0 INTRODUCTION
This is an
but
also
manufacturing
defects,
exceeding
design
limits
and
Figure 1.0
very low values of stress and will yield to a very considerable extent before
fracture occurs. The failure of material varies according to several factors. There
are many type of failure of material which includes foreign object damage (FOD),
fatigue failure, corrosion, creep failure and many more. [4] Despite from that the
most common failures are creep failure, fatigue failure and corrosion of the
material.
Creep failure happens usually occurs at elevated temperatures since slip
in the lattice structure is easier at this temperature. Even in designing the steam
and gas turbines the material for the rotor and stator turbine blade are carefully
chosen to minimize the creep failure. It would be catastrophic if the rapidly
rotating blades of the rotor touched the stator blades due to dimensional change
through creep. Creep can be easily defined as gradual extension of a material
under a constant applied load. Creep is an important factor when designing
metals when they are required to work continuously at high temperatures. The
phenomena of the creep failure are shown below:
The Primary Creep or the 1st stage creep are fairly rapid rate but slows
down as work hardening (strain hardening) sets in and the strain rate decreases.
The extension due to creep is additional to the instantaneous elongation of
material to be expected when any tensile load is applied. During the secondary
creep period, the increase in strain is approximately proportional to time. At this
stage the strain rate is constant and at its lowest value. During the tertiary creep
period of creep, the strain rate increases rapidly, necking occurs and the test
piece fails. Thus the initial stress, which was within the elastic range and did not
produce early failure, did eventually result in failure after some period of time.
3
The material having fatigue failure underwent the repeated stress cycle in
which maximum and minimum stresses are asymmetrical relative to the zero
stress level; mean stress m, range of stress r , and stress amplitude a are
indicated. S-N
cycles-to-failure for given cyclic stress. For frequencies < 200Hz, metals are
insensitive to frequency; fatigue life in polymers is frequency dependent. Below
shows the S-N behavior curve.
According to the graph above , the higher the magnitude of the stress, the
smaller the number of cycles the material is capable to sustain before failure.
Certain materials have a fatigue limit or endurance limit which represents a
stress level below which the material does not fail and can be cycled infinitely. If
the applied stress level is below the endurance limit of the material, the
structure is said to have an infinite life. Many non-ferrous metals and alloys, such
as aluminum, magnesium, and copper alloys, do not exhibit well-defined
endurance limits. These materials instead display a continuously decreasing S-N
response, similar to Curve B in Figure 3.2. In such cases a fatigue strength Sf for
a given number of cycles must be specified. An effective endurance limit for
these materials is sometimes defined as the stress that causes failure at 1x10 8 or
5x108 loading cycles. [8]
Fatigue will ultimately occur regardless of the magnitude of the stress. For
these materials, the fatigue response is specified as fatigue strength, which is
defined as the stress level at which failure will occur for some specified number
of cycles. There are two type of cyclic fatigue namely the high-cyclic fatigue and
low-cyclic fatigue. High-cyclic fatigue(HCF) is for low stress levels where
deformations are totally elastic, longer lives result. This requires large numbers
of cycles are required to produce fatigue failure. This type of failure is associated
with fatigue lives greater than about 104 to 107 cycles. In contrast, the low-cyclic
fatigue (LCF) is associated with relatively high loads that produce not only elastic
strain but also some plastic strain during each cycle. Consequently, fatigue lives
are relatively short occurs at less than about 10 4 to 105 cycles. Figure below
shows clear difference between the two behaviors.
into three phases. In the first phase namely crack initiation phase. As the crack
initiated a fatigue crack propagates along high shear stress planes (45 degrees)
. This is known as stage I or the short crack growth propagation stage. The crack
propagates until it is caused to decelerate by a microstructural barrier such as a
grain boundary, inclusions, or pearlitic zones, which cannot accommodate the
initial crack growth direction. Therefore, grain refinement is capable of increasing
fatigue strength of the material by the insertion of a large quantity of
microstructural barriers, i.e. grain boundaries, which have to be overcome in the
stage I of propagation. Surface mechanical treatments such as shot peening and
surface rolling, contribute to the increase in the number of microstructural
barriers per unit length due to the flattening of the grains.
The effect of fatigue failure also can be seen by naked eyes. By examining
the fracture side of the failure, two distinct regions can be felt. One being smooth
or burnished as a result of the material. The microstructure are as below :
properties of the material. Its ability to withstand load not only restricted below
the yield strength. The load can be applied above the yield strength as shown
below:
Figure 5.1 The range of strain hardening ability on the stress strain curve [10]
strength. The cyclic loading causes crack initiation on the material followed by
the crack propagation.
intensity occur at the crack , the failure of the material occur. The failure is
permanent where it can no longer turn to its original form. The fatigue failure can
be
reduce
by
strengthening
mechanism
such
as
work
hardening
and
7.0 REFERENCES
12