The Effect of Microstructure on the Fatigue Crack

Propagation Behavior of an AI-Zn-Mg-Cu Alloy

J. L I N D I G K E I T , A. GYSLER, A N D G. L U T J E R I N G

The effect of slip distribution on the fatigue crack propagation behavior in vacuum of a high
purity A1-5.9Zn-2.6Mg-1.7Cu alloy in various age-hardened conditions has been investi-
gated. The crack propagation resistance was observed to be significantly higher for
underaged microstructures containing shearable precipitates in comparison to overaged
conditions with nonshearable precipitates. The improved crack propagation resistance is
attributed in part to an increased amount of reversed slip in the plastic zone at the crack tip
due to a higher degree of planar slip for conditions with shearable precipitates. The observed
increase in fatigue crack propagation resistance with decreasing precipitate size for
microstructures containing a constant volume fraction of shearable precipitates cannot be
explained on the basis of such slip reversibility alone. The variation in ductility for the
different microstructures has also to be taken into account. It was found that the enhanced
crack propagation resistance can be correlated to the increased ductility with decreasing
precipitate size. This explanation was supported by the experimental observation that
microstructures containing different volume fractions and sizes of shearable precipitates but
exhibiting the same ductility showed approximately the same resistance against fatigue crack
propagation.

1. I N T R O D U C T I O N fatigue crack propagation behavior of aluminum and

B E S I D E S the modulus of elasticity ~also microstruc-
tural effects are now generally considered to affect the
fatigue crack propagation behavior of age-hardened
alloys, especially in the low and high cyclic stress
intensity factor regime. The microstructural parameters
which were found to have an influence on the crack
propagation resistance are the grain size2-5 and the slip
distribution, which might be changed by varying
stacking fault energy6-9 or degree of age-harden-
ing. 1~ Fatigue crack propagation measurements for
copper alloys with a wide variation in stacking fault
energy showed that significantly lower propagation
rates were observed with decreasing stacking fault en-
ergy. 6-9 However, no explanation for the decreasing
crack propagation rates with decreasing tendency for
dislocation cross slip processes was offered by these
authors. On the other side in a recent study Horn-
bogen and Zum Gahr ~~explained the observed im-
provements in fatigue crack propagation resistance of
an underaged as compared to an overaged microstruc-
ture for an Fe-Ni-AI alloy by a model of reversed slip
of dislocations at the crack tip. They concluded that
the propagation rate in a material which promotes a
planar slip mode will be strongly retarded by such
reversed dislocation movement during the unloading
part of a loading .cycle. ~~This also would explain the
lower propagation rates found in low stacking fault
energy materials. Other recent investigations o f the
J. LINDIGKEIT, formerly with German Aerospace Research
Establishment (DFVLR), Cologne, Germany, is now with Krupp
Research Institute, D-4300 Essen 1, Germany. A. GYSLER is with
German Aerospace Research Establishment (DFVLR), D-5000Co-
logne 90, Germany. G. LOTJERING, formerlywith Ruhr-University,
Bochum, Germany, is now with Technical UniversityHamburg-
Harburg, D-2100 Hamburg 90, Germany.
Manuscript submitted March 20, 1980.
ISSN 0360-2133/ 81/0911-1613500.75l0
METALLURGICALTRANSACTIONSA 9 1981 AMERICAN SOCIETY FOR METALS AND VOLUME 12A, SEPTEMBER 1981--1613
THE METALLURGICAL SOCIETY OF AIME
titanium alloys also showed experimental evidence
which demonstrated improvements in crack propaga-
tion resistance with increased tendency for planar
slip. H-12 However, it was found in these studies, that
such improvement was observed only when the fatigue
tests were performed in an inert environment.
Laboratory air for example was leading already to an
opposite ranking with regard to the fatigue crack pro-
pagation resistance between age hardening conditions
with a planar as compared to a more homogeneous
deformation mode. 11
The purpose o f the present study was to investigate
the effect of the slip distribution on the fatigue crack
propagation behavior of an AI-Zn-Mg-Cu alloy in an in-
ert environment. Various conditions with different heat
treatments were selected in order to obtain a wide
spectrum of different slip distributions: microstruc-
tures with shearable or nonshearable precipitates of
different sizes and volume fractions, but leading to
the same yield stress and microstructures with the
same volume fraction of shearable precipitates but
different particle sizes. With the investigation o f these
conditions it was hoped to further the understanding
of the influence of slip distribution on the fatigue
crack propagation behavior o f age-hardened alloys.
2. EXPERIMENTAL PROCEDURE
The high purity laboratory aluminum alloy with the
basic composition A1-5.9Zn-2.6Mg-l.7Cu (wt pct) was
prepared by Alcan Laboratories, Banbury, U. K., where
the cast ingots were rolled at 430 ~ to a thickness of 25
ram. The chemical composition of this alloy is shown in
Table I. Blanks of these plates were solution heat
treated at 450 ~ for 1 h, quenched in ice-water and
immediately rolled at room temperature to a final
 ments were applied which resulted in a constant yield
Table I. Chemical Composition of the Alumunlum Alloy (WI Pct) stress of 475 M N m - 2 : 1 h at 160 ~ and 100 h at 100 ~
(both shearable precipitates) and 70 h at 160 ~ (non-
Zn Mg Cu Cr Si Fe Mn Ti AI
shearable precipitates). To compare the effect of dif-
5.93 2.58 1.7 0.002 (0.01 (0.01 0.002 0.017 Balance ferent volume fractions and particle sizes of shearable
precipitates, the following age-hardening treatments
were chosen resulting in a constant yield stress of 280
thickness of about 12 ram. Tensile specimens, with gage M N m - 2 : 1 0 0 h at 20 ~ and 0.5 h at 100 ~ To study
dimensions of 5 mm diam and 25 mm length, and single the effect of different particle sizes at a constant volume
edge notched (SEN) specimens, with gage dimensions fraction the following age-hardening conditions were
of 2.5 mm thickness, 20 m m width and 50 mm length, selected: 0.5, 10 and 100 h at 100 ~ aging temperature.
were machined so that the stress axis upon testing The tensile properties of all these aging conditions are
would be parallel to the rolling direction. The specimens summarized in Table II.
were recrystallized at 450 ~ for 2 h, quenched in TEM studies of thin foils, prepared from samples
ice-water and aged at room temperature or stored at with the different age-hardening treatments (Table II),
room temperature for two days before aging them at showed that no semicoherent ~/'-particles were precip-
100 or 160 ~ for various times. The recrystallized itated within the matrix of specimens aged either at 20
material showed an equiaxed grain structure with a or 100 ~ Also no precipitate free zones were found
grain size of about 100 #m. The starter notch of the along grain boundaries for samples aged at both of
SEN specimens was machined by spark erosion cutting these temperatures as well as for samples aged 1 h at
after the final aging treatment. 160 C. The micrograph in Fig. 2(a) may serve as an
Tensile tests were performed at room temperature in example to characterize these microstructures. Aging
air employing an initial strain rate of 6 • 10 -4 s-1. All the alloy for 70 h at 160 C resulted in precipitate free
fatigue crack propagation tests were carried out at room zones along grain boundaries due to the precipitation of
temperature in vacuum ( ~ 10 -4 Pa) on a closed-loop equilibrium ,/-particles at the boundaries, as can be seen
servohydraulic machine under stress controlled sinusoi-
dal tension-tension loading with an R-ratio of 0.1 and a
frequency of 30 Hz. After initiating a fatigue crack at
the starter notch the load was reduced in several Table II. Tensile Properties
decrements until well established crack propagation E Oo 2 OF EF
rates of about 10 -6 m m / c y c l e were reached. No meas- Aging Condition ( G N m -2) ( M N m -2) ( M N m -z) ln(Ao/A~) n*
urements were utilized until the crack had propagated
100 h, 20 ~ 68.5 280 729 0.56 0.56
at last 1 mm beyond the region of plasticity associated 0.5 h, 100 ~ 68.8 280 704 0.56 0.55
with this initiation procedure. The crack length was 10 h, 100 ~ 68.5 413 752 0.44 0.37
measured optically with a travelling microscope. 100h, 100 ~ 68.7 475 756 0.40 0.38
The microstructures were investigated by thin foils, i h, 160 ~ 69.0 475 786 0.51 0.31
70 h, 160 ~ 68.9 475 665 0.31 0.33
prepared with a double-jet electropolishing apparatus,
using a JEOL electron microscope operating at 200 kV. *n = [d log(a - %)]/d log e.
The fracture surfaces were examined in a Cambridge
scanning electron microscope.
6OO
3. E X P E R I M E N T A L R E S U L T S
|
160~
3.1. Tensile Properties 4130

The dependence of yield stress 00.2 and true fracture

! RT
strain eF as a function of aging time is given in Fig. 1 for
aging temperatures of 20, 100 and 160 ~ At the lower //"
aging temperatures (20 and 100 ~ the yield stress 0.8
increased continuously within the time interval studied,
whereas the true fracture strain declined. At the higher
aging temperature of 160 ~ the yield stress passes
through a maximum (at about 10 h) indicating that the 0 6 ,.
alloy can be overaged within reasonable time at this "•"•'• RT
w
E
temperature. The ductility goes through a minimum,
reaching a relatively low value of about 0.27 after about
IOOeC
15 h (Fig. 1). The tensile fracture behavior was found to
be similar to the behavior of a comparable AI-Zn-
Mg-Cu alloy reported previously. 13 % O2
From the age-hardening curves in Fig. 1 different 0 10o 10~ 102 103
agelt~ t0me [h ]
heat treatment conditions were chosen for the fatigue Fig. 1--Tensile yield stress o 02 a n d true fracture strain cr as a function
crack propagation tests. To study the effect of shearable of aging time for three different aging temperatures of 20, 100 and
and nonshearable precipitates, different aging treat- 160 ~

1 6 1 4 - - V O L U M E 12A, S E P T E M B E R 1981 METALLURGICAL TRANSACTIONS A


Ca)
(b)
Fig. 2--Transmission electron micrographs for underaged and over-
aged microstructures. (a) 100 h at 100 ~ (b)70 h 160 ~
in Fig. 2(b). Within the matrix of this overaged condi-
tion small semicoherent ~/'-particles were precipitated
with sizes of about 20 nm, as wasdetermined from dark
field electron micrographs.
3.2. Fatigue Crack Propagation
The crack propagation results are shown as plots of
fatigue crack propagation rate d a / d N vs the cyclic
stress intensity factor AK. In Fig. 3 the results are
shown for the comparison between shearable and
nonshearable precipitates. This figure also shows the
scatter band obtained from two tests of the same
age-hardening condition which can be considered rep-
resentative for all the other d a / d N - A K curves. It can be
seen that pronounced differences in crack propagation
rates exist between the three different microstructures,
especially below AK-values of about 10 MNm -3/2. At
the lowest crack propagation rate (about 10 -6 mm/cy-
cle) which could be measured within reasonable testing
times, the overaged condition (70 h 160 ~ showed the
lowest AK-value (6 MNm -3/2) whereas the underaged
conditions exhibited a higher resistance against crack
propagation. The highest AK-value (8.5 MNm -3/2) was
found for the condition aged for 100 h at 100 ~
METALLURGICAL TRANSACTIONS A
Fig. 3--Fatigue crack propagation rate d a / d N as a function of cyclic
stress intensity factor AK for microstructures with shearable (1 h
160 ~ 100 h 100 ~ and nonshearable (70 h 160 ~ precipitates
(002 = 475 MNm -2 for all conditions).
Fig. 4--Fatigue crack propagation rate d a / d N as a function of cyclic
stress intensity factor AK for microstructures with different sizes and
volume fractions of shearable precipitates (a02 = 280 MNm -2 for
both conditions).
On the other hand only minor differences in crack
propagation rates were found between the two under-
aged microstructures which were aged to contain both
shearable precipitates (100 h 20 ~ and 0.5 h 100 ~
and to have the same yield stress of 280 MNm -2, as can
be seen in Fig. 4. The AK-values at low crack propa-
gation rates were almost the same for both conditions
(about 10 MNm-3/2).
Fatigue crack propagation results for underaged
microstructures, aged at 100 ~ for various times, are
given in Fig. 5. In the intermediate AK-region almost no
difference in crack propagation rates was found be-
tween the three different age-hardened conditions. At
low AK-values some deviation among the three curves
was observed, where the condition with the longest
aging time (100 h) showed the highest propagation rate
whereas the highest resistance against slow crack prop-
agation was observed for the microstructure with the
shortest aging time (0.5 h).
VOLUME 12A, SEPTEMBER 1981--1615
Fig. 5---Fatigue crack propagation rate da/dN as a function of cyclic
stress intensity factor AK for microstructures with different sizes of
shearable precipitates.

rb)
3.3. Fracture Surface Observations
Scanning electron microscopy studies of the fatigue
fracture surfaces of all microstructures revealed that
crack propagation occurred mainly transgranularly
along slip bands in the low and intermediate
AK-regime. This is shown by the micrographs in
Fig. 6,7, and 8, taken from regions where the lowest
crack propagation rates were measured. However the
slip step heights, visible on these micrographs, showed
pronounced differences. It was observed that significant
differences in the fracture surface appearance occurred
between those microstructures for which the most
pronounced differences in propagation rates were meas-
ured (Fig. 3). For example the micrograph in Fig. 6(a)
shows only a few very large slip steps, the orientation of

(c)

these steps with regard to the crack front varying from

(a)
Fig. 6--Fatigue fracture surfaces at low crack propagation rates
(da/dN = 10 -6 mm/cycle) for microstructures containing shearable
and nonshearable precipitates (SEM). (a) 100 h 100 ~ AK = 8.2
M N m -3/2, (b) 1 h 160 ~ AK = 7.0 M N m -3/2, (c) 70 h 160 ~ AK
= 6.0 MNm -3/2.
grain to grain. On the other hand the fracture surfaces
of specimens aged for 1 h and 70 h at 160 ~ which
resulted in a lower resistance against crack propagation
(Fig. 3), were exhibiting much finer slip steps within
each grain, as can be seen in Figs. 6(b) and (c).
Comparing the fracture surfaces at low AK-values for
the three different microstructures aged at 100 ~
where higher resistance against slow crack propagation
was found for specimens with shorter aging times
(Fig. 5), one can see that much finer slip steps were
observed for this aging condition (Fig. 7(a)) in com-
parison to the less resistant microstructure aged for
100 h at 100 ~ (Fig. 7(c)). In contrast to these observa-
tions, for microstructures which showed almost identical
d a / d N - A K curves, i.e., for 100 h at 20 ~ and 0.5 h at
100 ~ (Fig. 4), also the same fracture topography was
found. For both of these microstructures fine slip steps
were observed in the low AK-region, an example is
shown by the micrographs in Fig. 8.

1616--VOLUME 12A, SEPTEMBER 1981 M E T A L L U R G I C A L TRANSACTIONS A

 fa~
Fig, 7--Fatigue fracture surfaces at low crack propagation rates
(da/dN = 10-6 mm/cycle) for microstructures with different sizes of
shearable precipitates (SEM). (a) 0.5 h 100 ~ AK = 10 MNm -3/2,
(b) 10 h 100 ~ AK = 9.2 MNm -a/2, (c) 100 h 100 ~ AK = 8.2
MNm-3/2.
METALLURGICAL TRANSACTIONS A
(a)
fb)
Fig. 8--Fatigue fracture surface at low crack propagation rate for an
underaged microstructure (SEM): 100 h 20 ~ AK = 10 MNm-3/2;
da/dN = 1.2 • 10 -6 mm/cycle (micrograph (b) higher magnification
of (a)).
4. D I S C U S S I O N
The results obtained in the present work will be
discussed on the basis of existing fatigue crack prop-
agation models which take microstructural parameters
into account. The discussion will be focused mainly on
the low AK-regime where plane strain conditions are
applicable. First a model will be applied, which was
proposed by Hornbogen and Zum Gahr ~~to explain
their fatigue crack propagation results for an Fe-Ni-Al
alloy in an underaged and an overaged condition. This
model is based on the reversibility of dislocation motion
within the plastic zone close to the crack tip. These
authors pointed out that in a microstructure containing
shearable precipitates, which promote a planar dislo-
cation distribution, a certain number of dislocations will
be able to move backwards during unloading in the
same slip plane as during the forward motion in the
rising part of a loading cycle. Some of these dislocations
VOLUME 12A, SEPTEMBER 1981--1617
 will leave the material at the crack tip and therefore will
not contribute to crack propagation. The number of
dislocations moving in the opposite direction upon
unloading and which are able to leave the material
depends, of course, strongly on the degree of slip
planarity. For example, if dislocation cross slip pro-
cesses take place, induced either by high stacking fault
energies or by nonshearable precipitates, some dislo-
cations will move out of the original slip planes during
the rising part of the loading cycle and will therefore
reduce the number of dislocations moving backwards
on the initial slip plane. This would result in an
enhanced crack propagation rate.
This model, applied to the results obtained in the
present study, provides an explanation in a qualitative
way for some of the microstructural effects on the
fatigue crack propagation behavior. The increased re-
sistance against crack propagation of microstructures
containing shearable precipitates in Fig. 3 (1 h 160 ~
and 100 h 100 ~ in comparison to the structure with
nonshearable precipitates (70 h 160 ~ can therefore
be explained with a higher degree of reversed slip within
the plastic zone for both of the underaged conditions.
Further support for this explanation can also be drawn
from the fracture surface studies which showed that
high slip steps are related to the microstructures con-
taining shearable precipitates (100 h 100 ~ while
much finer slip steps were found for the condition with
nonshearable precipitates (compare Figs. 6(a) and (c)).
A fracture topography with large slip steps is typical for
microstructures with a highly planar slip distribution
and a large number of dislocations within a slip band
while finer slip steps on the fracture surface are
indicative of a more homogeneous slip distribution.
The fatigue crack propagation curves shown in Fig. 4
for the two microstructures, both containing shearable
precipitates (100 h 20 ~ and 0.5 h 100 ~ also can be
explained qualitatively with the reversed slip model. At
low AK-values almost the same resistance against crack
propagation was found for both aging conditions and
also the fatigue fracture surfaces did not show signif-
icant differences (Fig. 8). It is concluded therefore that
the degree of slip planarity between both microstruc-
tures may be similar and the coincidence between both
fatigue crack propagation curves (Fig. 4) reflects the
similarity in slip reversibility within the plastic zone at
the crack tip between both microstructures.
However, if one applies the same model to explain
the results obtained for microstructures which were
aged at 100 ~ for various times (Fig. 5), not even a
qualitative agreement can be deduced. At low
AK-values the highest resistance against crack propa-
gation was found for the microstructure which exhibited
the most homogeneous slip distribution (0.5 h 100 ~
Indications for such homogeneous slip can be derived
from the high tensile ductility of cr = 0.56 (Table II)
and from fine slip steps found on the fatigue fracture
surface (Fig. 7(a)) for this age-hardened condition. The
lack in agreement between the proposed slip rever-
sibility model (10) and the experimental results in Fig. 5
demonstrates that also other factors besides reversed
dislocation motion have to be considered in order to
explain all aspects of the fatigue crack propagation
1618--VOLUME 12A, SEPTEMBER 1981
behavior of age-hardened alloys. It should be men-
tioned that a similar discrepancy was also observed
between this concept of slip reversibility and the results
of fatigue crack propagation measurements on age-
hardened Ti-A1 alloys?4
In recent studies attempts have been made to predict
the fatigue crack propagation behavior from low and
high cycle fatigue properties./5-~7 The equation proposed
by Majumdar and Morrow ~6for example is:
da - 2 ( b + c) [ oy ]-l/(b+c)
dU = b + e + 1 _4(1 + n')o)c'y]
• C--0--D]2O
]Cb+c+'
" )/(b+r
_ [4(l + n,)c,r]~b'c+wc~+~')c',AK2
The following parameters can be determined from low
cycle fatigue tests: dr, c'v = cyclic uniaxial yield stress
and yield strain respectively, n' = cyclic strain hardening
exponent, c = fatigue ductility exponent and
~'j = fatigue ductility coefficient, determined from Cof-
fin-Manson plots. From high cycle fatigue tests one
obtains: b = fatigue strength exponent and a"I = fa-
tigue strength coefficient. The other parameters are: p*
-- microstructural size related to the mean free path
between major deformation barriers and COD = crack
opening displacement at maximum load.
It was reported by these authors ~6that the parameters
dt and c, as well as o'j, E and p" all have a pronounced
influence on the fatigue crack propagation rate. Other
material properties, like the cyclic yield stress o'y and
the cyclic strain hardening exponent n' were found to
have relatively minor importance in determining the
fatigue crack propagation resistance, according to
Eq. [1].
Unfortunately for the microstructures studied in the
present work no low cycle fatigue data are available and
therefore only a tentative evaluation of the models
mentioned above ~5-n7can be made with regard to our
experimental results. First of all no differences in crack
propagation rates between the different microstructures
should be obtained due to changes in the elastic
modulus, since no significantly different values were
observed (Table II). It will now be assumed that the
true tensile fracture strain c~- (Table II) may be an
approximate measure of the cyclic ductility coefficient
c'f in the Coffin-Manson relationship. Lin and Starke, 18
extrapolating Coffin-Manson plots for strain ampli-
tudes greater than 1.2 pct, obtained c~f-values for
A1-Zn-Mg-Cu alloys which were of the same order of
magnitude as measured tensile ductility values. The
tendency of the curves in Fig. 5 at low aK-values may
then be explained in a qualitative way. The reported
models predict decreasing fatigue crack propagation
P
rates with increasing ~j-values. 16,17 From Table II one
can see that cF increases with decreasing aging time at
an aging temperature of 100 ~ (see also Fig. 1).
Therefore the microstructure aged for 0.5 h at 1130~
should exhibit the highest resistance against crack
propagation due to the high oF-value (0.56) as compared
METALLURGICAL TRANSACTIONS A
 to both of the other conditions with lower oF-values.
The experimental determined d a / d N - h K curves
(Fig. 5) follow at low ilK-values indeed the prediction
in Eq. [1]?6
A comparison of the fatigue crack propagation curves
for microstructures with shearable precipitates, as
shown in Fig. 4, with regard to the proposed model, ~6
also shows qualitatively agreement with the prediction.
Assuming again a correlation between e'j and the true
fracture strain ~r, no significant differences in crack
propagation rates should be observed between both
microstructures (100 h 20 ~ and 0.5 h 100 ~ since
the measured eF-values are identical for both aging
conditions (Table II).
However the large differences in resistance to fatigue
crack propagation at low ilK-values, shown in Fig. 3 for
the three different microstructures, cannot be explained
on the basis of the different ductility values (Table II).
Crack propagation rates predicted from Eq. [1] on the
basis of the observed ~r-values alone would lead to a
different ranking of the three microstructures, as com-
pared to the experimentally measured curves (Fig. 3)
A consideration of crack closure as the rate con-
trolling mechanism also would incorporate the ductility
of the different microstructures. The extent of crack
closure depends very strongly on the true tensile
fracture strain and the retarding effect increases with
increasing ductility of a material. ~9Therefore the exper-
imental results in Figs. 4 and 5 also could be explained
on the basis of the crack closure concept, while it would
not adequately describe the ranking of the d a / d N - i l K
curves in Fig. 3.
5. CONCLUSIONS
1) A comparison between underaged and overaged
microstructures of an A1-Zn-Mg-Cu alloy, aged to have
the same tensile yield stress, showed that the fatigue
crack propagation resistance in vacuum is higher for
conditions containing shearable precipitates as com-
pared to overaged structures with nonshearable pre-
cipitates. This improvement is attributed in part to an
increased tendency for reversed slip of dislocations due
to the more planar slip behavior for conditions with
shearable precipitates.
2) Microstructures containing different volume frac-
tions and different sizes of shearable precipitates, but
the same tensile yield stress and true fracture strain,
exhibited the same fatigue crack propagation resistance
at low cyclic stress intensity factors. This behavior can
be explained with similarities in slip reversibility within
the plastic zone at the crack tip which also resulted in
identical fatigue fracture topographies for the different
microstructures.
METALLURGICAL TRANSACTIONS A
3) For microstructures containing a constant volume
fraction but different sizes of shearable precipitates, the
fatigue crack propagation resistance in the low
AK-regime was found to increase with decreasing
particle size or increasing tensile ductility. This result
cannot be explained alone on the basis of reversed slip
of dislocations within the plastic zone. Ductility for the
different microstructures have to be taken into account.
Existing fatigue crack propagation models as well as
crack closure concepts seem to explain in a qualitative
way the increased fatigue crack propagation resistance
with increasing ductility.
ACKNOWLEDGMENTS
The authors wish to acknowledge the assistance of
Mr. J. Endrejat in the experimental work. Thanks are
also extended to Alcan Laboratories, Banbury, U.K.,
for providing the alloy, and to the Deutsche For-
schungsgemeinschaft for financial support of this work.
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