crack-growth rates in several materials cannot be as clearly differentiated as they are in (a). The results indicate that fatiguecrack growth rates are not structure-sensitive; this is in contrast to most mechanical properties. This comes from Bates and Clark, Trans. ASM, 62, 380 (1969).
[Courtney, p. 590]
Page 838
Creep-Fatigue Interactions
Materials are generally used in hostile environments where diffusional processes can operate and/or where they are subject to environmental attack.
Ex. High-temperature turbine blade in an aircraft engine. Temperatures are in the creep regime. The environment is toxic. Rotational stresses and differences in thermal expansion result in cyclic loading.
Page 839
Creep-Fatigue Interactions
When the cyclic stress or strain amplitude is small compared to the mean stress (i.e., a << m) creep accelerated by fatigue.
This definition also applies when temperature is high and the applied frequency is low.
Under opposite circumstances we have fatigue failure accelerated by diffusional processes (i.e., creep).
At high temperatures fracture is caused by grainboundary cavitation, which is followed by cavity growth and cavity coalescence resulting in a flaw of critical size. Several modes of high temperature fracture are illustrated on the next viewgraph.
Page 840
Page 841
Creep-Fatigue Interaction
Recall from fracture mechanics that tensile stresses tend to open up cracks whereas compressive stresses tend to heal cracks. How can cyclic loading accelerate creep?
[Courtney, p. 603]
Page 842
Ni
fi
ti =1 t fi
N i = # cycles at stress amplitude ai N fi = # cycles to failure at stress amplitude ai ti = time spent at stress-temperature combination t fi = creep fracture life
Page 843
Exposure to high temperatures generally reduces Nf at a given pl. Oxygen in air can also have an embrittling effect on the fatigue life of materials. Elevated temperatures can enhance this effect. The next pages shows this. The frequency of cyclic loading () also has an effect. When is lower, sample lifetimes are smaller for a given plastic strain range.
[Courtney, p. 604]
Page 844
[Courtney]
Page 845
[Courtney, p. 605]
Page 846