ductile iron is studied in this paper. The mechanism of fatigue crack growth is modelled
using the boundary element method, customized for the accurate evaluation of the
interaction effects between cracks and microcracks emanating from graphite nodules.
The effects of nodule size and distribution and crack closure are considered, with
deviation bounds of computed results estimated through weight-function analyses. A
continuum approach is employed as a means of quantifying the shielding effect of
microcracking on the dominant propagating crack, due to the reduction of stiffness of
the material in the neighbourhood of the crack tip. Although the results obtained may
not yield actual numbers for real cases, they are in accordance with experimental
observations and demonstrate how the main factors affect the crack growth of the
macrocrack.
Keywords austempered ductile iron; boundary element method; fatigue crack growth;
microcracking; numerical modelling.
NOMENCLATURE
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INTRODUCTION
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of ADI are also better than those of other cast irons and
wrought steels, as measured by SN curves of polished
specimens. Fatigue properties can be further improved
by means of surface mechanical and thermal treatments.
The relationship between fatigue crack growth and
matrix microstructure is the focus of previous work by
one of the authors.5 A quantitative study of the morphology of fatigue crack growth proved that the crack
path preferentially intersects graphite nodules, and that
a microcracking process takes place in the region of
high-stress concentration around the tip of the macroscopic crack. Graphitematrix interfaces are extremely
irregular, with sharp corners that in some cases constitute
imminent microcracks that emanate from the nodules.
Ultimately the macroscopic crack advances by interaction
and coalescence of the microcracks, as shown in Fig. 1(b).
The authors propose that as microcracks simultaneously
propagate besides the main crack, the available elastic
energy for the propagation of the main crack is lowered
mainly because of the creation of a larger crack surface.
This reduces the general rate of advance and in some
cases causes the premature arrest of crack growth. The
above-mentioned mechanism provides evidence to
explain the relatively low propagation rates and high
effective propagation threshold values for this material.
This paper presents numerical and fracture mechanics
modelling of the mechanism of fatigue crack growth in
ADI, in order to provide further understanding of the
phenomena. The numerical tool for the analysis is based
on the boundary element method (BEM), customized
for the accurate evaluation of the interaction effects
between cracks, microcracks and graphite nodules.
Deviation bounds of the BEM results are estimated
through weight-function analyses. The shielding effect
of microcracking on the (macroscopic) main crack is
studied using a continuum mechanics approach.
NUMERICAL MODELLING
Method of analysis
Numerical modelling of fatigue crack growth requires
the capability of predicting the direction and amount of
crack growth as well as the robustness to update the
numerical model to account for the changing crack
geometry. The dual boundary element method (DBEM)
is a well-established numerical technique in this area of
fracture mechanics, as it eliminates the remeshing problems, which are typical of domain methods and other
boundary element formulations.6 General mixed-mode
crack problems are solved with the DBEM in a single
region formulation, in which the crack growth process
is efficiently simulated with an incremental analysis in
which crack extensions are modelled by adding new
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(1)
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(2)
(3)
(4)
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Fig. 4 Evolution of propagation paths for a general nodule array ahead of a long propagating fatigue crack.
Nodularity
(%)
Average r/d
Standard deviation
(%)
60
100
150
600
100
100
100
100
0.27682
0.26175
0.25294
0.25625
31.18
37.56
35.43
32.62
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respect to K0 , the stress intensity factor value corresponding to a crack emanating from an isolated circular
hole and subjected to a remote constant stress field.
Deviation bounds in K-values are around 10%, provided
the microcrack length is less than the nodule radius
(c/r<1). The deviation grows up to 20% for microcrack
lengths c=2r.
As mentioned above, the effect of nodules on macrocracks was studied through the analysis of the stress fields
on lines orientated perpendicularly to the remote applied
load. Figure 7 illustrates a typical distribution of the
maximum principal stress field s1 , along a line of length
equal to 25 nodule distances, x/d=25. The normalizing
parameter for s1 is the mean stress on the line sm .
Segments of the curve with zero stress correspond to
nodule positions. Spectral analysis of the stress distribution was performed using a Fast Fourier Transform
(FFT) methodology. The results are illustrated in Fig. 8
for r/d=0.2, 0.25 and 0.30. It can be seen that there is
a clear periodicity in the stress field, given by the
dominant peaks at T/d=1 for the three cases.
Consequently, the period T corresponds to the average
minimum nodule distance d. It is worth noting that as
r/d increases the dominant peak becomes more marked,
and the noise in the spectral data is reduced. This
behaviour is an indication that as r/d increases, and
consequently a more compact array of nodules is
obtained, the periodicity of the stress field is more
marked.
As with microcracks, the effect of variations in the
stress field on K-values was estimated through a weight
Continuum approach
Microcracking in regions near the tip of a crack can
have a shielding effect on the crack tip, redistributing
and reducing the average near-tip stresses. There are
two sources for the redistribution of stresses in the near-
2001 Blackwell Science Ltd. Fatigue Fract Engng Mater Struct 24, 591605
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Fig. 9 Deviations of K values for a long crack in an ADI microstructure with respect to a crack in an homogeneous material.
(5)
C D
G
1
1
1n G
9
(6)
Application to ADI
Figure 10(a) shows a schematic of the problem, when
applied to stationary and steadily growing cracks in ADI.
The shape of Ac results from considering that microcracks nucleate with no preferred orientation, and that
nucleation occurs when the maximum principal stress s1
reaches a critical tensile value sc , i.e.
Microcrack density b=0 (s1 )max <sc
b>0 (s1 )max sc
and
d2 =
1
G
n: n
1n
G
9
(7)
where G
9 is the effective shear modulus of the microcracked zone and n: is the effective Poissons ratio. It
is of interest to give some explicit deduction from Eq. (5).
In this sense the following result is exact to the lowest
order in d1 and d2 :
B A
5
3
Ktip
d1 + k2 +
d2
=1+ k1
K
8
4
(8)
(9)
G H
2M A2
p
P
(10)
(11)
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where Nvol stands for the nodule count per unit volume
(nod/mm3 ) and a nucleation parameter 0a1
accounts for the fact that only a fraction of nodules
actually nucleate cracks. Following Hilliard21 volume
and area nodule counts are related through the ratio
between the average nodule cross-section area and the
nodule volume, A
9 nod /V
9 nod , which results in
Nvol =Narea
A
pr2
3 Narea
9 nod
=Narea 4 3 =
V
pr
4
r
9 nod
3
(12)
A B
3 Narea 4 3
pr =Narea r2 p=0.09
Nvol V
9 nod =
4 r
3
M=a
5
3/2
p N area
2
(14)
(13)
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Eq. (11) as
Dent =
C A BD
snn
V E
C A BD
snt
V E
r
16
(1n2 ) 1
3
rc
r
16 (1n2 )
1
3 (2n)
rc
3/2 3
rc
3/2 2
rc
(15)
(16)
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where V stands for unit volume. Note that these contributions to the strain are also based on the assumption
that the interaction between a microcrack and its neighbours can be ignored. Results in Eqs (15) and (16) can
be assimilated to those obtained in Ref. [19] for a pennyshaped crack under constant load provided an equivalent
microcrack radius is defined as
req =rc3
SC A B D
r
1
rc
(17)
2
Considering now that A=preq
and P=2preq together
with the result in Eq. (14), then Eq. (10) for the crack
density parameter b yields
b=
A B SC A B D
rc
27
a
400p
r
r
rc
(18)
16n (3n)(1n2 )
b
15
(2n)
(19)
(20)
action, agree with the dilute limit estimates that approximate interaction.20
The values of k1 and k2 for the situations depicted in
Fig. 10, when microcracks nucleate at a critical maximum
normal stress, have been obtained in Ref. [19] which
after substitution in Eq. (8) results in
A B
A B
Ktip
K
stationary
Ktip
K
growing
=10.547d1 +0.674d2
=10.673d1 +0.822d2
(21)
(22)
for the stationary and steadily growing crack, respectively. A related result worth considering corresponds
to anisotropic microcracking, in which microcracks
nucleate perpendicular to the maximum principal stress
s1
A B
Ktip
K
anisotropic
1
1+5.83b
(23)
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REFERENCES
1 Authors. (1990) Ductile iron data for design engineers, Ductile
Iron Group of QIT-Fer & Titane, Canada.
2 Gundlach, R. B. and Janowak, J. F. (1991) A review of austempered ductile iron metallurgy. In: Proceedings AFS (American
Foundrymens Society, Inc.) 1991 World Conference on Austempered
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6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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APPENDIX
(A1)
(A2)