Factors Affecting Strain Life Fatigue

Results
For
Carbon and Low Alloy
Automotive Bar Steels

Thomas G. Oakwood

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 AISI Bar Steel Fatigue Project
Participants

Ground Vehicle Manufacturers.

Ground Vehicle Suppliers.
AISI Bar Steel Producers.
University Testing Laboratories.
University of Toledo, Toledo, Ohio
University of Waterloo, Waterloo, Ontario

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 Topics To Be Discussed

Structure and Content of AISI Bar Steel Fatigue

Database.
Analysis of Fatigue Performance From Data.
Work in Progress.
Plans for Future Work.

www.autosteel.org
 Topics To Be Discussed

Structure and Content of AISI Bar Steel Fatigue

Database.
Analysis of Fatigue Performance From Data.
Work in Progress.
Plans for Future Work.

www.autosteel.org
 Bar Steel Fatigue Database-
Content

Steel Grades
Carbon
Low Alloy
Micro-alloy
Processing
Normalized
Quenched and Tempered
Case Hardened
Hot Rolled, Controlled Cooled

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 Bar Steel Fatigue Database-
Information

Steel Characterization.
Composition
Processing History
Digital Photomicrographs of Microstructures
Mechanical and Cyclic Properties.
Tabulation of Axial Fatigue Data
Graphical Output of Strain-Life Curves and
Neuber Curves.

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 Bar Steel Fatigue Database-
Format

Direct-Access Internet Format.

Multiple Screens.
Master Index
Tabbed Material Properties Screens
Report Format
Excel
SAE
Independent Access for Microstructures and Graphs
Comparative Printing.

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 Bar Steel Fatigue Database-
Access

Private Access.
AISI Bar Steel Fatigue Committee Subscribers
Private Access to Data for Two Years
90 Iterations Complete
9 In Progress
40 Planned
Public Access.
General Public
Data Available After Two Year Restriction
71 Iterations Available

User Name and Password Required.

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 Topics To Be Discussed

Structure and Content of AISI Bar Steel Fatigue

Database.
Analysis of Fatigue Performance From Data.
Work in Progress.
Plans for Future Work.

www.autosteel.org
 Strain Life Equation

/2 = (f /E)(2Nf)b + f (2Nf)c
Where:
/2 = Strain Amplitude
E = Youngs Modulus
f = Fatigue Strength Coefficient
f = Fatigue Ductility Coefficient
b = Fatigue Strength Exponent
c = Fatigue Ductility Exponent
2Nf = Reversals To Failure

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 Strain Amplitude Curves
Normalized Steels
Total Strain Amplitude vs. Reversals to Failure for SAE Normalized Grades

0.1

1050M
1090
True Strain Amplitude

1141Al
1141Nb
0.01
1141V
1141V
1750
1541
1038
10V45

0.001
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07
Reversals to Failure, 2Nf

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 Strain Life Curves
Quenched and Tempered Steels
Total Strain Amplitude vs. Reversals to Failure for Quench & Tempered Grades
0.1 1141Al

1141Nb

1141V (16)

1038 (20)

10B21 (24)

1045 (26)

4130Al (29)
Strain Amplitude

4140 (30)

5140 (31)
0.01
51B60 (33)

9254V (34)

9254Al (35)

4140 (64)

4140 (65)

4140 (66)

4140 (67)

4140 (68)

0.001 4140 (69)

1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07
5160H (84)
Reversals to Failure, 2Nf

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 Fatigue Strength Determinations

Experimental Data
/2 = f (2Nf)b
/2 Fatigue Strength
f = Fatigue Strength Coefficient
b = Fatigue Strength Exponent
2Nf = Reversals To Failure

Linear Regression
/2 = f(BHN, Composition)

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 Fatigue Strength Normalized

/2 @ 106 Cycles (MPa) = 0.18BHN + 53.48 %C + 218.27 %Mn 2052.98 %S

-46.40 %Si + 1336.68 %Ni 56.56 %Cr
-380.44 %Mo + 36.10 (+/-4.60)

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 Fatigue Strength Normalized
Predicted Versus Experimental Fatigue Strength @ 10^6 Cycles
Normalized Steels
290

280

y = 0.9372x - 3.6903
Predicted Fatigue Strength, MPa

270
R2 = 0.9624
260

250

240

230

220

210

200
200 220 240 260 280 300 320
Experimental Fatigue Strength, MPa

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 Fatigue Strength Quenched
and Tempered

/2 @ 106 Cycles (MPa) = 2.52 BHN + 674.41 %C + 388.56 %Mn 4062.07 %S

-1225.32 %Si + 210.07 %Cr 2260.21 %Mo
+355.04 %Ni + 570.18 %Al - 1590.00 %V 476.48 (+/- 27.94)

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 Fatigue Strength Quenched
and Tempered
Predicted Versus Experimental Fatigue Strength @ 10^ 6 Cycles
Quenched and Tempered Steels

700

650

600
Predicted Fatigue Strength, MPa

y = 0.9672x - 7.3316
550
R2 = 0.9858
500

450

400

350

300

250

200
200 250 300 350 400 450 500 550 600 650 700
Experimental Fatigue Strength, MPa

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 Modified Strain Life Equation
(Reference: M. Roessle and A. Fatemi, Int. Journ. Fatigue, 22, 2000)

/2 = [(4.25BHN+225)/E](2Nf)-0.09
+ [(0.32BHN2 - 487BHN + 191000)/E](2Nf)-0.56
Where:
BHN = Brinell Hardness Number
/2 = Strain Amplitude
E = Youngs Modulus
2Nf = Reversals To Failure

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 Fatigue Prediction 1038
Normalized
Fatigue Approximation
Iteration No. 18 1038 Normalized to 163 BHN
10
Strain Amplitude, %

Experimental Data
0.1 Predicted From BHN

0.01
100 1000 10000 100000 1000000 10000000 100000000
Reversals to Failure

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 Fatigue Prediction 1141
Normalized
Fatigue Approximation
Iteration No. 11 (1141 AlFG Normalized to 223 BHN)
10
Strain Amplitude, %

Experimental Data
0.1
Predicted From BHN

0.01
100 1000 10000 100000 1000000 10000000 100000000
Reversals to Failure

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 Fatigue Prediction 9254
Quenched and Tempered
Fatigue Approximation
Iteration No. 35 (9254 Quenched and Tempered to 584 BHN)
10
Strain Amplitude, %

Experimental Data
0.1
Predicted From BHN

0.01
100 1000 10000 100000 1000000 10000000 100000000
Reversals to Failure

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 Fatigue Prediction C70
Controlled Cooled
Fatigue Approximation
Iteration No. 43 (C70 As-Rolled, Controlled Cooled BHN 241)
10
Strain Amplitude, %

0.1 Predicted From BHN

Experimental Data

0.01
100 1000 10000 100000 1000000 10000000 100000000
Reversals to Failure

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 Fatigue Prediction 4140
Quenched and Tempered
Fatigue Approximation
Iteration Nos. 64-69 (4140 Quenched and Tempered to BHN 375 avg.)

10
Strain Amplitude, %

4140 Q&T It. 64

4140 Q&T It. 65
0.1 4140 Q&T It. 66
Predicted From BHN
4140 Q&T It. 67
4140 Q&T It. 68
4140 Q&T It. 69

0.01
100 1000 10000 100000 1000000 10000000 100000000
Reversals to Failure

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 Summary

Fatigue Strength Can Be Predicted From

Composition And Hardness.
Limits:
Simple Linear Regression
Composition Range of the Data
Constant Processing and Microstructure
Strain Life Curve Can Be Predicted From Hardness.
Limits:
Microstructure
Surface Condition
Residual Stress
Prior Austenite Grain Size
Inclusions

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 Topics To Be Discussed

Structure and Content of AISI Bar Steel Fatigue

Database.
Analysis of Fatigue Performance From Data.
Work in Progress.
Plans for Future Work.

www.autosteel.org
 Work in Progress

Comparison of Fatigue Behavior of Atmosphere

and Vacuum Carburized Steels.
Simulated Carburized Case and Core
Surface Effects
Prior Austenite Grain Size

Effects of Sulfur Level on Fatigue Properties.

Transverse Testing

Effects of Varying Amounts of Bainite on the

Fatigue Properties of Carburized Steels.
Simulated Carburized Case

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 Topics To Be Discussed

Structure and Content of AISI Bar Steel Fatigue

Database.

Analysis of Fatigue Performance From Data.

Work in Progress.

Plans for Future Work.

www.autosteel.org
 Future Work

Effect of Variation in Composition Within SAE Limits on

Fatigue Properties.
Residual Stress Measurements.
Effect of Varying Hardness Due to Change in Microstructure
on Fatigue Properties.
Simulated Carburized Core

Comparison of Fatigue Properties of As-Rolled and Forged.

Micro-alloyed Steels.
The Effects of Random Overloads on Fatigue Behavior.
Continued Comparisons of the Fatigue Properties of
Atmosphere Carburized and Vacuum Carburized Steels.
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