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Chapter 5
Overview
2
Fatigue definition
A material subjected
to a repetitive or
fluctuating stress will
fail at a stress much
lower than that
required to cause
failure on a single
application of load.
Failures occurring
under conditions of
dynamic loading are
called fatigue failures.
Fatigue Mechanisms - two steps;
Crack Initiation and 3
Crack Propagation
Characterisation of Fatigue
There are three commonly
recognized forms of fatigue:
High cycle fatigue (HCF),
Low cycle fatigue (LCF),
Thermal mechanical
fatigue (TMF)
Fatigue strength is
determined by running
multiple specimen tests at a
number of different
stresses.
The objective is to identify
the highest stress that will
produce a fatigue life
beyond ten million cycles.
This stress is also known as the material's endurance limit or fatigue limit.
4
Gas turbines are designed so that the stresses in engine components do not
exceed this value including an additional safety factor.
Fatigue Crack Growth – LEFM approach
Mean stress
1
m max min
2
Stress range
max min
Stress amplitude
1
a max min
2
Stress Ratio
min K min
R
max K max
K – Range
K K max K min 5
Fatigue Crack Growth – LEFM approach
8
FATIGUE CRACK GROWTH - Regime A
Concept of the threshold stress intensity Kth:
When K is ≈ Kth,, where Kth is the threshold stress
intensity factor, the rate of crack growth is so slow that the crack
is often assumed to be dormant or growing at an undetectable
rate.
An operational definition for Kth often used is that if
the rate of crack growth is 10-8 mm/cycle or less the
conditions are assumed to be at or below Kth.
An important point is that these extremely slow crack
growth rates represent an average crack advance of less
than one atomic spacing percycle. How is this possible?
What actually occurs is that there are many cycles with
no crack advance, then the crack advances by 1 atomic
spacing in a single cycle, which is followed again by 9
many cycles with no crack advance.
FATIGUE CRACK GROWTH - Regime B
When we are in regime B (Paris regime) the following
calculation can be carried out to determine the number of
cycles to failure.
From Paris Law:
K can be expressed in terms of ;
da
C K
m
dN
Where Y depends on the specific specimen geometry.
K Y a
Thus the Paris Law becomes:
da
dN
C Y a m
m/2
ao a 0
FATIGUE CRACK GROWTH - Regime B
CON’T
For m > 2:
2 1 1
Nf m 2 / 2 m 2 / 2
m 2CY m m m / 2 a
o a f
For m = 2:
1 af
Nf ln
CY 2 ao
2
1 K C2
af
Y 2 2
max
Solution
It is first necessary to determine the length of the
longest crack the plate can support without
failure. A suitable stress intensity factor is:
K1c = 1.12 max (ac)
40 = 1.12 (20) (ac)
15
ac = 1.02 inches
Solution
For this case, Paris Law has the form
da/dN = C(K)m = C [1.12)(ac)]m
Substituting this material’s Paris law parameters,
we obtain;
da/dN = 7 x 10-10 (1.12)4(20)42a2
Rearranging the forgoing equations yields
da/a2 = 7 x 10-10 (1.12)4(20)42dN
Thus
1 1.02
2
N ( a 2
da)
7 x10 (1.12) (20) 0.1
10 4 4
17
Solution
First calculate C in Paris’ law
C = 10-7/283= 4.55 x 10-11,for crack in m/cycle
Obtain stress range, = 54 MPa
Substitute into the given expression:
2 1 1
Nf ( m2) / 2
( m2) / 2
(m 2)CY m ( ) m m / 2 ( ao ) (a f )
2 1 1
Nf
(0.005)1/ 2 (0.01)1/ 2
4.55 x10 111.023 (54) 3 3 / 2