Submitted To

Dr. Asif Rafiq

Submitted By:
2021-MM-16 (Fatima Azhar)

Subject:
Inspection and Quality Assurance

Date:
23-11-22

DEPARTMENT OF METALLURGICAL & MATERIAL ENGINEERING

UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE.
 Inspection and Quality Assurance
Week 12:

Contents:
1. What’s fatigue test
2. Problem regarding Fatigue test
3. Types of failure
4. Working
5. Data plotting
6. Factors affecting fatigue test
7. S-N curve
8. Importance in Industry
9. Monetary benefits

FATIGUE TEST:
 a metal subjected to a repetitive or fluctuating stress will fail at a stress much lower than that
required to cause fracture on a single application of load
 Failures occurring under conditions of dynamic loading are called fatigue failures, presumably
because it is generally observed that these failures occur only after a considerable period of
service

PROBLEMS

 A fatigue failure is particularly insidious because it occurs without any obvious warning
 Fatigue failure happens at very low yield strength that is not acceptable

TYPES OF FAILURE
 Fatigue results in a brittle fracture, with no gross deformation at the fracture. On a macroscopic
scale the fracture surface is usually normal to the direction of the principal tensile stress.
 A fatigue failure can usually be recognized from the appearance of the fracture surface, which
shows a smooth region, due to the rubbing action as the crack propagated through the section
(top portion of figure below), and a rough region, where the member has failed in a ductile
manner when the cross section was no longer able to carry the load.
 Frequently the progress of the fracture is indicated by a series of rings, or "beach marks,"
progressing inward from the point of initiation of the failure
 a failure usually occurs at a point of stress concentration such as a sharp corner or notch or at a
metallurgical stress concentration like an inclusion
 WORKING

Axial fatigue testing machine helps determine the fatigue strength of materials. In this test,
the load that applies along the sample axis then compares results to similar samples subjected
to various levels of cyclic loading (i.e., a known number of cycles).

DATA PLOTTING
Quantity which is sometimes used in presenting fatigue data is the stress ratio R. Stress ratio is defined
as
 FACTORS:

Three basic factors are necessary to cause fatigue failure.

(1) a maximum tensile stress of sufficiently high value,
(2) a large enough variation or fluctuation in the applied stress
(3) a sufficiently large number of cycles of the applied stress.
In addition, there are a host of other variables, such as stress concentration, corrosion,
temperature, overload, metallurgical structure, residual stresses, and combined stresses which
tends to alter the conditions for fatigue.

S-N CURVE:

The basic method of presenting engineering fatigue data is by means of the S-N curve, which
represents the dependence of the life of the specimen, in number of cycles to failure, A'^, on
the maximum applied stress
 Most investigations of the fatigue properties of metals have been made by means of the
rotating-beam machine, where the mean stress is zero.

 Fatigue tests at low stresses are usually carried out for 10^7 cycles and sometimes to 5 X
10^8 cycles for nonferrous metals.
 Most nonferrous metals, like aluminum, magnesium, and copper alloys, have an S-N
curve which slopes gradually downward with increasing number of cycles. These
materials do not have a true fatigue limit because the S-N curve never becomes
horizontal. In such cases it is common practice to characterize the fatigue properties of
 the material by giving the fatigue strength at an arbitrary number of cycles, for example,
10*8 cycles.
 An interesting test for obtaining a more rapid estimate of the fatigue limit than is
possible by conventional means was proposed by Prot.^ In this method, each specimen
is started at an initial stress below the expected value of the fatigue limit, and the stress
is progressively increased at a constant rate until fracture occurs. Several specimens are
tested at different values of stress increase per cycle. Prot suggested that a linear
relationship should exist between the stress at which fracture occurs and y/a, where a is
the stress increase per cycle. The fatigue limit is obtained from this plot by extrapolation
to y/a = 0. Profs method has undergone considerable investigation and modification'
and appears useful for the rapid determination of the fatigue limit of ferrous materials.

IMPORTANCE IN INDUSTRTY

Fatigue has become progressively more prevalent as technology has developed a greater
amount of equipment, such as auto mobiles, aircraft, compressors, pumps, turbines, etc.,
subject to repeated loading and vibration, until today it is often stated that fatigue accounts for
at least 90 per cent of all service failures due to mechanical causes.

MONETARY IMPORTANCE
Fatigue testing for oil and gas industries in a laboratory involves replicating the exact mechanical
effects faced by the materials on site. The testing involves replicating the force and strain as
close as possible to the actual situation and studying various forms of failure such as crack
development and cycles to failure. However, with laboratory environments, only a limited
number of test cases can be replicated and studied and it is very expensive to perform fatigue
testing on massive structures. Therefore, advanced methods such as fatigue analysis using FEA
have been used to produce reliable results for predicting fatigue failures in components.