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3. Intrusions, extrusions
1. Cyclic slip
2
Outline
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1. Cyclic slip
2. Persistent slip bands (PSB) n 3. Intrusions and extrusions n 4. Stage I crack growth n 5. Stage II crack growth
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Process of fatigue
4. Stage I (shear) fatigue crack
3. Intrusions, extrusions
1. Cyclic slip
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1. Cyclic slip
First cycle
Cyclic slip occurs within a grain and therefore operates on an atomic scale and are thus is controlled by features seen at that scale.
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1. Cyclic slip
Material Aluminum Iron Nickel Copper Gold Silv er Stainl ess Steel Brass Stacking Fault Energy ergs cm- 2 250 200 200 90 75 25 <10 <10
d=
G (b 2 b 3 ) 2
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1. Cyclic slip
Cu-Al alloys, Cu-Zn, Aust. SS Planar slip in Cu-Al
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1. Cyclic slip
Wavy slip materials Planar slip materials
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1. Cyclic slip
= 10-3
=10-5
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Example
OM surface OM etch pit
60 cycles
1,000 cycles
TEM
5,000 cycles
20,000 cycles
5m
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Outline
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1. Cyclic slip
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Outline
1. Cyclic slip n 2. Persistent slip bands (PSB)
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Fatigue crack initiation at an inclusion Cyclic slip steps (PSB) Fatigue crack initiation at a PSB
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Outline
1. Cyclic slip n 2. Persistent slip bands (PSB) n 3. Intrusions and extrusions
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Stage I fatigue cracks are the size of the grains and are thus controlled by features seen at that scale: grain boundaries, mean stresses, environment.
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1 K I rc = ' 2 y
Cyclic plastic zone is the region ahead of a growing fatigue crack in which slip takes place. Its size relative to the microstructure determines the behavior of the fatigue crack, i.e.. Stage I and Stage II behavior.
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Cracks growing from notches dont know that that stress field they are experiencing is confined to the notch root.
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Here the ?K is the remote stress intensity factor based on remote stresses.
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Outline
1. Cyclic slip n 2. Persistent slip bands (PSB) n 3. Intrusions and extrusions n 4. Stage I crack growth
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Stage II fatigue cracks much larger than the grain size and are thus sensitive only to large scale microstructural features - texture, global residual stresses, etc.
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Plexiglas
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Example
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a.
S=0
Remote Stress, S
b.
S = Sop
Plastic wake
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c.
S = Smax
d.
S=0
Plastic wake
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x =
x xy
S c 3 KI cos 1 sin sin = f1 () 2 R 2 2 2 2 R S c 3 KI cos 1 + sin sin = f2 ( ) 2 R 2 2 2 2 R S c 3 KI cos sin cos sin = f () 2R 2 2 2 2 2R 3
R x
y = xy =
The magnitude stress field near a crack tip depends upon the stress intensity factor (KI). Wouldnt it be nice if this quantity correlates with the speed with which fatigue cracks grow? Lets see if it works! Rather, lets see if we can MAKE it work!
K YS a
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Y=1
Finite width center cracked panel
S W
c W
Y = sec
B
2c
2c
S
Disc shaped crack in an infinite body
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Y=1.12
2c
Y=2/p
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da p = C ( K )m (K max ) dn
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Extrinsic Intrinsic
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Example
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C D
Effects of Environment
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Example
The fatigue crack growth rates for Al and Ti are much more rapid than steel for a given ?K. However, when normalized by Youngs Modulus all metals exhibit about the same behavior.
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Summary
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Fatigue is a complex process involving many steps but it may be broken down into the initiation and growth of fatigue cracks. The growth of fatigue cracks is often considered to be the most important feature of fatigue from an engineering perspective.
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