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Outline

F ti Fatigue - R i Review Fatigue crack initiation and propagation Fatigue fracture mechanics Fatigue fractography Crack propagation rate Example Factors affecting fatigue - Design factors -S f Surface effects ff - Environmental effects

Occurs under dynamic stresses 90% of metal failures occur in fatigue! Occurs in all kinds of materials Usually breaks .; no, or very little observable plastic deformation little, (some micro-deformation). low cycle fatigue

- high loads short Nf (104-105 cycles) high cycle fatigue g y f g low loads long Nf (>105)

Dr. M. Medraj

Dr. M. Medraj

Three t Th steps: .. .. fi l f il final failure (when area decreases ( h d sufficiently)

Fatigue data is normally shown as .. values. It is very useful to evaluate the probabilities of fatigue failure at certain stress level. This is more accurate than average values.

Fatigue life: Nf = Ni + Np Ni is the number of cycles to initiate fracture Np is the number of cycles to propagate to failure high cycle fatigue ( stress levels): most of the life is spent in crack initiation and Ni is high low cycle fatigue (.. stress levels): propagation step predominates and Np>Ni

Dr. M. Medraj

a fatigue fracture surface in a steel shaft. When the crack length exceeds a . value at the applied stress, catastrophic rupture occurs.

The science and Engineering of

Materials Materials 4th edition by D.R. DR Askeland and P.P. Phule.

MECH 321 lecture 11/4

Dr. M. Medraj

Fracture Mechanisms

Cracks that C k th t cause fatigue failure almost always initiate/nucleate at f ti f il l t l i iti t / l t t component surface at some stress concentration: scratches, dents, fillets, keyways, threads, weld beads/spatter.. On very smooth surfaces, SLIP steps can act as stress raisers.

stage I propagation crack tends to grow initially along crystallographic planes of high shear stress: high stresses and notches tend to shorten this stage. It may only propagate over a few grains. Length of stage I is controlled by presence of stress raisers such as: . . . stage II - crack growth rate increases (perpendicular to tensile stress direction)

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/5

Fracture Mechanisms

Fatigue crack propagation mechanism (stage II) by repetitive crack tip plastic blunting and sharpening; Double notch at crack tip, extends along shear planes zero tensile load or maximum comp. load small tensile load under tensile loading and then blunts due to deformation Compression closes crack and shear occurs in opposite sense leading to sharp notches again maximum tensile load small compressive load And then again and again. Sometimes this process leaves S i hi l markings on the fracture surface; and/or ... Indicate position of crack tip at some point in time.

MECH 321 lecture 11/6

Dr. M. Medraj

Fractography of Fatigue

beachmarks are macroscopic evidence of fatigue and can be observed with the naked eye classical fatigue fracture surface (clam-shell markings) always concentric with the fracture origin caused by interrupted loading, e.g. machine being switched on and off during stage II p p g g g propagation Origin e.g. e g Beachmarks may represent an 8hr daily shift: for a shaft operating at 3000 p g rpm, total number of cycles per day is Final failure

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/7

Fractography of Fatigue

However, f i H fatigue striations are microscopic and require a scanning i i i i d i i electron microscope (SEM) to observe them

each beachmark is composed of thousands of striations results from incremental advance of the fatigue crack during stage II propagation region of crack is usually relatively smooth and often discoloured in relation to the final fracture

These marks DO NOT indicate th i di t the crack growth k th per stress cycle.

- Each of these microscopic striations is usually caused by one stress cycle. - If the stress increases, the spacing usually increases. - Can count striations/mm to get ESTIMATE of crack growth rate.

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/8

Fractography of Fatigue

Beachmarks and striations will not appear on that region over which the rapid failure occurs. Rather the rapid failure may be Rather, either ductile or brittle; - evidence of plastic deformation will be present for ductile failure and ill b t f d til f il d absent for brittle failure. This region of failure may be noted in the following figure.

Fractography of Fatigue

Figure 6.47 Fatigue fracture surface. (a) At low magnifications, the beach mark pattern indicates fatigue as the fracture mechanism. The arrows p g show the direction of growth of the crack front, whose origin is at the bottom of the photograph. (b) At very high magnifications, closely spaced striations formed during fatigue are observed (x 1000). From h The science and Engineering of Materials 4th edition by D.R. Askeland and P.P. Phule.

MECH 321 lecture 11/9 Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/10

Dr. M. Medraj

R lt of fatigue studies have shown that Results f f ti t di h h th t the life of a structural component may be related to the rate of crack growth. During stage II propagation, cracks may grow from a barely perceivable size to some critical length. Experimental techniques are available that are employed to monitor crack length during the cyclic stressing. Data are recorded and then plotted as crack length a versus the number of cycles N.

rapid crack growth just prior to final fast fracture

da = A(K ) m ( dN and then taking logs of both sides : da log = m log K + log A dN gives straight line of slope m and intercept, logA

Initial crack length (1) initially, growth rate is small, but increases with increasing .. (2) growth rate increases with increasing applied stress level and for a specific crack length.

- crack grew even though Kmax < Kc - m is typically from 1 to 6 - crack grows faster if increases crack gets longer loading freq. increases.

K = Kmax-Kmin (stress intensity not KIc). If min is compressive, it closes the crack so min and Kmin are taken as being zero.

MECH 321 lecture 11/11

At low stress levels and/or small crack sizes, pre-existing si es pre e isting cracks will not ill grow with cyclic loading.

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/12

Dr. M. Medraj

Logarithm crack growth rate versus logarithm stress intensity factor range for a NiMoV steel.

One goal of failure analysis is to predict fatigue life of a component, given its service conditions. We are able now to develop analytical expression for Failure by integrating in the linear region:

So a straight-line segment will So, straight line result when log(da/dN)-versus-log K data are plotted the slope and intercept correspond to the values of m and log A, respectively. A & m are material constants

dN =

da which when integrated gives : A(K ) m Limits are initial flaw length, ao which can Nf ac da be determined by NDT, and critical crack Nf = dN = m length ac, which can b determined from l h h h be d df 0 a0 A( K ) fracture mechanics

ac

da A(Y a )

m

a0

m2

1 ( ) m

Y

ac a0

da am 2

this results when assuming that K and are constant (which often are not) Also ignores the time needed to initiate the crack. This analysis is only an estimate.

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/13 Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/14

Example

A relatively large sheet of steel is to be exposed to cyclic tensile and l ti l l h t f t li t b dt li t il d compressive stresses of magnitudes 100 MPa and 50 MPa, respectively. Prior to testing, it has been determined that the length of the largest surface crack is 2.0 mm. Estimate the fatigue life of this sheet if its plane strain fracture toughness is 25 MPam and the values of m and A are 3.0 and 1.0 x 10-12, respectively, for in MPa and a in m. Assume that the parameter Y is independent of crack length and has a value of 1.0.

Important factors are: mean stress level geometrical design surface condition metallurgical structure environment Mean Stress (m) in stress reversal, m= 0 m > 0, then S-N curve moves to lower values fatigue life .

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/16

Dr. M. Medraj

Geometrical Effects

Design Factors D i F component design is important notches or stress raisers act as crack initiation sites for fatigue:

grooves, scratches, keyways, threads, threads corrosion pits etc. etc

sharp corners and radii, any discontinuities all increase the stress

concentration

rounded fillets where gradual changes of diameter occur in shafts Scratches and machining marks reduce the fatigue life Surface polishing . the fatigue properties

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/17 Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/18

Geometrical Effects

Geometrical Effects

Dr. M. Medraj

Dr. M. Medraj

Effect of Welding

Dr. M. Medraj

Dr. M. Medraj

Surface Treatments

shot peening localized micro-plastic deformation using small steel balls (shot) impacting on surface. i ll t l b ll ( h t) i ti f It increases the fatigue properties significantly (aircraft components etc) also increases yield strength, hardness and fatigue life. h h d df i lif work hardening occurs in the surface surface hardness introduces a residual ..... stress

Surface burnishing

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/23 Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/24

Surface Treatments

Case Hardening: Surface hardening through g g carburizing or nitriding increases surface strength and hardness iron carbide or nitrides (hard) form in the surface layer to ~1mm depth or greater i increase in hardness i i h d increases th the resistance to fatigue. compressive stress in case hardening also generated due to difference in volume of case layer

Dr. M. Medraj

Dr. M. Medraj

Dr. M. Medraj

Dr. M. Medraj

Environmental Effects

Thermal Fatigue created at high temperature by fluctuating thermal stresses (t ) restraint in thermal expansion/contraction during uneven heating/cooling t = E l T l is the linear thermal expansion coefficient E is the modulus of elasticity T is the temperature difference, l T is the thermal strain t can be minimized by careful design elimination of restraint and temperature gradients (use expansion gaps) consideration of physical properties, (materials CTE, k)

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/29

Environmental Effects

Corrosion Fatigue simultaneous effect of cyclic stress and chemical attack i lt ff t f li t d h i l tt k formation of pits leading to stress concentration on surface and nucleation of fatigue cracks corrosion can enhance crack growth rate prevention is by: protective coatings (painting, galvanizing) selection of more corrosion resistant material reducing the corrosive environment

Dr. M. Medraj Mech. Eng. Dept. - Concordia University MECH 321 lecture 11/30

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