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FATIGUE AND FRACTURE
– CONCEPTS AND
APPLICATION.
Raghu V Prakash
Professor
Department of Mechanical Engineering
Indian Institute of Technology Madras
Chennai 600 036
E-mail: raghuprakash@iitm.ac.in
Is Failure a stepping stone for
success?
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Aloha Airlines Accident – April
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1988.
The aircraft lost 1/3 of its roof due to a stress fracture while cruising at 24,000 feet.
One Flight Attendant was sucked from the airplane, which subsequently made a
safe emergency landing.
Failure events.
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Comet Aircraft (1950’s)
Two aircrafts after climbing
certain altitude underwent
explosive decompressions of
fuselage that resulted in loss of
lives and aircraft.
Cabin pressurization and
depressurization led to fatigue
loading.
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Failure events.
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Japan Airlines Boeing
747SR crash, 1985.
Fatigue failure.
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Failure of crank shaft due to
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fatigue.
Classification of Failures.
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Problems with loads and design.
Problems with inspection, maintenance and repair.
Problems due to operating environment.
Despite several great strides in technology, failures
continue to occur, often with loss of human and
economic loss.
Failure analysis provides an opportunity to understand
the intricate relationship between design, operation of
components, failure modes so that we can correct
designs, issue guidelines for operation and maintenance
to avoid recurrence of such events.
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Terminology
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Amplitude
Range
Mean
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What makes Fatigue studies
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interesting ?
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Typical Fatigue Analysis.
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Service Loads Component Testing
Dynamic Analysis
Stress Analysis Fatigue Analysis Component Life
Material Properties
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Essential Elements of Fatigue
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Analysis.
Material Properties.
Fatigue Crack Initiation
Stress Vs Life approach (Endurance limit of stress)
Strain Vs Life approach (Low Cycle Fatigue)
Fatigue Crack Propagation.
Fracture Toughness.
Geometry Details.
Loading History.
Environment.
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Reality - Geometry
Geometrical complexities
due to:
Design requirements
Functional requirements
Limitations in space
Aesthetics
Inspection access
Weight reduction
Manufacturing process.
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Reality - Loading.
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Notalways a constant amplitude loading
Loading is random in nature.
Example: automobiles, aircraft, wind-turbines,
transmission towers.
Fighter aircraft
loading spectrum.
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Reality – Environment.
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High temperature (varying temperature)
Power-plant rotor components / turbines / compressors.
Corrosive environment
Marine structures / Chemical plant components.
Low Temperature
Structures working in Arctic regions / cold regions.
Humidity levels
More applicable for polymeric composite structures.
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History of Fatigue.
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History of Fatigue..
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History of Fatigue…
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Stress-Life Approach to Design.
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Effect of processing.
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Effect of Processing.
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Effect of mean stress on strain-
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life curve.
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Failure Life Data.
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In-situ property evaluation
In-situ measurement of mechanical properties
NDE Methods Miniature specimen
method
Miniature tensile Automated Ball
Shear punch
specimen Indentation
method
Static Cyclic Indentation
Infrared Non-linear Indentation
thermography Ulltrasonics
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Small specimen test methods
• Test Methods to evaluate:
– Tensile properties (σy.s, σUTS, % Elongation, K and n)
– Fracture properties (K1c, KJc, J1c).
– Impact strength properties (CVN energy).
– Fatigue Properties (failure life, crack growth).
– Transition temperature (DBTT).
Raghu Prakash, IIT-M 134
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Basics of Indentation Testing.
Instrumented Indentation test has been
proposed to be a better option among non-
conventional tests to determine σ-εproperties.
Indenters: Prismatic, Cylindrical, Spherical
Strain beneath the indenter is a function of
penetration depth for spherical indenter which
helps in derivation of stress-strain curve.
Shallow indentation impressions are less
damaging for the component.
Point to point variation of properties can be
measured.
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Automated ball indentation test
method.
• A non-destructive method of
evaluating the tensile properties of
materials.
• Strain controlled multiple
indentations at a single location on a
polished surface using a tungsten
carbide spherical indenter.
• Max. depth of penetration is about
15-20% of indenter diameter.
• Load-displacement record provides
the basis for property evaluation.
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Theory
True stress and strain due to indentation testing has been
expressed by: [Ref: Haggag et al, 1993]
t 4 P d p 2
p 0.2 d p D
2
d p 0.5CD hp 2 d p 2 hp 2 d p 2 hp D
2
C 5.47 P 1 E1 1 E2 hp Force vs displacement
0
1.12 1 -0.35 -0.3 -0.25 -0.2 -0.15 -0.1 -0.05 0
1.12 ln 1< 27
-500
27
max
-1000
Force, N
p E2
-1500
0.43 t Stainless steel
-2000
-2500
max 2.87 m max 1.12 ln 27
-3000
Displacement, mm
Residual plastic depth estimation
Static indentation response after
fatigue cycling..
SS 304
Changes in material property due to
prior damage can be estimated
using static indentation results.
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Load-displacement for P12, SA299 and serviced material
True Stress vs. Plastic Strain curves for SA299 Samples
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True Stress vs. Plastic Strain curves for SM Samples
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