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Objective
Crack Microstructure-Properties: II
Initiation
S-N Fatigue
curves
Cyclic 27-302
stress-strn
Crack Lecture 9
Propagate
Fall, 2002
Microstr.
effects Prof. A. D. Rollett
Design
2
Materials Tetrahedron
Processing
Performance
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
Microstructure Properties
effects
Design
3
Objective
• The objective of this lecture is to explain the
phenomenon of fatigue and also to show how
Objective
resistance to fatigue failure depends on
Crack
Initiation microstructure.
S-N • For 27-302, Fall 2002: this slide set contains
curves
Cyclic
more material than can be covered in the time
stress-strn available. Slides that contain material over
Crack
Propagate
and above that expected for this course are
Microstr. marked “*”.
effects
Design
4
References
• Mechanical Behavior of Materials (2000), T. H.
Courtney, McGraw-Hill, Boston.
Objective • Phase transformations in metals and alloys, D.A.
Crack Porter, & K.E. Easterling, Chapman & Hall.
Initiation
• Materials Principles & Practice, Butterworth
S-N
curves Heinemann, Edited by C. Newey & G. Weaver.
Cyclic • Mechanical Metallurgy, McGrawHill, G.E. Dieter, 3rd
stress-strn Ed.
Crack
Propagate • Light Alloys (1996), I.J. Polmear, Wiley, 3rd Ed.
Microstr. • Hull, D. and D. J. Bacon (1984). Introduction to
effects Dislocations. Oxford, UK, Pergamon.
Design
5
a := Alternating stress
m := Mean stress Notation
R := Stress ratio
:= strain
Nf := number of cycles to failure
A := Amplitude ratio
Objective ∆pl := Plastic strain amplitude
Crack ∆el := Elastic strain amplitude
Initiation K’ := Proportionality constant, cyclic stress-strain
n’ := Exponent in cyclic stress-strain
S-N
curves
c := Exponent in Coffin-Manson Eq.;
also, crack length
Cyclic E := Young’s modulus
stress-strn
b := exponent in Basquin Eq.
Crack
Propagate m := exponent in Paris Law
K := Stress intensity
Microstr.
effects ∆K := Stress intensity amplitude
Design
a := crack length
6
Fatigue
• Fatigue is the name given to failure in response to
alternating loads (as opposed to monotonic
Objective straining).
Crack
• Instead of measuring the resistance to fatigue
Initiation
failure through an upper limit to strain (as in
S-N
curves ductility), the typical measure of fatigue resistance
Cyclic is expressed in terms of numbers of cycles to
stress-strn failure. For a given number of cycles (required in
Crack an application), sometimes the stress (that can be
Propagate
safely endured by the material) is specified.
Microstr.
effects
Design
7
S-N Curves
• S-N [stress-number of cycles to failure] curve defines
locus of cycles-to-failure for given cyclic stress.
Objective • Rotating-beam fatigue test is standard; also
Crack alternating tension-compression.
Initiation
• Plot stress versus the [Hertzberg]
S-N
curves log(number of cycles
Cyclic
to failure), log(Nf).
stress-strn [see next slide,
also Courtney figs. 12.8, 12.9]
Crack
Propagate • For frequencies < 200Hz,
Microstr. metals are insensitive to
effects frequency; fatigue life in
Design polymers is frequency
dependent.
10
S-N
mean 3 without failure.
curves log Nf
Cyclic
stress-strn Note the presence of a
Crack
Propagate fatigue limit in many
Microstr. steels and its absence
effects in aluminum alloys.
Design
[Dieter]
11
Endurance Limits
• Some materials exhibit endurance limits, i.e.
a stress below which the life is infinite: [fig. 12.8]
Objective – Steels typically show an endurance limit, = 40% of
Crack yield; this is typically associated with the presence
Initiation of a solute (carbon, nitrogen) that pines
S-N dislocations and prevents dislocation motion at
curves small displacements or strains (which is apparent
Cyclic in an upper yield point).
stress-strn
Crack
– Aluminum alloys do not show endurance limits;
Propagate this is related to the absence of dislocation-pinning
Microstr.
solutes.
effects • At large Nf, the lifetime is dominated by nucleation.
Design – Therefore strengthening the surface (shot peening) is
beneficial to delay crack nucleation and extend life.
12
Fatigue fracture
surface
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
[Hertzberg]
Design
13
Objective
Crack
Initiation
S-N [Dieter]
curves Stage 2
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
14
Slip steps
and the
Objective stress-strain
Crack
Initiation loop
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
18
Design Philosophy: Damage Tolerant
Design
• S-N (stress-cycles) curves = basic characterization.
• Old Design Philosophy = Infinite Life design: accept
Objective empirical information about fatigue life (S-N curves);
Crack apply a (large!) safety factor; retire components or
Initiation
assemblies at the pre-set life limit, e.g. Nf=107.
S-N
curves • *Crack Growth Rate characterization ->
Cyclic • *Modern Design Philosophy (Air Force, not Navy
stress-strn carriers!) = Damage Tolerant design: accept
Crack
Propagate presence of cracks in components. Determine life
Microstr.
based on prediction of crack growth rate.
effects
Design
19
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Dieter]
21
Mean Stress
• Alternating stress a = (max-min)/2.
• Raising the mean stress (m) decreases Nf. [see slide 19,
Objective also Courtney fig. 12.9]
Crack • Various relations between R = 0 limit and the ultimate
Initiation (or yield) stress are known as Soderberg (linear to
S-N yield stress), Goodman (linear to ultimate) and
curves
Gerber (parabolic to ultimate). [Courtney, fig. 12.10, problem
Cyclic 12.3]
stress-strn
Crack
Propagate
endurance limit at zero mean stress
Microstr. a
effects ⎛ σ mean ⎞
σ a = σ fat ⎜
⎜1 − ⎟⎟
Design ⎝ tensile strength ⎠
tensile strength
mean
22
Objective
Crack [Courtney]
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects • Large number of cycles typically needed to reach
Design asymptotic hysteresis loop (~100).
• Softening or hardening possible. [fig. 12.26]
24
Cyclic stress-strain
• Wavy-slip materials [Courtney]
generally reach asymptote
in cyclic stress-strain:
Objective planar slip materials (e.g.
Crack
brass) exhibit history
Initiation dependence.
• Cyclic stress-strain curve
S-N
curves defined by the extrema,
i.e. the “tips” of the
Cyclic hysteresis loops. [Courtney
stress-strn fig. 12.27]
Crack
• Cyclic stress-strain curves
Propagate
tend to lie below those for
Microstr. monotonic tensile tests.
effects
• Polymers tend to soften in
Design cyclic straining.
25
Strain control
of fatigue
Objective
Crack
Initiation
S-N [Courtney]
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
27
Objective
Crack [Courtney]
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
30
∆Kth ∆K
33
*Paris Law
• Paris Law: dc m
= A(ΔK)
dN
Objective
Crack • m ~ 3 (steel); m ~ 4 (aluminum).
Initiation
S-N
• Crack nucleation ignored!
curves • Threshold ~ Stage I
Cyclic
stress-strn • The threshold represents an endurance
Crack
Propagate
limit.
Microstr. • For ceramics, threshold is close to KIC.
effects
Design
• Crack growth rate increases with R (for
R>0). [fig. 12.18a]
34
*Striations- mechanism
• Striations occur by development of slip bands
in each cycle, followed by tip blunting,
Objective
followed by closure.
Crack
Initiation • Can integrate the growth rate to obtain cycles
S-N as related to cyclic stress-strain behavior. [Eqs.
curves 12.6-12.8]
Cyclic
stress-strn
Crack
Propagate cf cf
dc dc
Microstr. N II = ∫ N II = ∫ m m
effects c0 dc / dN c0 Aα ( Δσ c )
Design
35
*Striations, contd.
• Provided that m>2 and is constant, can integrate.
Objective
A−1(α Δσ )−m 1−( m / 2 ) 1−( m / 2 )
Crack N II = [c0 −cf ]
Initiation •
(m / 2) −1
If the initial crack length is much less than the final length, c <c , then
0 f
Geometrical effects
• Notches decrease fatigue life through stress
concentration.
Objective • Increasing specimen size lowers fatigue life.
Crack • Surface roughness lowers life, again through stress
Initiation concentration.
S-N • Moderate compressive stress at the surface
curves increases life (shot peening); it is harder to nucleate a
Cyclic crack when the local stress state opposes crack
stress-strn opening.
Crack
Propagate • Corrosive environment lowers life; corrosion either
Microstr. increases the rate at which material is removed from
effects the crack tip and/or it produces material on the crack
Design surfaces that forces the crack open (e.g. oxidation).
• Failure mechanisms
38
Microstructure-Fatigue Relationships
• What are the important issues in microstructure-
fatigue relationships?
Objective • Answer: three major factors.
Crack 1: geometry of the specimen (previous slide); anything on the
Initiation surface that is a site of stress concentration will promote
S-N crack formation (shorten the time required for nucleation of
curves cracks).
Cyclic 2: defects in the material; anything inside the material that can
stress-strn reduce the stress and/or strain required to nucleate a crack
Crack (shorten the time required for nucleation of cracks).
Propagate
3: dislocation slip characteristics; if dislocation glide is confined
Microstr. to particular slip planes (called planar slip) then dislocations
effects
can pile up at any grain boundary or phase boundary. The
Design head of the pile-up is a stress concentration which can
initiate a crack.
39
∆Kth ∆K
40
Defects in Materials
• Descriptions of defects in materials at the sophomore level
focuses, appropriately on intrinsic defects (vacancies,
dislocations). For the materials engineer, however, defects
Objective include extrinsic defects such as voids, inclusions, grain
Crack
boundary films, and other types of undesirable second phases.
Initiation • Voids are introduced either by gas evolution in solidification or
by incomplete sintering in powder consolidation.
S-N
curves
• Inclusions are second phases entrained in a material during
solidification. In metals, inclusions are generally oxides from the
Cyclic surface of the metal melt, or a slag.
stress-strn • Grain boundary films are common in ceramics as glassy films
Crack from impurities.
Propagate
• In aluminum alloys, there is a hierachy of names for second
Microstr. phase particles; inclusions are unwanted oxides (e.g. Al2O3);
effects dispersoids are intermetallic particles that, once precipitated, are
Design thermodynamically stable (e.g. AlFeSi compounds); precipitates
are intermetallic particles that can be dissolved or precipiated
depending on temperature (e.g. AlCu compounds).
41
[Dieter]
44
Titanium alloys
[Polmear]
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack • For many Ti alloys, the proportion of hcp (alpha) and bcc (beta) phases
Propagate depends strongly on the heat treatment. Cooling from the two-phase region
results in a two-phase structure, as Polmear’s example, 6.7a. Rapid cooling
Microstr. from above the transus in the single phase (beta) region results in a two-
effects phase microstructure with Widmanstätten laths of (martensitic) alpha in a beta
matrix, 6.7b.
Design
• The fatigue properties of the two-phase structure are significantly better than
the Widmanstätten structure (more resistance to fatigue crack formation).
• The alloy in this example is IM834, Ti-5.5Al-4Sn-4Zr-0.3Mo-1Nb-0.35Si-0.6C.
46
*Design Considerations
• If crack growth rates are normalized by the elastic
modulus, then material dependence is mostly
Objective removed! [Courtney fig. 12.20]
Crack • Can distinguish between intrinsic fatigue [use Eq.
Initiation
12.4 for combined elastic, plastic strain range] for
S-N
curves
small crack sizes and extrinsic fatigue [use Eq. 12.6
for crack growth rate controlled] at longer crack
Cyclic
stress-strn lengths. [fig. 12.21….]
Crack • Inspection of design charts, fig. 12.22, shows that
Propagate
ceramics sensitive to crack propagation (high
Microstr.
effects
endurance limit in relation to fatigue threshold).
Design
47
*Design Considerations: 2
• Metals show a higher fatigue threshold in
relation to their endurance limit. PMMA and
Objective
Mg are at the lower end of the toughness
Crack
Initiation range in their class. [Courtney fig. 12.22]
S-N • Also interesting to compare fracture
curves
toughness with fatigue threshold. [Courtney fig.
Cyclic
12.23]
stress-strn
Crack • Note that ceramics are almost on ratio=1 line,
Propagate
Microstr.
whereas metals tend to lie well below, i.e.
effects fatigue is more significant criterion.
Design
48
*Fatigue
property map
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Courtney]
49
*Fatigue
property map
Objective
Crack
Initiation
S-N
curves
Cyclic
stress-strn
Crack
Propagate
Microstr.
effects
Design
[Courtney]
50
*Fatigue in Polymers
• Many differences from metals
• Cyclic stress-strain behavior often exhibits
Objective
Crack
softening; also affected by visco-elastic
Initiation effects; crazing in the tensile portion
S-N produces asymmetries, figs. 12.34, 12.25.
curves
Cyclic • S-N curves exhibit three regions, with steeply
stress-strn decreasing region II, fig. 12.31.
Crack
Propagate • Nearness to Tg results in strong temperature
Microstr. sensitivity, fig. 12.42
effects
Design
52
Fatigue: summary
• Critical to practical use of structural materials.
• Fatigue affects most structural components,
Objective
Crack
even apparently statically loaded ones.
Initiation • Well characterized empirically.
S-N
curves • Connection between dislocation behavior and
Cyclic fatigue life offers exciting research
stress-strn
Crack
opportunities, i.e. physically based models
Propagate are lacking!
Microstr.
effects
Design