Description of fatigue crack growth using

stress intensity factor

• Fatigue crack growth deals with answering the following question.
• How long does it take for a crack to grow from a certain initial size to a
maximum permissible size?
• The factors considered are
1. The initial crack size, ad (NDT- detectable crack size)
2. The maximum permissible or critical crack size, acr
3. The period of crack growth between ad and acr
The initial crack size corresponds to the maximum detectable size by NDT
techniques or a crack size assumed to be present.
The maximum permissible crack size is obtained by applying LEFM or EPFM
principle.
The period of crack is determined from the fatigue crack growth curve.
Fatigue crack growth curve
• The crack size, a0 is the initial crack present in a material due to discontinuities
like voids, flaws, damages, non homogeneity etc. ,which is undetectable by NDT.
• Fatigue crack growth curve is a plot of crack length vs no. of cycles (N)
Parameters of crack growth curve

• Minimum Stress, min

• Maximum stress, max

• Mean stress, m =( max + min )/2

• Variable or alternating stress , v =( max - min )/2
• Stress ratio, R = min / max
• Stress range,
• =( max - min )
Fatigue crack propagation rate

• It is the crack extension, a per number of cycles , n.

• The fatigue crack growth is usually expressed in differential form, da/dN
• The minimum number of cycles, dN is taken as one, since crack growth
during one cycle is discontinuous. During rising part of the load, crack
length increases and during the descending part there is less or no crack
growth.
• Experimental determination of fatigue crack growth curves for every
component ,loading condition and crack size are difficult.
• For constant amplitude loading a plot is made between da/dN and K
• The plot obtained is called sigmoidal curve due to its shape.
• Many crack growth laws viz. Paris law, Forman’s equation etc. are
attached to this plot.
Fatigue crack growth rate curve (da/dN vs K)
Fatigue crack growth rate curve (da/dN vs K)

• Figure shows the fatigue crack growth curve in log –log scale
• The curve is divided into three distinct regions based on the shape,
mechanisms of crack extension and influencing parameters.
• Region I
• Non continuum behaviour
• There is a threshold stress intensity factor range, Kth below which
crack will not propagate.
• Knowing the value of Kth ,it is possible to calculate permissible crack
lengths to avoid fatigue crack growth.
• Above threshold value, the crack growth increases rapidly.
• The influencing parameters are microstructure, mean stress and
environment
Fatigue crack growth rate curve (da/dN vs K) contd.

• Region II
In this region, a power law, Paris Law , relationship exists
= C ( K)
Where C and m ( value ranges from 2-3)are constants obtained experimentally.
Continuum behaviour exists ,exhibits striations
Small to large scale influence of microstructure depends on the type of
material.
Large influence of certain combinations of environment, mean stress and
frequency.
Mode III
The curve grows asymptotically and failure occurs when the Kmax reaches a
value equal to the KC .
Static Mode behaviour (cleavage, intergranular and dimples)
Large influence of microstructure, mean stress and thickness and little
influence of environment
Paris and Forman’s equations

• Paris equation
= C ( K)
This law describes the straight portion (stage II) of the crack growth
rate curve.
Forman’s equation ( Improved relation)

C ( K)
=
KC − K

This relation describes stage II and Stage III of the curve.

The C and m values are different than that in Paris equation.
These equations give a first estimate of crack growth behaviour.
Crack length vs No.of cycles curve for 6063 Al alloy
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