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Fatigue Limit Prediction of the

Matrix of 17-4PH Stainless Steel


Defu Nie
National Technology Research Center Based on Small Crack
on PVP Safety Engineering,
(Hefei General Machinery Research Institute),
Hefei, Anhui, 230031 China
Mechanics
e-mail: dove_ndf@sina.com.cn
The experimentally obtained fatigue limit of high strength steel is generally a value
reduced by inherent flaws, and such a value does not characterize the resistance of the
Yoshiharu Mutoh matrix of high strength steel to cyclic loading. To investigate the fatigue limit of the ma-
Nagaoka University of Technology,
trix, fatigue tests of 17-4PH stainless steel were performed. 17-4PH stainless steel
Nagaoka, Niigata 940-2188, Japan
showed a distinct dual-stage S-N curve: one stage corresponding to high stress where
e-mail: mutoh@mech.nagaokaut.ac.jp
crack initiated at the surface and another stage corresponding to low stress where crack
initiated from the subsurface inclusion (Al2O3). Based on small crack mechanics, a model
was proposed to predict the fatigue limit of the matrix of 17-4PH stainless steel and its
validity has been discussed. [DOI: 10.1115/1.4023428]

Keywords: fatigue limit, 17-4PH stainless steel, small crack

Introduction estimating fatigue limits reduced by inclusions, instead of under-


standing the complicated details of such phenomena themselves.
Since high pressure was successfully used as a commercial
The formula is expressed as
processing method of foods in 1992, high pressure processing has
been rapidly extended to the interdisciplinary field of bioscience pffiffiffiffiffiffiffiffiffi
and biotechnology [1–3]. Up to now, many applications remain r0w1 ¼ 1:56  ðHV þ 120Þ=ð areaÞ1=6 (1)
yet to be discovered [2,3]. Accordingly, this brings about ever-
growing demands for high pressure apparatuses. To develop a where r0w1 is the reduced fatigue limit due to inclusions under
safe, simple and convenient high pressure apparatus suitable for fully reversed fatigue loading,pHVffiffiffiffiffiffiffiffiis
ffi Vickers hardness of the ma-
different purposes, 17-4PH stainless steel is a promising candidate trix of high strength steel and area is square root of the inclusion
material for pressure vessel due to its favorable combination of area projected onto a plane perpendicular
pffiffiffiffiffiffiffiffiffi to applied stress. Note
good tensile strength and toughness, weldability, and excellent that units of r0w1 , HV, and area are MPa, kgf/mm2 and lm,
corrosion resistance [4–6]. And the low-carbon martensitic stain- respectively. And in Eq. (1), the coefficient for internal inclusions
less steel (17-4PH), hardened by fine copper-rich phase precipi- is 1.56 while the coefficient for surface inclusions
pffiffiffiffiffiffiffiffiffi is 1.43. By
0
tates, has been widely employed in various industrial fields [4–9]. knowing
pffiffiffiffiffiffiffiffiffi from Eq. (1), r w1 increases as area decreases. If
High pressure apparatus in service usually experience pressur- area approaches zero, the estimated fatigue limit will be infinite.
ization and decompression processes. Therefore, the fatigue prop- This is obviously invalid because r0w1 should be a finite value for
erties of 17-4PH stainless steel are very important for the safety a given high strength steel. It implies that there must exist a criti-
design of high pressure apparatus. Research on the fatigue of cal inclusion size, below which r0w1 will not be influenced by
materials has spanned a time period of nearly 200 yr [10]. Many inclusions any more. And Zhang et al. [22] has reported that fa-
textbooks well document that mild steels and other materials tigue cracks did not initiate from inclusions for 54SiCr6 steel
harden by strain-aging have a fatigue limit, below which speci- when the inclusion size was smaller than 1 lm. Correspondingly,
mens may be cycled indefinitely without causing failure [10–13]. there is a maximum fatigue limit characterizing the resistance of
However, many high strength steels do not generally exhibit a fa- the matrix of high strength steel to cyclic loading. This value not
tigue limit, that is, specimens continue to fail over 107, even 108 only defines the upper limit of Eq. (1), but also provides some
stress cycles [14–16]. In the last two decades, studies on very high insights into improvements in steel processing and material qual-
cycle fatigue have significantly extended the knowledge in this ity control. However, rare work has focused on the fatigue limit
field [14–21]. The fatigue limit of high strength steels is closely prediction of the matrix of high strength steel to date.
related to inclusions and casting defects. In many high strength The purpose of this study is to investigate the fatigue behavior
steels with inclusions and/or casting defects, there is dual-stage of 17-4PH stainless steel and to develop a model for predicting
stress-life (S-N) behavior: one corresponds to short life regime at the fatigue limit of the matrix of high strength steel based on small
high stress where crack initiates at the surface, and another corre- crack mechanics. This study not only is useful for engineers in
sponds to (very) long life regime at low stress where crack ini- their designs of food industry, but also adds some new experimen-
tiates from the subsurface inclusion or casting defect. In order to tal data to the existing data pool of pressure vessel and piping
deal with this kind of problems in practical fatigue design and industry.
structural integrity assessment, engineers generally prefer to
adopt Murakami model [18], a simple and effective formula for
Experimental Procedure
The material used in this study is a commercial precipitation
Contributed by the Pressure Vessel and Piping Division of ASME for publication
in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received July 23, 2012;
hardening matensitic 17-4PH stainless steel in H1025 condition.
final manuscript received December 6, 2012; published online March 18, 2013. Chemical composition of this steel is C 0.04, Si 0.33, Mn 0.75,
Assoc. Editor: Xian-Kui Zhu. P 0.03, S 0.01, Cr 15.48, Ni 4.74, Cu 3.32, Nb 0.40 in mass % and

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Fig. 1 Microstructure of 17-4PH stainless steel in H1025
condition

Fe ¼ balance. Figure 1 shows microstructure of 17-4PH stainless


steel observed by using an optical microscope. The microstructure
in H1025 condition mainly consists of tempered martensite. The
yield strength, tensile strength and Vickers hardness of this mate-
rial are 1056 MPa, 1073 MPa, and 390 kgf/mm2, respectively.
Fully reversed axial fatigue tests were carried out on an EMIC
HSFTM-1 electrodynamic vibration fatigue testing machine by Fig. 2 Schematic diagram showing dimensions of (a) smooth
using smooth specimens at a frequency of 100 Hz up to 108 specimen and (b) CT specimen (all dimensions in mm)
cycles. In order to apply small crack mechanics to analysis, fa-
tigue crack growth test was conducted on a SHIMADZU EHF-
EV010K1 servo-hydraulic fatigue testing machine by using a
compact tension (CT) specimen at a frequency of 20 Hz and a
stress ratio of 0.1. Crack length was measured by using a traveling
microscope with a resolution of 10 lm. Fatigue precrack was
introduced up to 3 mm from the starter notch, and then K-
decreasing test started by manually shedding load with crack
growth until a stress intensity range was reached at which no
crack growth was detected in 108 cycles. After that, the load was
kept constant. All the experiments were tested at room tempera-
ture in air and the wave form was sinusoidal. Figure 2 shows
dimensions of the smooth fatigue specimen and the CT specimen.
And all the specimens were prepared by grinding with emery pa-
per followed by polishing with 6, 3, and 1 lm diamond paste
before test. Fracture surfaces were observed by using a scanning
electron microscope (SEM) and an energy dispersive spectroscopy
(EDS) was used to examine composition of inclusions in fatigue
crack initiation points.
Fig. 3 Dual-stage S-N curve of 17-4PH stainless steel (smooth
specimens)
Results and Discussion
Fatigue Behavior of 17-4PH Stainless Steel. Figure 3 shows by using an EDS, as shown in Fig. 5. There are a very high alumi-
the S-N curve obtained by using the smooth specimens of 17-4PH num peak and a distinct oxygen peak from the inclusion. How-
stainless steel. The open square symbols represent that fatigue ever, the distinct aluminum peak and oxygen peak were not
cracks initiated from the specimen surfaces, while the open circles detected at the crack initiation site without inclusion (the circular
represent that fatigue cracks initiated from the subsurface inclu- dashed area in Fig. 4(b), where EDS Patten is similar to that of the
sions. The symbols with arrows denote that the specimens did not matrix of 17-4PH stainless steel. So EDS analysis indicates that
fail up to 108 cycles. It can be seen from the figure that 17-4PH the inclusions are Al2O3. Careful examination of all the fracture
stainless steel shows a distinct dual-stage S-N curve, namely at surfaces shows that the average size of inclusions, where the fa-
high stress amplitude, the location of crack initiation is on the sur- tigue cracks initiated, is about 10 lm.
face and the location transits from the surface to the subsurface
inclusion as the stress amplitude decreases. Modified Basquin Equation In high cycle fatigue regime,
To understand the fatigue behaviors of 17-4PH stainless steel Basquin equation (stress-based approach) is generally used to
more clearly, all the fracture surfaces were carefully observed by relate the stress amplitude (fully reversed and constant) to the
using a SEM. Figure 4 shows typical SEM images of fatigue frac- number of load reversals to failure, which is written as
ture surfaces at stress levels of 700 MPa and 750 MPa, respec-
tively, and insets are the high magnification fractographs of crack
initiation sites. Chemical composition of inclusions was examined ra ¼ r0f ð2Nf Þb (2)

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Fig. 5 EDS analysis of crack initiation sites (a) with an inclu-
Fig. 4 Examples of fracture surface observations (a) ra 5 700 sion and (b) without inclusions
MPa and (b) ra 5 750 MPa
Table 1 The fitting parameters for 17-4PH stainless steel
where ra, r0f ,
Nf, and b are, respectively, the stress amplitude, Stage r0f b
fatigue strength coefficient, number of cycles to failure, and
fatigue strength exponent. In order to obtain these parameters for Fist (high stress) 1478 0.05
17-4PH stainless steel, a commercial software “first OPT” was Second (low stress) 3992 0.11
used to fit the experimental data by choosing the “Levenberg-
Marquardt (LM) þ Universal Global Optimization (UGO)”
option. The advantage of this software is that the initial values for experimental data and the dash lines are the fitted curves. As
the fitting parameters are not required. The two stages of the S-N depicted in Fig. 6, the experimental data agree well with the modi-
curve of 17-4PH stainless steel were fitted, respectively, and the fied Basquin equation. And all the fatigue life predictions are
results are listed in Table 1. When described the S-N curve of within a factor of 2, as shown in Fig. 7.
17-4PH stainless steel in terms of Basquin equation, the fitted
results are not very good because the stress amplitude does not
exhibit a linear relationship with fatigue life on a log–log scale, Fatigue Limit Prediction of the Matrix of 17-4PH Stainless
especially for the first stage. Moreover, the fitted curve for the first Steel. 17-4PH stainless steel has a dual-stage S-N curve: the first
stage is always below that for the second stage up to 108 reversals. stage at high stress represents resistance of the matrix to cyclic
Such a result is not rational. Since the fatigue limit will be loading and the second stage at low stress mainly characterizes
improved if no inclusions exist in 17-4PH stainless steel, the fitted effect of inclusions on fatigue property. Fatigue limit is usually
curve for the first stage should be above that for the second stage obtained at 107 or 108 cycles (108 cycles is used in this study). In
in the very long life regime. So Basquin equation was modified to some sense, such a value mainly reflects the influence of the inclu-
describe the S-N curve of 17-4PH stainless steel: sions rather than the fatigue strength of the matrix of 17-4PH
stainless steel. From practical fatigue design and structural reli-
ra ¼ r0 þ r0f ð2Nf Þb (3) ability point of view, the experimentally obtained fatigue limit is
very important and hence has been well investigated. It can be
where a translation parameter (r0) was added to describe the predicted by Murakami’s model, which has attracted much atten-
deviation from the linear relationship between ra and Nf on the tion of engineers and researchers as it isffi simple and effective. Sub-
pffiffiffiffiffiffiffiffi
log–log scale. The same settings were used to fit the experimental stituting HV ¼ 390 kgf/mm2 and area ¼ 8:86 lm in Eq. (1), the
data. Figure 6 shows the experimental data and fitted curves based estimated fatigue limit is equal to 553 MPa, which is 5.33%
on the modified Basquin equation, where the open symbols are larger than the actual value 525 MPa. However, viewed from

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Fig. 6 Comparison of experimental data and modified Basquin
Fig. 8 Fatigue crack growth behavior of 17-4PH stainless steel
equation

However, Tanaka et al. [23] summarized experimental data for a


wide variety of engineering alloys and found that Smith’s model
only showed the upper border of experimental data and El Had-
dad’s model [25] was more appropriate.
In the present study, the inclusions in 17-4PH stainless steel are
regarded as small cracks and half of the average size of the inclu-
sions (ai) is treated as small crack length. Substituting a ¼ ai in El
Haddad’s model, the experimentally obtained fatigue limit (r0w1 )
can be expressed as
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
r0w1 =rw1 ¼ a0 =ða0 þ ai Þ (5)

where rw1 is the fatigue limit of the matrix of high strength steel
under fully reversed fatigue loading. For 17-4PH stainless steel,
ai ¼ 5 lm and r0w1 ¼ 525 MPa. If a0 is known, rw1 can be pre-
dicted by Eq. (5). DKth can be obtained by fatigue crack growth
testing. Figure 8 shows fatigue crack growth behavior of 17-4PH
stainless steel at a frequency of 20 Hz and a stress ratio of R ¼ 0.1.
Fig. 7 Comparison of the observed and predicted lives in 17- This figure mainly shows two different regimes, namely,
4PH stainless steel near-threshold regime and Paris regime. Fatigue crack growth rate
(da/dN) steeply decreases with decreasing DK in the near-threshold
metallurgical quality control and improvement in material proc- regime and finally DK reaches the threshold value (DKth ¼ 4.4
essing, the fatigue limit of the matrix of 17-4PH stainless steel is MPa m1/2) at the rate of 108 mm/cycle. The Paris regime exhibits
also important, which is the maximum expected fatigue strength a linear variation of log (da/dN) with log (DK) as follows
by improving the cleanness of steel. It also has advantage to fur-
ther understand the fatigue characteristic of high strength steels da=dN ¼ 2:8  109 ðDKÞ3:2 (6)
and the effect of inclusions.
As for high strength steels, the experimentally obtained fatigue In general, fatigue crack growth tests are performed by using CT
limits are the reduced values due to inclusions or casting defects. specimens at a positive stress ratio (R > 0) whereas fatigue tests
An intriguing question is how to get the fatigue limits of the are conducted under fully reversed loading (R ¼ 1). In order to
matrixes of high strength steels. Considering Murakami’s model get a0, experimental data should be converted into the same stress
[18], the key point is that the inclusions and casting defects are ratio. Relatively, methods for modifying fatigue test data are
treated as small cracks. Moreover, many experimental results prove mature. Goodman equation (10) is used in this study
that such an assumption is appropriate. So mechanics related to
small cracks should be valid for fatigue limit prediction of the ma- rw ¼ rw1 ð1  rm =rTS Þ
trix of high strength steel. On the basis of small crack mechanics, rm ¼ rw ð1 þ RÞ=ð1  RÞ (7)
an intrinsic crack length (a0) is used to correlate the fatigue limit of
the matrix of high strength steel (rw) and the threshold stress inten-
where rm and rTS are the mean stress and the tensile strength of
sity factor range of long fatigue cracks (DKth) [23]
materials, respectively. By substituting all the available data
  (DKth ¼ 4.4 Mpa m1/2, r0w1 ¼ 525 MPa, ai ¼ 5 lm, rTS ¼ 1073
1 DKth 2 MPa and R ¼ 0.1) in Eqs. (4), (5), and (7), the fatigue limit of the
a0 ¼ (4)
4p rw matrix and the intrinsic crack length of 17-4PH stainless steel are
obtained: rw1 ¼ 629 MPa and a0 ¼ 11.5 lm. rw1 ¼ 629 MPa
DKth is assumed to be independent on inherent flaws. Smith instead of r0w1 applied to Eq. (1) yields a critical inclusion size of
assumed that the fatigue limit of specimens including small cracks 4.6 lm determining whether the fatigue limit of 17-4PH stainless
would approach rw when the small crack length (a) was shorter steel is influenced by the inclusions or not. This calculation was
than a0 whereas it would decrease with increasing a [24]. done by using the fatigue data and the fatigue crack growth data

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