Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Microstructure-Properties: II
Fatigue
27-302
Lecture 9
Fall, 2002
Prof. A. D. Rollett
Materials Tetrahedron
Processing
Performance
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Microstructure
Properties
Objective
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
References
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
sa :=
sm :=
Alternating stress
Mean stress
R := Stress ratio
e :=
strain
Nf :=
number of cycles to failure
A := Amplitude ratio
epl :=
Plastic strain amplitude
eel :=
Elastic strain amplitude
K := Proportionality constant, cyclic stress-strain
n := Exponent in cyclic stress-strain
c :=
Exponent in Coffin-Manson Eq.;
also, crack length
E :=
Youngs modulus
b :=
exponent in Basquin Eq.
m :=
exponent in Paris Law
K :=
Stress intensity
K :=
Stress intensity amplitude
a :=
crack length
Notation
Fatigue
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Microstr.
effects
Design
S-N Curves
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
10
Microstr.
effects
smean 1
smean 2
smean 3
log Nf
Design
[Dieter]
11
Endurance Limits
Some materials exhibit endurance limits, i.e.
a stress below which the life is infinite: [fig. 12.8]
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
12
Fatigue fracture
surface
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Hertzberg]
13
Microstr.
effects
Design
Stage 2
[Dieter]
14
Microstr.
effects
Design
15
Microstr.
effects
Design
16
Dislocation Slip
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Crack Nucleation
17
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
Slip steps
and the
stress-strain
loop
18
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
19
Microstr.
effects
Design
Alternating Stress s a
Mean stress sm = (smax +smin)/2.
Pure sine wave Mean stress=0.
Stress ratio R = smax/smin.
For sm = 0, R=-1
Amplitude ratio A = (1-R)/(1+R).
Statistical approach shows significant
distribution in Nf for given stress.
20
Microstr.
effects
Design
[Dieter]
21
Mean Stress
Alternating stress sa = (smax-smin)/2.
Raising the mean stress (sm) decreases Nf. [see slide 19,
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
sa
s me an
s a s fat
1
tensile strength
tensile strength
smean
22
Microstr.
effects
Design
23
[Courtney]
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
24
Cyclic stress-strain
Wavy-slip materials
generally reach asymptote
in cyclic stress-strain:
planar slip materials (e.g.
Objective
brass) exhibit history
Crack
dependence.
Initiation
Cyclic stress-strain curve
S-N
defined by the extrema,
curves
i.e. the tips of the
Cyclic
hysteresis loops. [Courtney
stress-strn
Crack
Propagate
Microstr.
effects
Design
fig. 12.27]
[Courtney]
25
Microstr.
effects
Design
26
Strain control
of fatigue
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Courtney]
27
Microstr.
effects
Design
Constitutive relation s K e n
for cyclic stress-strain:
n 0.1-0.2
Fatigue life: Coffin Manson relation:
e p
2
ef 2N f
28
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
29
Microstr.
effects
Design
[Courtney]
30
Microstr.
effects
Design
e el e pl sf
2N f
2
2
2
E
ef 2N f
31
Microstr.
effects
Design
Crack Length := a.
Number of cycles := N
Crack Growth Rate := da/dN
Amplitude of Stress Intensity := K = sc.
Define three stages of crack growth, I, II and III,
in a plot of da/dN versus K.
Stage II crack growth: application of linear elastic fracture
mechanics.
Can consider the crack growth rate to be related to the applied
stress intensity.
Crack growth rate somewhat insensitive to R (if R<0) in Stage II
[fig. 12.16, 12.18b]
32
da/dN
I
II
Kc
III
effects
Design
Kth
33
*Paris Law
Paris Law:
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
dc
m
A(K)
dN
m ~ 3 (steel); m ~ 4 (aluminum).
Crack nucleation ignored!
Threshold ~ Stage I
The threshold represents an endurance
limit.
For ceramics, threshold is close to KIC.
Crack growth rate increases with R (for
R>0). [fig. 12.18a]
34
*Striations- mechanism
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
cf
dc
NII
c0 dc / dN
cf
NII
c0
dc
m
m
A s c
35
*Striations, contd.
Provided that m>2 and is constant, can integrate.
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
A1s m 1m / 2 1m / 2
N II
c0
cf
(m / 2) 1
36
Microstr.
effects
Design
37
Geometrical effects
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
38
Microstructure-Fatigue Relationships
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
39
da/dN
I
II
Kc
III
Design
Kth
40
Defects in Materials
Descriptions of defects in materials at the sophomore level
focuses, appropriately on intrinsic defects (vacancies,
dislocations). For the materials engineer, however, defects
Objective
include extrinsic defects such as voids, inclusions, grain
boundary films, and other types of undesirable second phases.
Crack
Initiation Voids are introduced either by gas evolution in solidification or
by incomplete sintering in powder consolidation.
S-N
Inclusions are second phases entrained in a material during
curves
solidification. In metals, inclusions are generally oxides from the
Cyclic
surface of the metal melt, or a slag.
stress-strn
Grain boundary films are common in ceramics as glassy films
Crack
from impurities.
Propagate
In aluminum alloys, there is a hierachy of names for second
Microstr.
phase particles; inclusions are unwanted oxides (e.g. Al2O3);
effects
dispersoids are intermetallic particles that, once precipitated, are
thermodynamically stable (e.g. AlFeSi compounds); precipitates
Design
are intermetallic particles that can be dissolved or precipiated
depending on temperature (e.g. AlCu compounds).
41
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
graph courtesy of J.
Staley, Alcoa
42
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
graph courtesy of J.
Staley, Alcoa
43
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Dieter]
44
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Polmear]
45
Titanium alloys
[Polmear]
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
For many Ti alloys, the proportion of hcp (alpha) and bcc (beta) phases
depends strongly on the heat treatment. Cooling from the two-phase region
results in a two-phase structure, as Polmears example, 6.7a. Rapid cooling
from above the transus in the single phase (beta) region results in a twophase microstructure with Widmansttten laths of (martensitic) alpha in a beta
matrix, 6.7b.
The fatigue properties of the two-phase structure are significantly better than
the Widmansttten structure (more resistance to fatigue crack formation).
The alloy in this example is IM834, Ti-5.5Al-4Sn-4Zr-0.3Mo-1Nb-0.35Si-0.6C.
46
*Design Considerations
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
47
*Design Considerations: 2
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
48
*Fatigue
property map
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Courtney]
*Fatigue
property map
49
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Courtney]
50
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
ni
1
i N fi
* Courtneys Eq. 12.9 is confusing; he has Nf in the numerator also
51
*Fatigue in Polymers
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
52
Fatigue: summary
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design