Professional Documents
Culture Documents
Research Article
An Analytical Model for Fatigue Crack Propagation
Prediction with Overload Effect
Received 2 May 2014; Revised 22 June 2014; Accepted 23 June 2014; Published 23 July 2014
Copyright © 2014 Shan Jiang et al. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
In this paper a theoretical model was developed to predict the fatigue crack growth behavior under the constant amplitude
loading with single overload. In the proposed model, crack growth retardation was accounted for by using crack closure and
plastic zone. The virtual crack annealing model modified by Bauschinger effect was used to calculate the crack closure level in
the outside of retardation effect region. And the Dugdale plastic zone model was employed to estimate the size of retardation
effect region. A sophisticated equation was developed to calculate the crack closure variation during the retardation area. Model
validation was performed in D16 aluminum alloy and 350WT steel specimens subjected to constant amplitude load with single or
multiple overloads. The predictions of the proposed model were contrasted with experimental data, and fairly good agreements
were observed.
b
𝜋 𝜎op − 𝜎min 2
dr df = ( ) 𝜋(a − b)
O O 8 𝛼𝜎y
𝜋 𝜎max − 𝜎op 2
Dr dr = ( ) 𝜋(a)
8 2𝛽𝜎y
df 𝜋 𝜎 − 𝜎min 2
Dr = ( max ) 𝜋(a − b)
8 2𝛽𝜎y
single overload has a significant impact on the crack closure the length of “𝑏” can be considered as nonfractured material.
within the large plastic zone [23]. Therefore, crack closure So, there is an equivalent reversed plastic zone with diameter
variation is probably a good explanation of the retardation 𝐷𝑟 , and the virtual crack tip position is 𝑂 . In the following
phenomenon. In this paper, a mechanism-based method will loading process, when the stress level increases from 𝜎min to
be developed to predict fatigue crack growth behavior under 𝜎op , the superposition of the stress within the forward plastic
the single overload, in which crack closure and plastic zone zone with diameter 𝑑𝑓 and the residual stress within the
concept are considered. distance “𝑏” ahead of the virtual crack is zero and the crack
The paper is organized as follows. First, the fatigue crack tip opens. So, the equation 𝑑𝑓 = 𝐷𝑟 − 𝑑𝑟 can be established.
growth model and the modified virtual crack annealing crack Additionally, for anisotropic materials, the Bauschinger effect
closure model are briefly reviewed. Second, our proposed has a significant impact on the cyclic plastic deformation
model for crack growth retardation behavior estimation is ahead of crack tip. Thus, equation can be expressed as
discussed in detail. The model is derived based on plastic
2 2
zone and crack closure variation. And then model validation 𝜋 𝜎max − 𝜎min 𝜋 𝜎max − 𝜎op
is performed using the experimental data in D16 aluminum ( ) 𝜋 (𝑎 − 𝑏) − ( ) 𝜋 (𝑎)
8 2𝛽𝜎𝑦 8 2𝛽𝜎𝑦
alloy and 350WT steel from the literature. Finally, some (2)
2
conclusions and future work are given based on the current 𝜋 𝜎𝑜𝑝 − 𝜎min
study. = ( ) 𝜋 (𝑎 − 𝑏) ,
8 𝛼𝜎𝑦
da/dN
Load 𝜎overload
𝜎max
𝜎min
N
a (a)
a
solution is 𝜎op = 𝜎min , which indicates that there is no crack 𝜎op 2 4𝛾2 − 1 𝑅
𝑌𝐶 = ( ) = + × , (5)
closure and the overlapped length is zero. The other solution 𝜎max 𝐶 1 + 4𝛾2 1 + 4𝛾2 𝑅ol
is 𝜎op /𝜎max = (1/(1 + 4𝛾2 ))[2 + (4𝛾2 − 1)𝑅]. This observation
indicates that either there is no crack closure or there is where 𝛾 is Bauschinger effect factor, 𝑅 is the load ratio, and
a unique crack closure level under constant amplitude 𝑅ol is the overload ratio. The left side of (5) is the ordinate of
loadings. In this paper, the modified virtual crack annealing point 𝐶. Similarly, the ordinate of point 𝐷 can be illustrated
model is used to make predictions of the fatigue crack growth by the following:
behavior in the outside of retardation effect region.
Retardation caused by overloads is a typical phenomenon 2 4𝛾2 − 1
𝑌𝐷 = + × 𝑅. (6)
of loading interaction effect. A great number of papers 1 + 4𝛾2 1 + 4𝛾2
were presented to investigate the single overload [24–28].
Generally, overloads will induce large plastic deformation The horizontal ordinate of point 𝐷 is
ahead of the crack tip and retard the crack growth rate in
𝑋𝐷 = 𝑎0 + 𝐷𝑚 , (7)
the subsequence loading of a certain range. As the developing
of the crack, the retardation effect gradually recedes. When where 𝑎0 is the horizontal ordinate of point 𝐶, which is
the crack grows beyond the large plastic zone, the retardation the crack length when single overload is applied. 𝐷𝑚 is the
effect vanishes completely. Before the crack growth rate diameter of plastic zone created by that single overload. If
decreases, there is an accelerated crack growing stage, which point 𝐷 is considered to be the ordinate origin, the equation
has been termed delayed retardation. That transient acceler- of the curve between points 𝐶 and 𝐷 is
ation right after overload is small enough to be neglected in
this investigation. As it is shown in Figure 2, the crack growth 𝑌𝐶 − 𝑌𝐷 𝑛
length is “Δ𝑎” under the influence of a single overload. 𝑓 (𝑥) = 𝑛 ⋅ (−𝑥) , (8)
(𝑋𝐶)
The crack growth behavior is shown in Figure 3. After
the overload, the crack growth rate increases transitorily and where 𝑌𝐶 and 𝑌𝐷 are, respectively, the ordinate of points 𝐶
then decreases sharply. Once the 𝑑𝑎/𝑑𝑁 value reaches to and 𝐷 and 𝑋𝐶 is the horizontal ordinate of point 𝐶. When the
minimum, crack growth rate increases gradually and finally value of 𝑛 can be 2, 1, and 0.5, the curve is, respectively, shown
recovers to the equilibrium constant amplitude loading as (A), (B), and (C) in Figure 4. Based on the current study,
growth rate. 𝑛 = 1 is a good approximation for aluminum alloy. If the 𝑂 is
The crack tip plastic zone associated with the application considered to be the ordinate origin, (7) can be rewritten as
of a single overload is shown in Figure 4(a). A new approach
to estimation of crack opening stress under the influence of 𝑌𝐶 − 𝑌𝐷 𝑛
𝑓 (𝑥) = 𝑌𝐷 + 𝑛 ((𝑋𝐶 + 𝐷𝑚 ) − 𝑥) . (9)
single overload is proposed, as shown in Figure 4(b). When (𝑋𝐶 − 𝑋𝐷)
4 Mathematical Problems in Engineering
O3
O1 O2
(a)
𝜎op /𝜎max
C Y
YC
(B) (C)
(A)
D
YD
XC XD a
(b)
Figure 4: (a) Crack-tip plastic zone due to single tensile overload; (b) the mathematical derivation of 𝜎op based on crack closure model.
Based on the discussion above, the new crack closure Table 1: Standard chemical composition [28].
model is established as (10), which is used to describe fatigue
Chemical composition of D16 aluminum alloy
crack propagation behavior under single overload inter-
spersed in a constant amplitude loading spectrum. Consider Element Cu Mg Mn Si Fe Zn
Weight % 3.8–4.9 1.2–1.8 0.3–0.9 0.5 0.5 0.3
𝜎op
1
{
{
{ 2+1
((4𝛾2 − 1) 𝜎min + 2𝜎max )
{
{ 4𝛾
{
{ 3. Experimental Validation
{
{
{
{ before single overload
{
{ 1 3.1. Crack Growth Predictions in D16 under Constant Loading
{
{ ((4𝛾2 − 1) 𝜎min + 2𝜎ol )
{
{ 2+1 and Single Overload. The experimental data for model vali-
{
{ 4𝛾
{
{ dation are from the literature [27, 28]. The material used in
{
{
{
{ single overload both papers was D16 aluminum alloy. The standard chemical
{
{
{
{ 2 4𝛾2 − 1 composition is shown in Table 1. And the mechanical prop-
{
{ ( + × 𝑅)
{ 2 1 + 4𝛾2
{ 1 + 4𝛾
{ (10) erties of this material in longitudinal (LT) orientation were
={ as follows: 𝜎𝑦 = 347 MPa, 𝐾𝑐 = 40 ∼ 45 MPa∗m0.5 , and
{
{ ((4𝛾2 − 1) / (1 + 4𝛾2 )) ((𝑅/𝑅ol ) − 𝑅)
{
{ percentage elongation = 12%.
{
{ +
{
{ (−𝐷𝑚 )
𝑛 Before any predictions can be made, there are several
{
{
{
{ 𝑛 unknown parameters (see (1) and (10)) that need to be
{
{ × (𝑎0 + 𝐷𝑚 − 𝑎) calibrated. Three sets of 𝑑𝑎/𝑑𝑁 ∼ 𝑑𝐾 testing data are used to
{
{
{
{
{
{ evaluate these parameters (Figure 6), which are assumed to
{
{ under influence of single overload
{
{ depend on the material only [27]. The calibrated parameters
{
{ 1 are 𝑚 = 2.4534 and 𝐶 = 1.2331E-9, and Bauschinger effect
{
{
{ 2+1
((4𝛾2 − 1) 𝜎min + 2𝜎max )
{
{ 4𝛾 factor 𝛾 is 0.97.
{
{
after influence of single overload. Then additional two sets of 𝑎-𝑁 data are used to validate
{ the proposed model. The specimen configuration for these
The cycle by cycle algorithm is used to implement tests is [27] width = 100 mm, length = 500 mm, and thickness
the above model. The flow chart for fatigue crack growth = 4 mm. Initial half crack length is 𝑎 = 5.0 mm. The specimen
prediction based on the modified crack closure model is was subjected to a constant amplitude load sequence with
shown in Figure 5. 𝜎max = 64 MPa, 𝑅 = 0. And the overload ratio is 2.
Mathematical Problems in Engineering 5
Initial condition
R = Smin /Smax
a = a0
SOL = Smax × ratio
Start
2 4𝛾2 − 1
Kop = Kmax ×( + × R) Input load spectrum
1 + 4𝛾2 4𝛾2 + 1
da Check for
= C(ΔKeff )m Yes load spectrum/Smax > 1
dN
a = a + da
𝜋 K 2 No
D= ×( )
8 Sy
Check for
D>0
No
Yes
2 4𝛾2 − 1 Yes
Sop 1 = SOL · ( 2
+ 2 × R/Rol ) No
1 + 4𝛾 4𝛾 + 1
2 4𝛾2 − 1 4𝛾2 − 1
Sop 2 = Smax · ( 2
+ 2 × R) Kop = Kmax × (
2
+ 2 × R)
1 + 4𝛾 4𝛾 + 1 1 + 4𝛾 2 4𝛾 + 1
i
ΔKeff = Kmax − Kop
Sop (i)/Smax = D − ∑ daj
j=overload
da
= C(ΔKeff )m
dN End
a = a + da
The model predictions are compared to the experimental agreement is observed between the model prediction and
data in Figure 7. The 𝑥-axis is the number of cycles, and the experimental data.
𝑦-axis is crack length. The red circlets represent the fatigue Additional set of testing data is used for the model
crack growth under the constant amplitude loading; and the validation in the same material and similar specimen config-
small blue squares are the counterpart under the constant uration [28]. Specimen dimensions are as follows: length =
amplitude load with single overload. It is observed that the 180 mm, width = 45 mm, and thickness = 1.5 mm. Initial
predictions by proposed model match the testing data well. crack length is 𝑎 = 4.0 mm. The specimens are subjected to
More detailed information can be obtained in the two different loading spectra: (1) constant amplitude loading
𝑑𝑎/𝑑𝑁-𝑎 curve in Figure 8. Right after the single overload, with no overloads (𝜎max = 60 MPa, 𝑅 = 0.1) and (2)
the fatigue crack growth rate increases in a short time constant amplitude load with single overload applied at the
and then decreases sharply. After a certain crack length, certain crack length (overload ratio is 2) [28]. Following
the retardation phenomenon vanishes and the crack growth the same procedure, the comparisons between predictions
rate turns back to the original trend. Note that very good and experimental data are shown in Figure 9. Under the
6 Mathematical Problems in Engineering
10−2
10−3
da/dN (mm/cycle)
10−3
da/dN (mm/cycle)
10−4
10−4
10−5
0.03
0.04
Crack length (m)
0.025
0.035
0.02
0.03
Crack length (m)
0.015
0.025
0.01
0.02 0.005
0.015 0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
0.01 Number of cycles/cycle ×105
0.005 Expt CA + OL
0 2 4 6 8 10 12 14 16 18 Expt CA
Number of cycles/cycle ×104 Pred of Manjunatha and Parida CA + OL
Pred of Manjunatha and Parida CA
Expt CA Pred CA Pred CA
Expt CA + OL Pred CA + OL Pred CA + OL
Figure 7: 𝑎-𝑁 curve for constant amplitude and single overload Figure 9: 𝑎-𝑁 periodic spike loading.
cases.
10−3
10−3
da/dN (mm/cycle)
da/dN (mm/cycle)
10−4
10−4
101 102
0.5
dK (MPa∗m )
R = 0.1 test data R= 0.3 test data
R = 0.1 calibration R= 0.3 calibration 101 102
R = 0.2 test data R= 0.4 test data 0.5
Stress intensity range (MPa∗m )
R = 0.2 calibration R= 0.4 calibration
Expt CA + overloads
Figure 10: 𝑑𝑎/𝑑𝑁-𝑑𝐾 calibration figure. Pred CA + overloads
0.035
In Figure 12, crack growth rate variation caused by over-
0.03 loads is also compared with our model prediction. It is clear
Crack length (m)
4. Conclusion
0.01
0 0.5 1 1.5 2 2.5 3
In this investigation, a theoretical model is developed to
Number of cycles/cycle ×105
predict the fatigue crack growth behavior under the constant
Expt CA + OL amplitude loading with single overload. The crack growth
Pred CA retardation was accounted for by using crack closure concept
Pred CA + OL and plastic zone. Model was validated in D16 aluminum
alloy and 350WT steel subjected to several different loading
Figure 11: 𝑎-𝑁 curve for constant amplitude and single overload
cases.
spectra, and the predictions matched experimental data well.
The following conclusions can be drawn based on the current
investigation.
the mechanical properties of 350WT in longitudinal (LT) (1) Fatigue crack growth is slowed down by application
orientation are as follows: 𝜎𝑦 = 350 MPa, 𝜎UTS = 524 MPa, of single overload cycle. A convincing reason for this
Modulus of elasticity = 205 GPa, and Poisson’s ration = 0.30 retardation phenomenon is that after the overload a
[30]. large plastic zone will form ahead of the crack tip,
Similarly, the parameters are calibrated by the 𝑑𝑎/𝑑𝑁 ∼ which can increase the crack closure level within this
Δ𝐾 data in the literature [19], as shown in Figure 10. The region. And as the crack grows through the large
fitting coefficients are 𝐶 = 4.3136𝐸 − 11 and 𝑚 = 2.9245, plastic zone, the crack closure level will gradually
and the Bauschinger effect factor 𝛾 is 1.05. decrease which can be described as a linear function.
Figure 11 shows the comparison between the predicted 𝑎- The retardation effects disappear after a certain char-
𝑁 curve and the experimental data in 350WT steel speci- acteristic crack length extension from the overload
mens. The single overloads are applied at the crack length of 15 position. This extension is approximately equal to
and 25 mm. It can be seen that there are two obvious retarded monotonic plastic zone size caused by the overload.
regions right after the overload in the experimental data. The
prediction follows almost the same trend as the experimental (2) The proposed model is derived from fatigue crack
observation. Predicted total fatigue lives are slightly lower growth mechanisms (such as crack closure, plastic
than the experimental values. zone, and Bauschinger effect), and it does not require
8 Mathematical Problems in Engineering
any additional parameters which has no physical T351 aircraft aluminum alloy,” Theoretical and Applied Fracture
meaning. Mechanics, vol. 43, no. 1, pp. 121–132, 2005.
[3] P. Paris and F. Erdogan, “A critical analysis of crack propagation
(3) The above statement is only valid under the current laws,” Journal of Fluids Engineering, vol. 85, no. 4, pp. 528–533,
investigated loading spectrums and materials. In the 1963.
future, the whole frame work should be extended to [4] E. Wolf, “Fatigue crack closure under cyclic tension,” Engineer-
other materials. Additionally, branching and bifur- ing Fracture Mechanics, vol. 2, no. 1, pp. 37–45, 1970.
cation caused by overload can also retard the crack [5] J. C. Newman Jr., Prediction of Crack Growth under Variable-
growth rate, which should be investigated in the Amplitude Loading in Thin-Sheet 2024-T3 Aluminum Alloys,
future. Engineering against Fatigue, University of Sheffield, 1997.
[6] W. Elbert, “The significance of fatigue crack closure,” in Damage
Tolerance in Aircraft Structures: A Symposium Presented at the
Nomenclature Seventy-Third Annual Meeting American Society for Testing and
𝑎: Crack length Materials, pp. 486–230, ASTM International, Toronto, Canada,
June 1971.
Δ𝑎: Crack growth in one cycle
𝑑𝑎: Infinitesimal crack increment [7] W. Zhang and Y. Liu, “In situ SEM testing for crack closure
investigation and virtual crack annealing model development,”
𝑑𝑎/𝑑𝑁: Fatigue crack growth rate per cycle
International Journal of Fatigue, vol. 43, pp. 188–196, 2012.
𝜎min , 𝜎max : Minimum and maximum stress in one
[8] W. Zhang and Y. Liu, “Investigation of incremental fatigue crack
loading cycle
growth mechanisms using in situ SEM testing,” International
𝜎op : Stress level at which the crack begins to Journal of Fatigue, vol. 42, pp. 14–23, 2012.
grow
[9] J. C. Newman Jr., “A crack-closure model for predicting
𝜎ol : Stress level of single overload fatigue crack growth under aircraft spectrum loading,” ASTM
𝑅: Stress ratio International—STP Series, vol. 748, pp. 53–84, 1981.
𝑅ol : Overload ratio [10] J. C. Newman Jr., “A crack opening stress equation for fatigue
𝐾max , 𝐾min : Maximum/minimum stress intensity crack growth,” International Journal of Fracture, vol. 24, no. 4,
factor pp. R131–R135, 1984.
Δ𝐾: Stress intensity factor range [11] J. Z. Zhang and P. Bowen, “On the finite element simulation
𝐾op : Stress intensity factor at which the crack of three-dimensional semi-circular fatigue crack growth and
begins to grow closure,” Engineering Fracture Mechanics, vol. 60, no. 3, pp. 341–
Δ𝐾eff : Effective stress intensity factor range 360, 1998.
𝐷𝑚 : Monotonic plastic zone size [12] F. V. Antunes, A. G. Chegini, R. Branco, and D. Camas, “A
𝐷𝑓 : Forward plastic zone size numerical study of plasticity induced crack closure under plane
𝑑𝑟 , 𝐷𝑟 : Reverse plastic zone size strain conditions,” International Journal of Fatigue, 2014.
𝜎𝑦 : Material yield strength [13] B. Budiansky and J. W. Hutchinson, “Analysis of closure in
𝛼: Bauschinger effect factor in loading fatigue crack growth,” Journal of Applied Mechanics, vol. 45, no.
process 2, pp. 267–276, 1978.
𝛽: Bauschinger effect factor in unloading [14] J. Llorca and V. S. Gálvez, “Modelling plasticity-induced fatigue
process crack closure,” Engineering Fracture Mechanics, vol. 37, no. 1, pp.
𝛾: Bauschinger effect factor. 185–196, 1990.
[15] P. F. P. de Matos and D. Nowell, “Modeling fatigue crack closure
using dislocation dipoles,” 2006.
Conflict of Interests [16] J. H. Kim and S. B. Lee, “Behavior of plasticity-induced crack
closure and roughness-induced crack closure in aluminum
The authors declare that there is no conflict of interests alloy,” International Journal of Fatigue, vol. 23, supplement 1, pp.
regarding the publication of this paper. S247–S251, 2001.
[17] J. Willenborg, R. M. Engle, and H. A. Wood, “A crack growth
retardation model using an effective stress concept,” Tech. Rep.,
Acknowledgment 1971.
The research is financially supported by the specialized [18] O. E. Wheeler, “Spectrum loading and crack growth,” Journal of
research fund for the doctoral program of higher education Basic Engineering Transactions of the ASME, vol. 94, no. 1, pp.
181–186, 1972.
funding under the contract no. 20131102120047.
[19] X. Huang, M. Torgeir, and W. Cui, “An engineering model
of fatigue crack growth under variable amplitude loading,”
References International Journal of Fatigue, vol. 30, no. 1, pp. 2–10, 2008.
[20] S. Daneshpour, M. Koçak, S. Langlade, and M. Horstmann,
[1] R. C. Alderliesten and J. J. Homan, “Fatigue and damage “Effect of overload on fatigue crack retardation of aerospace
tolerance issues of Glare in aircraft structures,” International Al-alloy laser welds using crack-tip plasticity analysis,” Interna-
Journal of Fatigue, vol. 28, no. 10, pp. 1116–1123, 2006. tional Journal of Fatigue, vol. 31, no. 10, pp. 1603–1612, 2009.
[2] A. T. Kermanidis, P. V. Petroyiannis, and S. G. Pantelakis, [21] B. K. C. Yuen and F. Taheri, “Proposed modifications to the
“Fatigue and damage tolerance behaviour of corroded 2024 Wheeler retardation model for multiple overloading fatigue life
Mathematical Problems in Engineering 9
International
Journal of Journal of
Mathematics and
Mathematical
Discrete Mathematics
Sciences