Form Manual700

Fatigue Crack Formation Analysis
NASFORM Module
NASGRO 7.0 Alpha

May 2012
ii
TABLE OF CONTENTS
SYMBOLS .............................................................................................................................. iii
ABBREVIATIONS ................................................................................................................... v
SUMMARY............................................................................................................................... 1
1.0 Introduction ........................................................................................................................ 3
2.0 Stress-Life Method ............................................................................................................ 5
2.1 Theoretical Background ............................................................................................. 5
2.2 Details of Analysis ..................................................................................................... 7
3.0 Strain-Life Method ............................................................................................................ 8
3.1 Theoretical Background ............................................................................................. 8
3.1.1 Stress-Strain Relationships ............................................................................... 8
3.1.2 Strain Conversion Methods ........................................................................... 10
3.1.3 Strain-Life Equations ..................................................................................... 11
3.1.4 Damage Accumulation Equations .................................................................. 14
3.2 Details of Analysis ................................................................................................... 15
ACKNOWLEDGMENTS ....................................................................................................... 17
REFERENCES ........................................................................................................................ 18
Appendix A List of Materials with Stress-Life Fitted Data .............................................. A-1

Appendix B List of Materials with Strain-Life Tabular Data ............................................ B-1
Appendix C List of Materials with Strain-Life Fitted Data ............................................... C-1
Appendix D Load Spectrum Block Formats ..................................................................... D-1
iii
SYMBOLS
Symbol
Quantity
A
A, B, C, P
Amplitude Ratio in Loopin tabular method

Constants in S-N equation
u
y
f
Ultimate tensile strength
Yield strength
True fracture strength
%RA
=
=
Percent reduction in area

True fracture ductility
n
K
E
=
=
=
=
Monotonic strain hardening exponent

Monotonic strength coefficient
Youngs modulus
Cyclic yield strength
K
n
f
=
=
=
Cyclic strength coefficient

Cyclic strain hardening exponent
Fatigue strength coefficient
=
=
Fatigue strength exponent

Fatigue ductility coefficient
c
e
=
=
=
Fatigue ductility exponent

Remote(nominal) strain
Exponent used for loopin material parameter
Kt
Kf
Stress concentration factor
Fatigue Notch factor
S eq
Equivalent stress in S-N equation
S max
S min
S S max S min
Remote peak stress (from spectrum)
Remote valley stress (from spectrum)
Remote stress range (from spectrum)
Local (notch) stress
Local peak stress (at notch)
Local valley stress (at notch)
Local stress range (at notch)
Local (notch) strain
Local peak strain (at notch)
Local valley strain (at notch)
Local strain range (at notch)
Nf
=
=
Local strain amplitude (at notch)

No. of cycles to failure at given stress range
2Nf
No. of reversals to failure at given stress range
max
min
max min
max
min
max min
/ 2
iv
ni
N fi
No. of applied cycles in the ith step of a block
No. of cycles to failure for the ith step in a block
ABBREVIATIONS
ACAS.....As cast
AFOR.As forged
AREC.As received
ANN ....................................... Annealed
ASQ....As quenched
ASTM .................................... American Society for Testing and Materials
AUST. .................................... Aus tempered
BA .......................................... Beta annealed
CD .......................................... Cold-drawn
CDSR ..................................... Cold-rolled, Strain relieved
CR .......................................... Cold-rolled(10%, 20% etc)
CRT........................................ Cold-rolled and tempered
CW..Cold-worked
DA.......................................... Dry air environment
DRT ....................................... Drawn at temp
DW ......................................... Distilled water environment
ELI ......................................... Extra-low interstitial
Eq ........................................... Equation (number)
ESA ........................................ European Space Agency
EXTR ..................................... Extrusion
FORG ..................................... Forging
HAZ ....................................... Heat affected zone
HHA ....................................... High humidity air environment
HR .......................................... Hot rolled
HRB ....................................... Hot rolled bar
HR&A .................................... Hot rolled and annealed
HRNORM .............................. Hot rolled and normalized
HRS........................................ Hot rolled sheet
HRP........................................ Hot rolled plate
MA ......................................... Mill annealed
NASA .................................... National Aeronautics and Space Administration
NDE ....................................... Nondestructive evaluation
NORM ................................... Normalized
OA.......................................... Over-aged
PA .......................................... Peak-aged
PCHAN .................................. Plate channel
Plt ........................................... Plate
PRES ...................................... Pre strained
Q&T ....................................... Quenched and tempered
Q&T-D ................................... Quenched and tempered and drawn
Q&T-Def................................ Quenched and tempered def
RA .......................................... Recrystallization annealed
Rnd ......................................... Round rod
vi
ROL-Q&T.............................. Rolled and Q&T

SA .......................................... Submerged arc
SCT ........................................ Sub-cooled and tempered
Sht .......................................... Sheet
SH .......................................... Strain hardened
SHQ ....................................... Sol heated and quenched
SR .......................................... Stress relieved
ST........................................... Solution treated
STA ........................................ Solution treated and aged
ST&RTA................................ Soln treated, RT aged
STS ........................................ Space treated, strained
SW ......................................... Seawater environment
UNK ....................................... Unknown
UTS ........................................ Ultimate tensile strength
WHAZ ................................... Weld heat affected zone
YS .......................................... Tensile yield strength
Summary
This manual describes the theory and operation of the fatigue crack formation
analysis module NASFORM. This module is one of the four NASGRO modules. For a
given spectrum block and a specified stress concentration factor ( N ) or fatigue notch
factor (S-N), this module computes the crack formation life in blocks. There are two main
choices of material models incorporated, viz., stress-life (S-N) and strain-life( N ). The
stress-life correlation is primarily applicable to high-cycle fatigue where the effects of
notch-root plasticity are not significant. The strains in this case are predominantly elastic.
Nominal stress is used to correlate with the observed life of a specimen. This method was
implemented by the European Space Agency (ESA) into ESAFATIG. This code has been
adapted for use in NASGRO. The graphical user interface (GUI) developed by ESA was
replaced by a new GUI which is based on wxWindows to facilitate portability across
platforms. Future enhancements will include the implementation of the more general
spectrum definition formats available in the crack growth module of NASGRO. The
material database provided by ESA, originally published in the MIL-HDBK, was
incorporated into the software with minimal changes. One of the reasons for incorporating
this somewhat outdated method is to provide the users with the ability to use this extensive
database of available fatigue properties.
The strain-life approach is more general and is suitable for both high-cycle and lowcycle fatigue analyses. It was initially developed for low-cycle applications such as nuclear
reactors, jet engines and helicopters. This method is more appropriate when notch-root
plasticity is significant. It allows proper modeling of the local strain and local mean stress
using schemes such as Neubers rule. The cyclic stress-strain behavior is used to model the
fatigue mechanism accurately. Either the Ramberg-Osgood fit or tabular data can be used to
model the stress-strain relation. The strain life data can also be either fitted to an equation
with various mean-stress corrections or used directly in tabular form. The method is welldocumented in literature. Some details are provided in this document. The core of the
software was originally developed by the University of Dayton Research Insititute for the
NASA Johnson Space Center under the name FORMS98. Their PC-specific GUI has been
replaced with a new GUI using wxWindows. The material database files supplied by them
have been consolidated and reformatted to suit the new GUI. Material data has been
organized into two categories, viz., constants fitted to Ramberg-Osgood and strain-life
equations and tabular data. Screening and verification of this data is an ongoing activity.
As in the case of the stress-life method, the spectrum definition is currently restricted to a
single block. Future versions will share the more general definition of NASGRO using a
combination of blocks called schedule. Other aspects of fatigue such as multi-axial effects
will be addressed in future releases.
The GUI for NASFORM is designed such that the problem input is divided into three main
groups geometry, material and spectrum. The user can easily navigate between various
sections and see the input parameters. There are also help pages accessible from the dropdown menus that are context-sensitive. The complete documentation for NASGRO can also
be accessed from one of the menus. Once the input is complete, the information can be
saved to a project file and retrieved later. After completing the run, output is viewed in a
text window by clicking on a button. Future versions will include more user-friendly
features such as plotting the output and viewing material data curve fits. The capability to
generate a design curve and plotting it is also planned for future versions.
1.0 Introduction
Engineering components are often subjected to repeated loads during their service life. The
failure of metals due to repeated loading is known as fatigue failure. The term fatigue was
introduced by Poncelet in 1839. Pioneering study of fatigue was performed by Albert (1829)
and Wohler (1871). Wohler conducted rotating bending tests to study fatigue in railroad
axles and plotted the alternating stress vs cycles (S-N) to failure. He found that below a
certain level of alternating stress, the life of the specimen was very long for certain
materials. This stress below which life is practically unlimited is called the endurance limit.
Later Baushinger (1903) discovered the effects of cyclic loading on metals and the presence
of hysteresis loop. Coffin and Manson (1955) developed the modern strain-life method
better suited to low-cycle fatigue analysis. If the stress levels are generally low and elastic
conditions dominate, the number of cycles to failure is high (millions) and the process is
termed high-cycle fatigue. On the other hand if the load levels are relatively high and the
life is below a few thousands of cycles, it is termed low-cycle fatigue. It is now recognized
that the to and fro slip between crystal planes due to local plastic deformation at locations of
stress concentration is the primary mechanism of fatigue failure. This means that even if the
nominal (remote) stress is elastic, there needs to be at least a small amount of local plasticity
for fatigue damage to progress.
This manual describes the methods of fatigue crack formation analysis. The two main
options available in the material input section of the NASFORM module are: stress-life and
strain-life. For general background on the topic of fatigue of metals, the textbook by
Dowling [1] and the monograph by Mitchell [2] are recommended. The stress-life
correlation is primarily applicable to situations of high-cycle fatigue where the effects of
notch-root plasticity are not significant. In this method, the sequence effects of a random
load spectrum cannot be modeled accurately. The method used here is based on the
formulation given in MIL-HDBK [3]. Section 2 gives more details of the theory and
operation of this method. The FORTRAN code using the stress-life approach was originally
developed by the European Space Agency (ESA) [4] with the name ESAFATIG.
The strain-life approach is more general and is suitable for both high-cycle and low-cycle
fatigue analysis. It was initially developed for low-cycle applications such as nuclear
reactors, jet engines and helicopters. This method is especially useful when notch-root
plasticity is significant. It allows proper modeling of the local strain and mean stress using
schemes such as Neubers rule. The cyclic stress-strain behavior is used to model the
fatigue mechanism accurately. Either the Ramberg-Osgood fit or tabular data can be used to
model the cyclic stress-strain relation. The strain-life data can also be either fitted to an
equation with various mean-stress corrections or used directly in tabular form. The method
is well documented in literature [1, 2]. Section 3 gives more details of the theory and
operation of this method.
2.0 Stress-Life Method

2.1 Theoretical Background
This section provides the theoretical background for the stress-life equations used in
NASFORM. A comprehensive treatment of fatigue analysis and the underlying theory may
be found in [1, 2]. The MIL-HDBK [3] gives an empirical equation fitted to stress-life data
as follows:
log N f A B log( S eq C )
(2.1)
where the equivalent stress is given by
S eq S max (1 R) P
with the usual definition of stress ratio
(2.2)
R S min / S max
(2.3)
with S min, S max being the minimum and maximum stresses in a particular step of the spectrum
block. The constants A, B, C, P are provided in the database. In addition, another constant
L is used to define the equivalent stress below which life becomes greater than 108 cycles.
Any stress below the value of L is assumed to cause no damage. For each of the materials,
the values of Rmin and Rmax are also specified along with the above fitting constants. If the
applied stress ratio for a step is not within the valid range, a warning is printed in the output.
The material database was compiled using [3, 5, 6]. Figs. 1 and 2 show the S-N curves for
the 4130 steel.
When other components of loading such as bending and pin load are present, the values of
S min, S max are defined as summation of the components as follows:
S min S 0 min S1min S 2 min S 3 min
(2.4)
S max S 0 max S1max S 2 max S 3 max
(2.5)
In the above equations, S 0 , S1 , S 2 , S 3 represent tension, bending across thickness, bending
across width and pin loading respectively.
The cumulative damage due to a block of spectrum loading is computed using the PalmgrenMiner rule for linear damage summation:
n
D i
(2.6)
N fi
where ni is the applied number of cycles and N fi is the number of cycles to failure for the
current step as per eqn (2.1), and the subscript i denotes the step number in the block.
Thus, the life of a component in number of blocks is given by
Life in blocks
1
D
(2.7)
S-N Curve fit: 4130 Steel

5000
4500
4000
S-N curve fit

Curve Parameters
P = 0.88
A = 9.625
B = 2.01
C = 422.6
L = 422.6
3500
3000
2500
2000
1500
1000
500
0
1
10
100
1000
10000 100000 1e+006 1e+007 1e+008
Life in Cycles, Nf
Fig. 1 A typical S-N Curve
S-N Curve fit: 4130 Steel

5000
R = -1
R = 0.0
R = 0.2
Curve Parameters
P = 0.88
A = 9.625
B = 2.01
C = 422.6
L = 422.6
4500
4000
3500
3000
2500
2000
1500
1000
500
0
1
10
100
1000
10000 100000 1e+006 1e+007 1e+008
Life in Cycles, Nf
Fig. 2 Dependence of the S-N Curve on stress ratio
2.2 Details of Analysis

The analysis requires three groups of data input as follows:
A. Geometry: Enter the stress notch factor K f on the Title page. The value of
K f is used in the analysis by directly multiplying the equivalent stress S eq by K f .
The user should choose this value carefully, considering whether the material data
already incorporates the effect of the notch. If so, the value should be 1.0.
B. Material data
Choose Stress-life (S-N) data from the list of materials presented by the three
drop-down boxes. Once the properties are filled into the text boxes, the
values can be changed as desired. It should be noted that these updated
values are printed in the output, not the original database values. The radio
box for selecting the units of analysis is set to US units by default. Clicking
on this radio box automatically loads and converts the material properties as
needed.
C. Load or stress history: Select the block file name after choosing one of the
following format options:
Block Format Options:
1. Peak-valley sequence
2. Max, Min, Cycles
3. NASGRO format
Details of the formats for each of the above options are given in Appendix
D. A scale factor can be entered to control the magnitude of loads. Note that
the units of scaled stress spectrum should be either in ksi or MPa depending
on the choice made using the radio box for selection of units on the material
tab.
After entering the required data, clicking on the Run button starts the computations. The
cursor is displayed as an hour-glass while the program is executing. Once the run is
completed, a message pops up and the output can then be viewed using the View output
button. If desired, the run can be aborted by clicking on the Stop button. The input can be
saved in a named project file and retrieved and edited as desired. In case there is an error
during execution, viewing the xxx.screen file from the help menu usually gives a clue to
the source of the error. The input file to the computation core (xxx.sdat) may also be viewed
from the help menu.
When formats 1 and 2 are used, only tension loading can be applied. When format 3 is used,
the user can specify tension, bending 1, bending 2 and pin load. In this case, the equivalent
stress is computed by adding these four load components as shown in eqns 2.4, 2.5.
3.0 Strain-Life Method

3.1 Theoretical Background
This section provides the theoretical background of the equations used in the strain-life
option of NASFORM. Most of this material has been taken from references [1, 2, 7].
3.1.1 Stress-Strain Relationships
Under monotonic loading, the stress-strain relationship can be typically expressed as:
n

(3.1)
E K
where the first term represents the elastic portion and the second term represents the plastic
portion of strain. This empirical relation was first developed by Ramberg and Osgood in
1943. In this relation, E is the elastic modulus, K is the monotonic strength coefficient and n
is the strain hardening exponent.
When a material is cycled through a given strain range, after certain number of cycles, it
goes through a stable hysteresis loop and the loops thus generated at different strain ranges
can be characterized by a single cyclic stress-strain curve. This curve passes through the tips
of each of the hysteresis loops. The cyclic stress-strain relation for many metals can also be
characterized by the Ramberg-Osgood relation:
1
n'

(3.2)

E K'
where K is the cyclic strength coefficient and n is the cyclic strain hardening exponent.
Fig. 3 shows a typical fit to Ramberg-Osgood equation for RQC-100 steel.
Ramberg-Osgood fit: RQC-100 Steel

1400
1200
Stress(Mpa)
1000
800
Curve fit
Curve Parameters
E = 207008.
Kp = 1434.
np = 0.14
600
400
200
0
0
0.02
0.04
0.06
0.08
0.1
Strain
Fig. 3 Stress-Strain Curve fit for RQC-100 using Ramberg-Osgood method.

For use with Neubers rule for computing local strain, the following relation describes the
hysteresis loop(Massings hypothesis):
1
n'

2
2K'
E
where the sign denotes the range of stress or strain.
(3.3)
Alternately, the stress-strain relation can be described by means of tabulated Cyclic and
Hysteresis Stress-Strain Data.
For some materials, the constants K and n were not available in the original database. In
such cases, Morrows equations were used to compute them from the fatigue ductility
properties. The following are Morrows equations:
n b / c
(3.4)
(3.5)
K f /( f ) n
These computations are done at the time of loading the properties into their respective
boxes.
10
3.1.2 Strain Conversion Methods

This sub section deals with methods used to convert the remote loading to local strain near a
notch root. The goal is to compute the local strain from the remote applied nominal stress
and the elastic stress concentration factor at the notch root. Various formulations are in use
and they are listed below:
Neubers Rule: The geometric mean of the stress and strain concentration factors is equal to
the elastic stress concentration factor. The following relations define the Neubers rule:
E
2
K t K K
2
(3.6)
S e
S
which by using (3.2) leads to
1
K t S 2 n'
(3.7)

E K'
E
and the hysteresis form of the same is

1
K t S 2 2 n'
(3.8)
E
E
2K '
Once the stress range is solved from eqn (3.8) by using an iterative method, the strain range
can be solved from eqn (3.3).
There are three other relations used to convert nominal stress to local strain as follows:
Seeger & Heuler:
1
1
n'
n'
S
S
Kt S

E K'
E K'
the hysteresis form is

1
1
n'
n'
K t S
2
2

E
2
K
'
E
2
K
'
(3.9)
(3.10)
Molskis Strain Energy Method:
K t S 2
E
2 n '

E (n'1) K '
K t S 2
(3.11)
1
2 4 n '
E
(n'1) 2 K '
Glinkas Strain Energy Method:
(3.12)
11
K t S 2
K t2 S S n ' 2
n'

2E
(n'1) K '
2 E (n'1) K '
K t S 2
8E
(3.13)
1
K t2 S S n ' 2
n '
2(n'1) 2 K '
8E 2(n'1) 2 K '
(3.14)
The above nonlinear equations are solved by iterative methods and the local stress and strain
can be determined. Typically, the nominal stress history which is directly proportional to the
applied load is converted to the local strain history and rainflow cycle counting is used to
count the strain cycles. These strain cycles are then used in computing the fatigue damage
using the principles described in the next section.
3.1.3 Strain-Life Equations

In this approach, the plastic deformation near a notch-root is the life-governing parameter.
This method was originally developed in the 1950s and 60s to deal with low-cycle fatigue
applications such as nuclear reactors and jet engines. The method was also successfully
applied in the automotive and aircraft industries.
A strain versus life curve is a plot of strain amplitude versus life cycles to failure. Typically,
fully reversed loading (R = -1) is used in tests. The following equations are empirical fits to
test data that describe the relation between the local strain and the number of cycles to
failure. Some of these equations also take into account the effect of mean stress.
Coffin-Manson equation:
' f
b
c
2 N f ' f 2 N f
(3.15)
2
E
This equation which assumes zero mean stress, is illustrated in Fig. 4 below:
12
Strain-Life Curve fit: RQC-100 Steel

0.1
Elastic
Plastic
Total
Curve Parameters
E = 30023.
fs = 180.
b = -0.07
fd = 0.66
c = -0.6
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
1
10
100
1000
10000 100000 1e+006 1e+007 1e+008
Life in Cycles, Nf
Fig. 4 Typical Strain-Life curve fit for RQC-100 Steel
Morrow
' f mean
b
c
2 N f ' f 2 N f
2
E
This equation is shown below for a few different values of mean stress.
(3.16)
13
Strain-Life Curve fit: RQC-100 Steel

0.1
Mean =-350 MPa
Mean = 0 MPa
Mean = 350 MPa
Mean = 700 MPa
Curve Parameters
E = 207008. MPa
fs = 1241. MPa
b = -0.07
fd = 0.66
c = -0.6
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
1
10
100
1000
10000 100000 1e+006 1e+007 1e+008
Life in Cycles, Nf
Fig. 5 Effect of mean stress on fatigue life using Morrow correction.
Manson-Halford
c
' mean b
' f mean
b
c
2 N f ' f f
2N f
2
E
' f
(3.17)
Smith-Watson-Topper
'f
2b
bc
max
2 N f 'f 'f 2 N f
2
E
The above equation assumes that life depends on the product max /2
2
Loopin(tabular method)
1

1 , for

2 equ 2 a A
1
0,
A
(3.18)
14
1

1 , for

2 equ 2 a A
1
0
A
(3.19)
3.1.4 Damage Accumulation Equations

The following are commonly used damage summation rules:
Palmgren-Miner
n
Ni 1
fi
(3.20)
Generalized Palmgren-Miner
ni
(3.21)
C
Nf
Non-linear Damage Rule

p
n
i 1, 0 p 1
Nf
(3.22)
Only the linear Palmgren-Miner rule is operational in the current version. The other two
will be implemented in future versions.
15
3.2 Details of Analysis

As in the case of Stress-Life approach, there are three major groups of input: geometry,
material and spectrum information.
A. Geometry: Enter the stress concentration factor K t on the Title page. The
value of K t is used in the strain conversion analysis as described by the equations in
3.1.2.
B. Material data
Cyclic/Hysteresis stress-strain data
Options:
1.
Tabular stress versus strain.
2. Constants E, K and n
Strain-life ( N ) data
Options:
1. Tabular a vs. Nf for several
values
2. Constants for the Coffin-Manson equation forms

a.
Coffin-Manson
b. Morrow
c. Manson-Halford
d. Smith-Watson-Topper
C. Load or stress history: Select the block file name after choosing one of the
following format options:
Block Format Options:
1. Peak-valley sequence
2. Max, Min, Cycles
3. NASGRO format
Details of the formats for each of the above options are given in Appendix
D. A scale factor can be entered to control the magnitude of loads. Note that
the units of scaled stress spectrum should be either in ksi or MPa depending
on the choice made using the radio box for selection of units on the material
tab.
After entering the required data, clicking on the Run button starts the computations. The
cursor is displayed as an hour-glass while the program is executing. Once the run is
completed, a message pops up and the output can then be viewed using the View output
button. If desired, the run can be aborted by clicking on the Stop button. The input can be
saved in a named project file and retrieved and edited as desired. In case there is an error
during execution, viewing the xxx.screen file from the help menu usually gives a clue to
the source of the error. The input file to the computation core(xxx.edat) may also be viewed
from the help menu.
16
Once the basic inputs as described above are collected, a broad outline of the internal
procedure is as follows:
1.
Component Analysis
ii. Component load (P) to nominal (net) stress (S) relation
iii. Elastic stress concentration factor (Kt) for hot spot
iv. Assemble pre-load value
v. Assemble Load transfer fraction
vi. Residual stress-strain value
2.
Convert nominal stress (S) to local stress and strain and cycle count to close
each strain hysteresis loop (Rainflow cycle count)
A. Convert each Si to ( , )i while tracking the , hysteresis ranges
B. Close Hysteresis Loop (count a cycle) when current strain range exceeds
previous strain range. Then return tracking to prior strain range origin.
Repeat A and B until all points in load history are paired to form a closed
cycle.
3.
Calculate Nf (fatigue damage = 1/Nf) for each closed cycle in the block.
4.
Calculate Life in blocks using Miners rule

a. Number of spectrum block repeats to crack formation = (1/Nfi)
17
Acknowledgements
This fatigue analysis module is a synthesis of the work of many individuals and
organizations. The core FORTRAN modules along with the material databases were mainly
based on the ESAFATIG and FORMS98 codes provided by the European Space Agency
and University of Dayton Research Institute. These were freely adapted for use with the
new GUI developed by the NASGRO team. Timely answers to questions related to these
original codes were provided by Gerben Sinnema of ATOS Group (ESA) and Dennis
Buchanan of UDRI. Their help is greatly appreciated.
The Federal Aviation Administration has provided partial financial support for this
project and the same is gratefully acknowledged.
18
References
1. Dowling, N.E., Mechanical Behavior of Materials, Prentice Hall, 1993.

2. Fundamentals of Modern Fatigue Analysis for Design, in Fatigue and Microstructure,
American Society of Materials, pp. 385-437, 1979.
3. Military Handbook Metallic Materials and Elements of Aerospace Vehicle Structures,
MIL-HDBK-5F, 1987 version with 1988 updates.
4. ESAFATIG Users manual, version 4.1, TOS-MCS/2000/41/ln, September 2000.
5. ESA/ESTEC Fracture and Fatigue Testing Test Report Fatigue Test of Threaded
Fasteners, WP2 W6 Part 1 screws, Revision B, September 1991, Estec contract no.
8520/NL/JG.
6. MBB ERNO Technical Note Fatigue Test Results for M5 Ti6Al4V and A286 Bolts,
Doc No. D2-IN-TN-297-GR, Issue 1 March 1990.
7. Buchanan, D.J., Tritsch, D.E., Development of a new Public-domain Fatigue Crack
Formation Life-Prediction Code (FORM), UDR-TR-1999-00029, University of Dayton
Research Institute, April 1999.
APPENDIX A List of Materials with Stress-Life Fitted data
c
c1 .
[a1]
[a2]
[a3]
[a4]
[a5]
[a6]
[b1]
[b2]
[b3]
*
c2 .
[a1]
[a2]
[a3]
[a4]
[a5]
[a6]
[a7]
[a8]
[a9]
[a10]
[a11]
[a12]
[a13]
[a14]
[a15]
*
c3 .
[a1]
[a2]
[a3]
[a4]
[a5]
[a6]
[a7]
[a8]
[a9]
[a10]
*
c4 .
[a1]
*
d
d1 .
[a1]
[a2]
[b1]
ultra high strength steels (code c)

4130
4130
4130
4130
4130
4130
4130
4130
4130
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
l,
l,
l,
l,
l,
l,
l,
l,
l,
Kt=1.0
Kt=1.0
Kt=1.5
Kt=2.0
Kt=4.0
Kt=5.0
Kt=1.0
Kt=2.0
Kt=4.0
sheet R=(-1.0;-1.0)
sheet R=(-0.6;0.02)
sheet R=(-1;0.0)
sheet R=(-1;0.2)
sheet R=(-1;0.4)
sheet R=(-1;0.5)
sheet, ftu=1240 MPa
sheet, ftu=1240 MPa
sheet, ftu=1240 MPa
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
steel,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
l,
Kt=1.0
Kt=3.3
Kt=1.0
Kt=3.3
Kt=1.0:
Kt=3.3
Kt=1.0:
Kt=3.3
Kt=1.0:
Kt=3.3
Kt=1.0
Kt=3.3
Kt=1.0
Kt=2.0
Kt=3.0
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
rolled
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
bar,
300M steel,
300M steel,
300M,steel
300M steel,
300M steel,
300M steel,
300M steel,
300M steel,
300M steel,
300M steel,
l,
t,
l,
l,
l,
l,
l,
l,
t,
l,
Kt=1.0
Kt=1.0
Kt=1.0
Kt-1.0
Kt=1.0
Kt=1.0
Kt=2.0
Kt=3.0
Kt=3.0
Kt=5.0
forged
forged
forged
forged
forged
forged
forged
forged
forged
forged
billet,
R=(-1;0.33)
billet,
R=(-1;0.2)
decarb. & shot peen., R=(-1;0.33)
& shot peen R=(-1;0.33)
& machin., R=(-1;0.33)
ch.milled, R=(-.33;0.33)
billet,
R=(-1;0.33)
billet,
R=(-1;0.33)
billet,
R=(-1;0.2)
billet,
R=(-1;0.33)
ftu=860 MPa R=(-1;0.0)

ftu=860 MPa R=(-1;0.0)
ftu=1030 MPa R=(-1;0.0)
ftu=1030 MPa R=(-1;0.0)
ftu=1030 MPa T=315C R=(-1;0.0)
ftu=1030 MPa T=315C R=(-1;0.0)
ftu=1030 MPa T=426C R=(-1;0.0)
ftu=1030 MPa T=426C R=(-1;0.0)
ftu=1030 MPa T=538C R=(-1;0.0)
ftu=1030 MPa T=538C R=(-1;0.0)
ftu=1380 MPa R=(-1;0.43)
ftu=1380 MPa R=(-1;0.74)
ftu=1790 MPa R=(-1;0.54)
ftu=1790 MPa R=(-1;0.54)
ftu=1790 MPa R=(-1;0.54)
9Ni-4Co-.30C, s & t, Kt=3.0 hand forged
R=(0.06;0.4)
stainless steels (code d)

A-286,
A-286,
A-286,
l, Kt=1.0, bar T=426C

l, Kt=3.4, bar T=426C
l, Kt=1.0, bar T=538C
R=(-1;0.0)
R=(-1;0.4)
R=(-1;0.66)
R=(-1;0.6)
R=(0.2;0.6)
R=(-1;0.48)
20
[b2]
[c1]
[d1]
[d2]
*
d2 .
[a1]
*
e
e1 .
[a1]
*
e2 .
[a1]
[a2]
[a3]
[a4]
[a5]
*
e3 .
[a1]
[a2]
[a3]
*
e4 .
[a1]
[a2]
[a3]
[a4]
[a5]
[a6]
*
e5 .
[a1]
[a2]
*
e6 .
[a1]
[a2]
[a3]
[a4]
[a5]
*
m
m1 .
[a1]
[a2]
[a3]
[a4]
[a5]
*
A-286, l, Kt=3.4, bar T=538C R=(-1;0.74)

A-286, l, Kt=1.0, bar T=677C R=(-1;0.2)
A-286, STA d=3/16" p:32/inch NAS-6703-12M screw R=(0.6;0.8)
A-286 M5, W. No. 1.4944.4 screw R=(0.04;0.65)
A2-80, M5, ISO 3506-1979 austenitic screw R=(0.6;0.8)
age hardening steels (code e)
15-5ph (h1025), l & t, Kt=3.0
17-4ph
17-4ph
17-4ph
17-4ph
17-4ph
(h900),
(h900),
(h900),
(h1025),
(h1100),
bar
R=(-1;0.9)
l, Kt=1.0 bar R=(-1;0.1)

l, Kt=3.0 bar R=(-1;0.1)
l, Kt=4.0 bar R=(-1;0.6)
l & t, Kt=3.0 bar R=(-1;0.5)
l, Kt=4.0 bar R=(-1;0.6)
ph13-8mo (h1000), l & t, Kt=1.0 forged bar R=(-1;0.1)

ph13-8mo (h1000), l & t, Kt=3.0 forged bar R=(-1;0.5)
ph13-8mo (h1000), l, Kt=1.0 hand forging R=(-1;0.1)
ph15-7mo
ph15-7mo
ph15-7mo
ph15-7mo
ph15-7mo
ph15-7mo
(th1050),
(th1050),
(th1050),
(th1050),
(th1050),
(th1050),
l,
l,
l,
l,
t,
t,
Kt=1.0
Kt=4.0
Kt=1.0
Kt=4.0
Kt=1.0
Kt=3.0
sheet
sheet
sheet,
sheet,
sheet,
sheet,
R=(-1;0.1)
R=(-1;0.5)
T=260C
R=(-1;0.0)
T=260C
R=(-1;0.5)
T=371C
R=(0.01;0.33)
T=538C
R=(0.01;0.33)
custom 450 (h900), l, Kt=3.0

custom 450 (h1050), l, Kt=3.0
bar
bar
R=(-1;0.5)
R=(-1;0.5)
custom
custom
custom
custom
custom
bar
bar
bar
bar
bar
R=(-1;-1)
R=(0.026;0.026)
R=(0.5;0.5)
R=(-1;0.5)
R=(-1;0.5)
455
455
455
455
455
(h950), l,
(h950), l,
(h950), l,
(h950), l,
(h1000), l,
aluminium alloys
2014-T6
2014-T6
2014-T6
2014-T6
2014-T6
al,
al,
al,
al,
al,
Kt=1.0
Kt=1.0
Kt=1.0
Kt=3.0
Kt=3.0
(code m)
l, Kt=1.0 various wrought R=(-1;0.06)

l, Kt=1.6 rolled bar
R=(-1;0.46)
l, Kt=2.4 rolled bar
R=(-1;0.74)
l, Kt=3.4 rolled & extruded bar
R=(-1;0.74)
l & s, Kt=2.4 hand forging R=(-1;-1)
21
m2 .
[a1]
[a2]
[a3]
[a4]
[a5]
[a6]
[a7]
[a8]
[a9]
*
m3 .
[a1]
[a2]
[a3]
[a4]
*
m4 .
[a1]
*
m5 .
[a1]
[a2]
[b1]
[b2]
[b3]
[b4]
[c1]
[c2]
[c3]
[d1]
[d2]
[e1]
[e2]
*
m6 .
[a1]
[a2]
[a3]
[a4]
[a5]
[b1]
[b2]
[b3]
*
m7 .
[a1]
[a2]
[a3]
[a4]
[a5]
[b1]
[b2]
*
m8 .
[a1]
[a2]
2024-T3
2024-T3
2024-T3
2024-T3
2024-T3
2024-T4
2024-T4
2024-T4
2024-T4
al,
al,
al,
al,
al,
al,
al,
al,
al,
2219-T851
2219-T851
2219-T851
2219-T851
l,
l,
l,
l,
l,
l,
l,
l,
l,
al,
al,
al,
al,
Kt=1.0
Kt=1.5
Kt=2.0
Kt=4.0
Kt=5.0
Kt=1.0
Kt=1.6
Kt=3.4
Kt=2.4
l,
l,
l,
l,
Kt=2.0
Kt=3.2
Kt=3.0
Kt=5.0
6061-T6 al, l, Kt=1.0

7050-T7351x,
7050-T7351x,
7050-T7451,
7050-T7451,
7050-T7451,
7050-T7451x,
7050-T7452,
7050-T7452,
7050-T7452,
7050-T74 ,
7050-T74 ,
7050-T7651x,
7050-T7651x,
l & t,
l & t,
l
,
t
,
l & t,
l
,
l
,
t & s,
l&t&s,
l
,
l
,
l & t,
l & t,
7075-T6,
7075-T6,
7075-T6,
7075-T6,
7075-T6,
7075-T6,
7075-T6,
7075-T6,
Kt=1.0
Kt=1.5
Kt=2.0
Kt=4.0
Kt=5.0
Kt=1.0
Kt=1.6
Kt=3.4
7049-T73,
7049-T73,
7049-T73,
7049-T73,
7049-T73,
7149-T73,
7149-T73,
l
l
l
l
l
l
l
l
,
,
,
,
,
,
,
,
l & t
s
l&t&s
l
l&t&s
t
t
,
,
,
,
,
,
,
bare sheet
bare sheet
bare sheet
bare sheet
bare sheet
var. wrought
rolled bar
var. wrought
rolled bar
plate
plate
plate
plate
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.7)
R=(-1;0.7)
R=(-1;0.5)
R=(-1;0.46)
R=(-1;0.74)
R=(-1;0.85)
R=(-1;0.75)
R=(-1;0.75)
R=(-1;0.75)
R=(-1;0.75)
various wrought
Kt=1.0
Kt=3.0
Kt=1.0
Kt=1.0
Kt=3.0
Kt=2.6
Kt=1.0
Kt=1.0
Kt=3.0
Kt=1.0
Kt=3.0
Kt=1.0
Kt=3.0
extruded
extruded
plate
plate
plate
extruded
hand forgings
hand forgings
hand forgings
die forgings
die forgings
extruded
extruded
bare sheet
bare sheet
bare sheet
bare sheet
bare sheet
various product
rolled bar
rolled bar
Kt=1.0
Kt=1.0
Kt=2.4
Kt=1.0
Kt=3.0
Kt=1.0
Kt=3.0
R=(-1;0.5)
R=(-1;0.1)
R=(-1;0.1)
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.5)
R=(-0.4;0.2)
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.5)
R=(0.0;0.0)
R=(-1;0.33)
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.4)
R=(-1;0.5)
R=(-1;0.5)
R=(-1;0.7)
R=(-1;0.7)
R=(-1;0.5)
R=(-1;0.74)
R=(-1;0.46)
die & hand forging

die forging
die forging
hand forging
hand forging
hand forging
hand forging
7475-T7351, l & t , Kt=1.0 plates

7475-T7351 & T7651, l & t , Kt=3.0
plates
R=(0.0;0.1)
R=(0.1;0.1)
R=(-0.4;0.1)
R=(0.0;0.1)
R=(0.0;0.1)
R=(-0.5;0.5)
R=(-0.5;0.5)
R=(-1;0.5)
R=(-1;0.5)
22
p
p1 .
[a1]
[b1]
[b2]
[b3]
[c1]
[c2]
[c3]
[c4]
[c5]
[c6]
[c7]
[c8]
[c9]
[d1]
*
p2 .
[a1]
[a2]
[b1]
[b1]
[c1]
[c2]
*
p3 .
[a1]
[a2]
[a3]
[a4]
[b1]
[b2]
[b3]
*
q
titanium alloys (code p)

Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
Ti-6Al-4V
,
,
,
,
,
,
,
,
,
,
,
,
,
,
l, Kt=2.43 annealed bar

R=(-1;0.7)
l, Kt=1.0 ann. extrusion
R=(0.01;0.01)
l, Kt=2.8 ann. extrusion
R=(-1;0.43)
l, Kt=2.8 ann. extrusion T=204C R=(-1;0.43)
l, Kt=1.0 sol.treat. aged sheet R=(-1;0.54)
l, Kt=2.8 sol.treat. aged sheet R=(-1;0.54)
l, Kt=1.0 sol.treat. aged T=204C R=(-1;0.54)
l, Kt=1.0 sol.treat. aged plate R=(-1;0.3)
t, Kt=1.0 sol.treat. aged plate R=(0.1;0.1)
l, Kt=3.0 sol.treat. aged plate R=(-1;0.3)
d=3/16" p:32/inch ABS 0114-12-P screw R=(0.6;0.8)
Ti-8Al-1Mo-1V,
Ti-8Al-1Mo-1V,
Ti-8Al-1Mo-1V,
Ti-8Al-1Mo-1V,
Ti-8Al-1Mo-1V,
Ti-8Al-1Mo-1V,
t,
t,
t,
t,
t,
t,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Ti-13V-11Cr-3Al,
Kt=1.0
Kt=2.6
Kt=1.0
Kt=2.6
Kt=1.0
Kt=2.6
l,
l,
l,
l,
l,
l,
l,
duplex annealed
duplex annealed
dup. ann. sheet
dup. ann. sheet
dup. ann. sheet
dup. ann. sheet
Kt=1.0
Kt=3.0
Kt=1.0
Kt=1.0
Kt=1.0
Kt=1.0
Kt=1.0
annealed sheet R=(-1;0.0)

annealed sheet R=(-1;0.0)
annealed sheet T=315C R=(-1;0.0)
annealed sheet T=426C R=(-1;0.0)
sol.treat. aged sh&pl R=(-1;0.0)
sol.treat. aged sh T=315C R=(-1;0.0)
sol.treat. aged sh T=426C R=(-1;0.0)
nickel base alloys

q1 .
[a1]
[a2]
[b1]
[b2]
[c1]
*
Inconel
Inconel
Inconel
Inconel
Inconel
718,
718,
718,
718,
718,
t,
t,
t,
t,
t,
Kt=1.0
Kt=3.0
Kt=1.0
Kt=3.0
Kt=3.0
sheet R=(-0.5;0.1)
sheet R=(-0.5;0.1)
T=204C R=(-0.5;0.1)
T=204C R=(-0.5;0.1)
T=343C R=(-0.5;0.1)
T=343C R=(-0.5;0.1)
(code q)
sheet
R=(-1;0.2)
sheet
R=(-1;0.2)
sheet T=538C R=(-1;0.6)
sheet T=538C R=(-1;0.82)
sheet T=760C R=(-1;0.6)
23
APPENDIX B List of Materials with Strain-Life Tabular data

C
Ultra high strength steels (code c)
c1 .
[a1]
4130 steel, sheet, loopin
*
c2 .
[a1]
4340 steel, sheet
[b1]
HYTUF UTS=246
*
c3 .
[a1]
300 M stell
*
c4 .
[a1]
HP9-4-.2C steel
[b1]
HP9-4-.3C steel
*
c5 .
[a1]
Unalloyed Steel, AF1410, UTS = 228 Ksi, Unknown
*
------------------------------------------------------e
Age-hardening steels (code e)
e1 .
[a1]
15-5 PH
*
e2 .
[a1]
MP-35N
*
e3 .
[a1]
PH13-8Mo
*
------------------------------------------------------m
Aluminum alloys
(code m)
m2 .
[a1]
2014-T6 Aluminum, sheet
[a2]
2024-T4
[a3]
2024-T851
[a4]
2219-T851
*
m7 .
[a1]
7049-T73511, sheet
[b1]
7050-T73651, sheet
[b2]
7050-T736511, sheet
[b3]
7050-T73651(ST), sheet
[c1]
7075-T6, sheet
[c2]
7075-T73511, sheet
[d1]
7175-T73652, sheet
[e1]
7475-T7351, sheet
[e2]
A 201.0-T7 Aluminum Casting
--------------------------------------------
24
Titanium alloys (code p)
p1
[a1]
Ti-6Al-4V alpha-beta, sheet, extr
[a2]
Ti-6Al-4V alpha-beta, Plate
[a3]
Ti-6Al-4V RAEL1 plt
[a4]
Ti-6Al-4V HIP casting
*
p2
[a1]
Ti-6Al-6V-2Sn alpha-beta, sheet
*
p3
[a1]
Ti-3Al-10V-2Fe beta, sheet
*
------------------------------------------q
Nickel base alloys
q1 [a1]
(code q)
Inconel 718, SAE, sheet, loopin
25
Appendix C- List of materials with Strain-Life fitted data

a
cast irons, cast steels (code a)
a1 . A 538 casti iron

[a1] Cast Irons - A 538-A
[a2] Cast Irons - A 538-B
[a3] Cast Irons - A 538-C
*
a2 . Cast 0030, 080, 090, 80-60
[a1] Cast steel 0030 Norm UTS 497
[a2] Cast steel 0030 Q&T UTS 483
[a3] Cast steel 0030 Q&T UTS 745
[b1] Cast steel 080 AsRecd UTS 637
[b2] Cast steel 080 Norm UTS 516
[c1] Cast steel 090 Q&T UTS 637
[d1] Cast Iron 80-60 As cast UTS 664
*
b
general steels (code b)
b1 .
1005-1009, 1015, 1020, 1035
[a1]
1005-1009 steel, UTS 359
[a2]
1005-1009 steel, UTS 469
[a3]
1005-1009 steel, UTS 414
[a4]
1005-1009 steel, UTS 345
[a5]
1005 steel, UTS 321
[a6]
1005 steel, UTS 355
[a7]
1005 steel, UTS 358
[a8]
1005 steel, UTS 322
[a9]
1006 steel, UTS 318
[a10]
1006 steel, UTS 318
[a11]
1006 steel, UTS 318
[a12]
1008 steel, UTS 363
[b1]
1015 steel, Normalized UTS
[b2]
[b3]
[c1]
1018 stell HR UTS 354
[c2]
[c3]
[d1]
[d2]
[d3]
1020 steel, Hot Rolled UTS
[e1]
[e2]
[f1]
[f2]
[g1]
[g2]
1035 steel, Q&T UTS 1605
[g3]
*
414(SAE)
415 (Dowling)
415 (Boardman)
441 (SAE)
392
441
547
566
454
454
476
26
b2
1040, 1045, 1080, 10B21, 10B22
[a1]
1040 steel, AS FORGED UTS 621(SAE)
[b1]
1045 steel, Q&T UTS 724(SAE)
[b2]
[b3]
[b4]
[b5]
[b6]
[b7]
1045 steel, HR & Normalized UTS 621(Dowling)
[b8]
1045 steel, ANN UTS 751(Boardman)
[b9]
1045 steel, HR UTS 671(Boardman)
[b10]
1045 steel, Q&T UTS 1956(Boardman)
[b11]
[b12]
[b13]
[b14]
[b15]
[c1]
[c2]
[c3]
[c4]
[c5]
[c6]
1080 steel, Aus UTS 1349(Boardman)
[c7]
[c8]
[d1]
10B21 steel, HR UTS 503(Boardman)
[d2]
10B21 steel, Q&T UTS 814(Boardman)
[d3]
[d4]
[d5]
[d6]
[d7]
[e1]
[e2]
*
b3 .
10B30, 10B62, Man-Ten, RQC
[a1]
10B30 Q&T UTS 1240
[a2]
10B30 Q&T UTS 1240
[b1]
10B62
[c1]
Man-Ten steel (Dowling)
[d1]
RQC steel (Dowling)
[d2]
RQC-100 steel, UTS 938 (SAE)
[d3]
RQC-100 steel, UTS 931 (SAE)
*
b4 .
1522, 1541, 15B27, 15B35
[a1]
1522 steel, HR UTS 1005
[a2]
[b1]
[c1]
[d1]
15B27 steel, HR UTS 916
[d2]
15B27 steel, HR UTS 1054
[e1]
15B35 steel, UTS 2073
[e2]
15B35 steel, Q&T UTS 1679
*
b5 . AM 350, 1144 , 1541F, HSLA H-11
[a1]
AM 350, UTS 1317
[a2]
AM 350, UTS 1903
27
[b1]
[b2]
[c1]
[c2]
[d1]
*
b6 .
[a1]
[a2]
[b1]
[b2]
[b3]
[c1]
*
c
Unalloyed
Unalloyed
Unalloyed
Unalloyed
HSLA H-11
1144, UTS 931

1144, UTS 1304
1541F, UTS 951
1541F, UTS 889
A36, DQSK, P&O

A 36, HR UTS 413
A 36, Weld Haz UTS 666
DQSK steel, HR UTS 319
P&O steel, HR UTS 331
ultra high strength steels (code c)
c1 . 4130 , 4142
[a1]
[a2]
[a3]
4130 steel, Q&T UTS 895 (SAE)
[a4]
4130 steel, Q&T UTS 1426 (SAE)
[b1]
4140 HSLA steel, Q&T UTS 1076
[c1]
4142 HSLA steel,As Q UTS 2450 (Dowling)
[c2]
4142 HSLA steel, Q&T UTS 2240 (Dowling)
[c3]
[c4]
[c5]
4142 HSLA steel, Drawn, UTS 1062
[c6]
4142 HSLA steel, Drawn, UTS 1248
[c7]
[c8]
[c9]
[c10]
[c11]
4142 HSLA steel, Q&T Deformed UTS 1931
[c12]
[c13]
4142 HSLA steel, As Quenched UTS 2448
[c14]
[c15]
4142 HSLA steel, Q&T UTS 1412 (SAE)
[c16]
[c17]
[c18]
[c19]
[c20]
[c21]
[c22]
*
c2 . 4340 , 5160, 52100, 9262, 950, 950X, 960X, 980X
[a1]
4340 steel, UTS 1172 (Dowling)
[a2]
4340 steel, UTS 1468 (Dowling)
[a3]
4340 steel, UTS 827 (SAE)
[a4]
[a5]
[a6]
4340 steel, UTS 826 (Boardman)
[a7]
[a8]
[a9]
[a10]
[b1]
Ausformed U-HSLA H-11, UTS 2580
28
[c1] HSLA steel 5160 Q&T UTS 1669

[c2] HSLA steel 5160 Q&T UTS 1584(Boardman)
[c3] HSLA steel 52100 Q&T UTS 2013
[c4] HSLA steel 52100 Q&T UTS 2011(Boardman)
[d1] HSLA 8630 UTS 785 (Boardman)
[e1] HSLA 8640 UTS 1373 (Boardman)
[f1] HSLA steel 9262 - ANN UTS 924
[f2] HSLA steel 9262 - Q&T UTS 1000
[f3] HSLA steel 9262 - Q&T UTS 1565
[f4] HSLA steel 9262 - Q&T UTS 923(Boardman)
[f5] HSLA steel 9262 - Q&T UTS 999(Boardman)
[g1] HSLA 950 - Plt UTS 556
[h1] HSLA 950C - Plt UTS 565
[h2] HSLA 950C - Bar UTS 565
[i1] HSLA 950X - UTS 441
[i2] HSLA 950X - UTS 531
[i3] HSLA 950X - UTS 441(Boardman)
[i13] HSLA 950X - Sht L(Boardman)
[j1] HSLA 960X - UTS 480(Boardman)
[k1] HSLA 980X - UTS 696
[k2] HSLA 980X - UTS 692(Boardman)
29

[l1] HSLA Q&T UTS 1319
*
m
m1 .
[a1]
[a2]
*
m2 .
[a1]
[a2]
[a3]
[b1]
[b2]
[b3]
[c1]
[c2]
[c3]
[c4]
[d1]
*
m5 .
[a1]
[b1]
[b2]
[c1]
[c2]
[c3]
[d1]
[d2]
*
aluminium alloys
(code m)
1100
1100 Al, UTS 110 (ASM)
1100 Al, UTS 110 (SAE)
2014, 2024, 2219
2014-T6 al, UTS 510(ASM)
2014-T6 al, UTS 538
2014-T6 al, UTS 510(SAE)
2024-T351 al, UTS 476
2024-T351 al, UTS 455
2024-T351 , URS 469 (SAE)
2024-T4 al, UTS 469, T
2024-T4 al, UTS 469, C
2024-T4 al, UTS 476
2024-T4 al, UTS 476 (SAE)
2219-T851 al, UTS 469
5000 series
5086-F al, UTS 310
5182 al, UTS 303
5182 al, UTS 338
5454 al, 10% CR
5454 al, 20% CR
5454 al, 20% CR
5456-H311 al, UTS 400 (ASM)
5456-H311 al, UTS 400 (SAE)
30
m6 .
[a1]
*
m7 .
[c1]
[c2]
[c3]
[d1]
*
p
6061
6061-T651 al, UTS 310
7075
7075-T6, UTS 579 (ASM)
7075-T6, UTS 578 (Dowling)
7075-T6, UTS 579 (SAE)
7075-T73, UTS 483
titanium alloys (code p)
p1 . 6Al-4V Titanium
[a1]
Ti-6Al-4V , UTS 1233
*
q
nickel base alloys (code q)
q1
[a1]
*
Inconel 718
Inconel 718, X-Ni, UTS 1213
31
APPENDIX D Load Spectrum Block Formats

There are three options for the format of the spectrum block.
1. Peak-Valley format:
A title line followed by peak, valley values as shown below:
peak valley format
250.00
350.00
250.00
350.00
250.00
350.00
250.00
350.00
180.38
292.38
2. Max, Min, Cycles format:

A title line followed by max, min, cycles values as shown below:
max min cycle format
36.92
88.07
48.98
76.02
50.83
74.18
5.27
68.42
11.08
98.93
26.73
83.28
49.33
60.68
399.0
399.0
399.0
3050.
2.0
2.0
2.0
3. NASGRO format
A title line followed by cycles, 4 pairs of ( max, min ) values as shown below:
nasgro format
4.000
250.00 350.00
00.00 100.00
8.000
180.38 292.38 -80.38
92.38
9.000
37.17 249.17 -37.17
49.17
9.000
-36.63
48.63 -36.63
48.63
16.00
-12.67 103.07 -12.67 103.07
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

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Fatigue Crack Formation Analysis

NASGRO 7.0 Alpha

Appendix A List of Materials with Stress-Life Fitted Data .............................................. A-1

Amplitude Ratio in Loopin tabular method

Ultimate tensile strength

True fracture strength

Percent reduction in area

Monotonic strain hardening exponent

Cyclic strength coefficient

Fatigue strength exponent

Fatigue ductility exponent

Stress concentration factor

Fatigue Notch factor

Equivalent stress in S-N equation

Remote peak stress (from spectrum)

Remote valley stress (from spectrum)

Remote stress range (from spectrum)

Local (notch) stress

Local peak stress (at notch)

Local valley stress (at notch)

Local stress range (at notch)

Local (notch) strain

Local peak strain (at notch)

Local valley strain (at notch)

Local strain range (at notch)

Local strain amplitude (at notch)

No. of reversals to failure at given stress range

No. of applied cycles in the ith step of a block

No. of cycles to failure for the ith step in a block

ROL-Q&T.............................. Rolled and Q&T

2.0 Stress-Life Method

where the equivalent stress is given by

S max S 0 max S1max S 2 max S 3 max

S-N Curve fit: 4130 Steel

S-N curve fit

Fig. 1 A typical S-N Curve

S-N Curve fit: 4130 Steel

Fig. 2 Dependence of the S-N Curve on stress ratio

2.2 Details of Analysis

3.0 Strain-Life Method

Ramberg-Osgood fit: RQC-100 Steel

Fig. 3 Stress-Strain Curve fit for RQC-100 using Ramberg-Osgood method.

3.1.2 Strain Conversion Methods

and the hysteresis form of the same is

the hysteresis form is

Molskis Strain Energy Method:

Glinkas Strain Energy Method:

3.1.3 Strain-Life Equations

Strain-Life Curve fit: RQC-100 Steel

Fig. 4 Typical Strain-Life curve fit for RQC-100 Steel

Strain-Life Curve fit: RQC-100 Steel

Fig. 5 Effect of mean stress on fatigue life using Morrow correction.

3.1.4 Damage Accumulation Equations

Non-linear Damage Rule

3.2 Details of Analysis

2. Constants for the Coffin-Manson equation forms

Calculate Life in blocks using Miners rule

1. Dowling, N.E., Mechanical Behavior of Materials, Prentice Hall, 1993.

APPENDIX A List of Materials with Stress-Life Fitted data

ultra high strength steels (code c)

ftu=860 MPa R=(-1;0.0)

9Ni-4Co-.30C, s & t, Kt=3.0 hand forged

stainless steels (code d)

l, Kt=1.0, bar T=426C