Fatigue Crack Propagation

Fatigue Crack Growth

Once a crack is present in a material, it will
tend to grow under the influence of cyclic
loading.
The crack may be initiated by fatigue, or
may be pre-existing from manufacture, or
may be caused by an impact, or similar
event (e.g., a thermal shock.)
The crack will grow to a critical length then
fracture of the component will occur.
Driving Force for Crack Growth
The driving force for crack growth is the
range in the stress intensity factor during
cycling.
0 R for
0 R for
a (a/W) K
< =
> =
=
max
min max
f
o o A
o o o A
t o A A
Cyclic Loading
o
mean
=
o
max
+o
min
2
o
range
= o
max
o
min
o
amplitude
=
o
max
o
min
2
StressRatio, R =
o
min
o
max
Rotating Machinery
Airframes, Bridges, Tanks, etc,
Crack Growth Rate, da/dN
X
X
C
r
a
c
k

L
e
n
g
t
h
,

a

Cycles, N
a
o

a
c2

Ao
2
Ao
1
Ao
1
<

Ao
2
a
c1

da/dN
2

da/dN
1

Paris Law
Paris Region
Stable Growth
T
h
r
e
s
h
o
l
d

R
e
g
i
o
n

S
l
o
w

G
r
o
w
t
h

F
a
s
t

F
r
a
c
t
u
r
e


R
e
g
i
o
n

R
a
p
i
d
-
u
n
s
t
a
b
l
e


G
r
o
w
t
h

log(AK)
l
o
g
(
d
a
/
d
N
)

da
dN
= A(AK)
m
A
m
Crack Growth Rates and
Microstructural Features
Fractographic Evidence of Crack Growth
fatigue
striations
10 m
Fatigue Striations in Al-alloy:
5 small cycles between overloads
Crack Growth
direction
No Load
Loaded
Max Load
Load reduced
No Load
Loaded again
Slip
Crack Growth Mechanisms
Model for
Crack Growth
4
1
2
5
6
7
Crack Propagation Life, N
p

Total fatigue life is the sum of the crack initiation life and the
crack propagation (growth) life.
p i f
N N N + =
For some components, where stress levels are high and/or the critical
crack size is small, the crack propagation life is neglected in design.
For other structures, including pressure vessels, ship structures,
transport aircraft, etc. the crack growth life may be a substantial
component of total life.
N
p
=
da
A(AK)
m
a
o
a
c
}
Limits of Integration
The initial crack length, a
o
, is usually either
found by inspection or a reasonable minimum
size of crack is assumed for the analysis.

The critical crack size is found from:



Where o
max
is the maximum stress.
(its not the stress range)
2
c
c
(a/W)
K 1
a
|
|
.
|

\
|
=
max
f o t
Procedure for Constant Amplitude
Crack Growth life Calculation
Obtain appropriate crack growth rate data
for material, environment and stress ratio
Determine starting crack size, a
o

Determine critical crack size, a
c

Determine AK for starting crack size, a
o
. If

AK< AK
th
then crack will not grow
If

AK> AK
th
then integrate to get crack
growth life. (Can conservatively use Paris
Law, if appropriate)

General Paris Law Solution for N
p

c
o
a
a
m
p
a (a/W) A
da
N
) f t o A
(
(

=
c o
3 3 2 3
p
a
1
a
1
Y A
2
N
) (
/
o A t
Special Case: m=3; f(a/W) constant=Y
General Solution:
A more general solution will include the
actual growth rate data in the threshold and
near-threshold region.
If the starting crack size is relatively small,
this will represent a major portion of growth
life, so it may be un-economical to neglect it.
The life in the fast fracture region is
generally neglected. Use this data carefully.
Try it!
A fatigue crack 1.5 mm long has been discovered in a
main wing spar of a CC-130 Hercules undergoing
structural tear down and inspection. Given the loading,
material and geometry shown, estimate the number of
flying hours to fracture, and comment on the results.
7075-T73511 al alloy
K
c
(6mm) = 40 MPa\m

S
y
= 455 MPa
A = 1.3x10
-10
m/cycle
m = 3
Y = 1.27 (assume constant)
AS
Section A-A Through Spar (inches)
Crack
a
Loading
time
100 cycles=1 flying hour
75
10
S
t
r
e
s
s

(
M
P
a
)

0
133 0
75
10
. R = =
OK...
a
o
= 1.5 mm, find a
o

(56.1mm) 0.0561m
75 27 1
40 1
YS
K 1
a
2
2
c
c
=
|
|
.
|

\
|
=
|
|
.
|

\
|
=
) ( .
max
t t
=
c
o
a
a
m
p
a Y A
da
N
) ( t o A
Stress Range, Ao = o
max
-o
min
= (75 - 10) MPa = 65 MPa
For m=3, Y constant:
hrs flight 1060
cycles 100
hr 1
cycles 106000
cycles 106000
1 056 0
1
0015 0
1
27 1 65 10 x 3 1
2
N
a
1
a
1
Y A
2
N
3 3 2 3 10
p
c o
3 3 2 3
p
= =
=
(

=
(
(

. .
) . ( ) ( .
) (
/
/
t
o A t
Crack Growth Curve
5 mm at half life!
a/ac =15%
95000 cycles
at half length!
N/Np =89%
Comments & Observations
There is a substantial period of crack
growth for this component. The fatigue
crack can be monitored, inspected, and the
component can be replaced or repaired after
500 more hours of operation.

Half-life (factor of safety on life) is a safer
criterion than length, because cracks grow
too rapidly as they become longer.