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Fatigue - Review
Fatigue crack initiation and propagation
Fatigue fracture mechanics
Fatigue fractography
Crack propagation rate
Example
Factors affecting fatigue
- Design factors
- Surface effects
- Environmental effects
low
high
Dr. M. Medraj
Nf = Ni + Np
Ni is the number of cycles to initiate fracture
Np is the number of cycles to propagate to
failure
high cycle fatigue ( stress levels):
most of the life is spent in crack initiation
and Ni is high
low cycle fatigue (.. stress levels):
propagation step predominates and Np>Ni
Dr. M. Medraj
Fatigue life:
Fracture Mechanisms
Three steps:
..
..
final failure (when area decreases
sufficiently)
stage I propagation
crack tends to grow initially along
crystallographic planes of high shear stress:
high stresses and notches tend to shorten this
stage.
It may only propagate over a few grains.
Length of stage I is controlled by presence of
stress raisers such as:
.
.
.
stage II - crack growth rate increases
(perpendicular to tensile stress direction)
Dr. M. Medraj
Fractography of Fatigue
Fracture Mechanisms
Fatigue crack propagation mechanism (stage II) by repetitive crack tip plastic
blunting and sharpening;
Double notch at crack tip,
extends along shear planes
zero tensile load or
maximum comp. load
Final failure
Dr. M. Medraj
Fractography of Fatigue
Fractography of Fatigue
Dr. M. Medraj
Fractography of Fatigue
Dr. M. Medraj
crack length
da
= A( K ) m
dN
and then taking logs of both sides :
da
log
= m log K + log A
dN
gives straight line of slope m
and intercept, logA
Dr. M. Medraj
Dr. M. Medraj
Example
dN =
ac
a0
da
A(Y a )
1
( ) m
m2
Y
ac
a0
da
am 2
this results when assuming that K and are constant (which often are not)
Also ignores the time needed to initiate the crack.
This analysis is only an estimate.
Mech. Eng. Dept. - Concordia University
Dr. M. Medraj
Dr. M. Medraj
Design Factors
component design is important
notches or stress raisers act as
crack initiation sites for fatigue:
grooves, scratches, keyways,
threads, corrosion pits etc.
concentration
in stress reversal, m= 0
Surface Effects
Dr. M. Medraj
Surface Treatments
Surface Treatments
Case Hardening:
Surface hardening through
carburizing or nitriding increases
surface strength and hardness
iron carbide or nitrides (hard)
form in the surface layer to
~1mm depth or greater
increase in hardness increases the
resistance to fatigue.
compressive stress in case
hardening also generated due to
difference in volume of case layer
Environmental Effects
Environmental Effects
Thermal Fatigue
created at high temperature by fluctuating thermal stresses (t )
restraint in thermal expansion/contraction during uneven
heating/cooling
t = E l T
l is the linear thermal expansion coefficient
E is the modulus of elasticity
T is the temperature difference, l T is the thermal strain t
Dr. M. Medraj
Dr. M. Medraj
Corrosion Fatigue
simultaneous effect of cyclic stress and chemical attack
formation of pits leading to stress concentration on surface and
nucleation of fatigue cracks
corrosion can enhance crack growth rate
prevention is by:
protective coatings (painting, galvanizing)
selection of more corrosion resistant material
reducing the corrosive environment
Dr. M. Medraj
Next time:
Creep
Dr. M. Medraj