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High Cycle Fatigue a Mechanics of Materials Perspective

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Sections

Introduction
1.1. HISTORICAL BACKGROUND
1.2. WHAT IS HIGH CYCLE FATIGUE?
1.3. HCF DESIGN CONSIDERATIONS
1.4. HCF DESIGN REQUIREMENTS
1.5. ROOT CAUSES OF HCF
1.5.1. Field failures
1.6. DAMAGE TOLERANCE
1.6.1. Application to HCF
1.7. CURRENT STATUS
1.8. FIELD EXPERIENCE
Characterizing Fatigue Limits
2.1. CONSTANT LIFE DIAGRAMS
2.2. GIGACYCLE FATIGUE
2.3. CHARACTERIZING FATIGUE CYCLES
2.4. FATIGUE LIMIT STRESSES
2.5. EQUATIONS FOR CONSTANT LIFE DIAGRAMS
2.6. HAIGH DIAGRAM AT ELEVATED TEMPERATURE
2.7. ROLE OF MEAN STRESS IN CONSTANT LIFE DIAGRAMS
2.8. JASPER EQUATION
2.9. OBSERVATIONS ON STEP TESTS AT NEGATIVE R
Accelerated Test Techniques
3.1. HISTORICAL BACKGROUND
3.1.1. Coaxing
3.2. EARLY TEST METHODS
3.3. STEP TEST PROCEDURES
3.3.1. Statistical Considerations
3.3.2. Influence of number of steps
3.3.3. Validation of the step-test procedure
3.3.4. Observations from the last loading block
3.3.5. Comments on step testing
3.4. STAIRCASE TESTING
3.4.1. Probability plots
3.4.2. Statistical analysis
3.4.2.1. Dixon and Mood method
3.4.2.2. Numerical simulations
3.4.2.3. Sample size considerations
3.4.2.4. Construction of an “artificial” staircase
3.5. OTHER METHODS
3.6. RANDOM FATIGUE LIMIT (RFL) MODEL
3.6.1. Data analysis
3.7. SUMMARY COMMENTS ON FLS STATISTICS
3.8. CONSTANT STRESS TESTS
3.8.1. Run-outs and maximum likelihood (ML) methods
3.9. RESONANCE TESTING TECHNIQUES
3.10. FREQUENCY EFFECTS
LCF–HCF Interactions
4.1. SMALL CRACKS AND THE KITAGAWA DIAGRAM
4.1.1. Behavior of notched specimens
4.2. EFFECTS OF LCF LOADING ON HCF LIMIT STRESS
4.2.1. Studies of naturally initiated LCF cracks
4.3. CRACK-PROPAGATION THRESHOLDS
4.3.1. Overloads and load-history effects
4.3.1.1. An overload model
4.3.1.2. Analysis using an overload model
4.3.2. Examples of LCF–HCF interactions
4.4. DESIGN CONSIDERATIONS
4.4.1. LCF–HCF nomenclature
4.4.2. Example of anomalous behavior
4.4.3. Another example of anomalous behavior
4.5. COMBINED CYCLE FATIGUE CASE STUDIES
Notch Fatigue
5.1. INTRODUCTION
5.2. STRESS CONCENTRATION FACTOR
5.4. FATIGUE NOTCH FACTOR
5.4.1. kf versus kt relations
5.4.2. Equations for kf
5.5. FRACTURE MECHANICS APPROACHES FOR SHARP NOTCHES
5.6. CRACKS VERSUS NOTCHES
5.7. MEAN STRESS CONSIDERATIONS
5.8. PLASTICITY CONSIDERATIONS
5.8.1. Negative mean stresses
5.9. FATIGUE LIMIT STRENGTH OF NOTCHED COMPONENTS
5.9.1. Non-damaging notches
5.10. SIZE EFFECTS AND STRESS GRADIENTS
5.10.1. Critical distance approaches
5.11. ANALYSIS METHODS
5.12. EFFECTS OF DEFECTS ON FATIGUE STRENGTH
5.13. NOTCH FATIGUE AT ELEVATED TEMPERATURE
Fretting Fatigue
6.1. INTRODUCTION
6.2. OBSERVATIONS OF FRETTING FATIGUE
6.3. REPRESENTING TOTAL CONTACT LOADS, Q AND P
6.4. LOAD AND STRESS DISTRIBUTIONS
6.5. EFFECTS OF LOCAL AND BULK STRESSES ON STRESS INTENSITY
6.6. MECHANISMS OF FRETTING FATIGUE
6.7. MECHANICS OF FRETTING FATIGUE
6.8. STRESS ANALYSIS OF CONTACT REGIONS
6.8.1. Multiple crack considerations
6.8.2. Analytical solutions
6.9. ROLE OF SLIP AMPLITUDE
6.10. STRESS-AT-A-POINT APPROACHES
6.11. FRACTURE MECHANICS APPROACHES
6.12. A COMBINED STRESS AND K APPROACH
6.13. COMPARISON OF FRETTING-FATIGUE FIXTURES
6.14. ROLE OF COEFFICIENT OF FRICTION
6.14.1. Average versus local coefficient of friction
6.15. SUMMARY COMMENTS
Foreign Object Damage
7.1. INTRODUCTION
7.2. FIELD EXPERIENCE AND OBSERVATIONS
7.3. REPAIR BY BLENDING
7.5. FOD DATA MINING AND INVESTIGATION
7.6. DEFINITION OF FOD
7.7. TYPES OF DAMAGE
7.8. SCOPE OF THE FOD PROBLEM
7.8.1. Laboratory simulation methods
7.8.1.1. Solenoid gun
7.8.1.2. Pendulum
7.8.1.3. Quasi-static
7.8.2. Simulations using a leading edge geometry
7.8.3. Role of residual stresses
7.8.4. Energy considerations
7.9. FATIGUE LIMIT STRENGTH
7.9.1. Simulations using a flat plate
7.9.2. Other laboratory FOD simulations
7.10.1. Perturbation study
7.11. SUMMARY COMMENTS
HCF Design Considerations
8.1. FACTORS OF SAFETY
8.1.1. Modeling errors
8.1.2. Material variability
8.2. FRACTURE MECHANICS CONSIDERATIONS
8.2.1. Effects of defects
8.2.2. Application to LCF–HCF
8.3. DAMAGE TOLERANCE FOR HCF
8.3.1. Material allowables
8.4. THRESHOLD CONCEPT FOR HCF
8.4.1. Representing fatigue limit data
8.4.2. Threshold considerations
8.4.3. Experimental threshold measurements
8.4.3.1. “Jump-in” method
8.4.4. Mechanisms in threshold testing
8.4.5. Load-history effects
8.4.5.1. Compression precracking
8.4.5.2. Load-shed rates
8.4.6. Crack closure
8.4.6.2. Crack propagation stress intensity factor
8.4.7. An engineering approach to thresholds
8.4.8. Observations from field failures
8.5. PROBABILISTIC APPROACH TO HCF/FOD DESIGN
8.6. RESIDUAL STRESSES IN HCF DESIGN
8.6.1. Application to notches
8.6.2. Shot peening
8.6.3. Deep residual stresses
8.6.3.1. Application to an airfoil geometry
8.6.3.2. Crack arrest
8.6.3.3. Crack growth retardation
8.6.3.4. A numerical example
8.6.4. Autofrettage
Final Report for the USAF High Cycle Fatigue Program
Evaluation of the Staircase Test Method using Numerical Simulation
Estimation of HCF Threshold Stress Levels in Notched Components
Analytical Modeling of Contact Stresses
Experimental and Analytical Simulation of FOD∗
FOD in JSSG

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