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10
Fatigue Crack
Propagation
2
SIMILITUDE IN FATIGUE
Consider a growing crack
in the presence of a
constant amplitude cyclic
stress intensity.
∆K = (Kmax − Kmin)
f1 K , R
da
R = Kmin/Kmax
dN
da/dN = crack growth per cycle
The influence of the plastic zone and plastic wake on crack
growth is implicit in the above Equation, since the size of the
plastic zone depends only on Kmin and Kmax.
3
SIMILITUDE IN FATIGUE
If Kmin and Kmax varies during cyclic loading, the crack growth in a
given cycle may depend on the loading history as well as the
current values of Kmin and Kmax :
f 2 K , R, H
da
dN
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SIMILITUDE IN FATIGUE
Fatigue crack growth analyses become considerably more
complicated when prior loading history is taken into account,
hence the dependence on H is neglected whenever possible.
f 3 J , R
da
dN
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EMPIRICAL FATIGUE CRACK GROWTH EQUATIONS
The curve contains three region, the intermediate region is linear, but
the crack growth rate deviates from the linear trend at high and low ∆K
levels.
At the low end, da/dN
approaches zero at a
threshold ∆K, below which
the crack will not grow.
The power law was apparently discovered by Paris and Erdogan, hence
it is known as Paris law. They proposed an exponent of 4, which was in
line with their experimental data. Subsequent studies over the past
three decades, however, have shown that m can range from 2 to 4 for
most metals in the absence of a corrosive environment.
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EMPIRICAL FATIGUE CRACK GROWTH EQUATIONS
Forman proposed the following relationship for Region II and Region III:
da CK m da CK m 1
OR Kc
dN 1 R K c K dN K max 1
Klesnil and Lukas modified Paris law to account for the threshold:
da
dN
C K m K thm
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EMPIRICAL FATIGUE CRACK GROWTH EQUATIONS
da
CK m 1 K th p
K where C, m, p, and q are
dN 1 Kmax
Kc
q
material constants.
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EMPIRICAL FATIGUE CRACK GROWTH EQUATIONS
In all the empirical fatigue crack growth equations discussed above, the
fatigue crack growth rate depends only on the loading parameters ∆K
and R.
Dowling and Begley applied the J integral to fatigue crack growth under
large-scale yielding conditions where K is no longer valid.
da
CJ m
dN
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EXAMPLE 10.1
Derive an expression for the number of stress cycles required to grow a
semicircular surface crack from an initial radius ao to a final size af,
assuming the Paris-Erdogan equation describes the growth rate.
Assume that af is small compared to plate dimensions, the crack
maintains its semicircular shape, and that the stress amplitude ∆σ is
constant.
Solution:
For a semicircular surface crack;
λs is surface correction
Q is flaw shape parameter
φ is the angle of a point along the crack
2c is the diameter of the major axis of
full crack
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EXAMPLE 10.1
Neglecting the φ dependence of the surface correction factor λs.The
stress-intensity amplitude can be approximated by
1.04
K a
2.464
C 0.663 a
da m m2
dN
Which can be integrated to determine fatigue life:
1 af
N
C 0.663
m a0
a m 2 da
a01 m 2 a1f m 2
N for m 2
C m2 1 0.663 m
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Problem 10.2
A structural component made from a high-strength steel is subject to
cyclic loading, with σmax = 210 MPa and σmin = 70 MPa. This
component experiences 100 stress cycles per day. Prior to going into
service, the component was inspected by nondestructive evaluation
(NDE), and no flaws were found. The material has the following
properties: σYS = 1000 MPa, KIc = 25 MPa . The fatigue crack growth
rate in this material is the same as in Problem 10.1 (m = 3 & C = 6.87 ×
10 −12) .
(a) The NDE technique can find flaws ≥ 2 mm deep. Estimate the
maximum safe design life of this component, assuming that
subsequent in-service inspections will not be performed. Assume that
any flaws that may be present are semicircular surface cracks and that
they are small relative to the cross section of the component.
(b) Repeat part (a), assuming an NDE detectability limit of 10 mm.
13
CRACK CLOSURE
An accidental discovery by Elber in 1970 resulted in several decades of
research into a phenomenon known as crack closure.
Elber assumed that the portion of the cycle that is below Kop does not
contribute to fatigue crack growth because there is no change in crack-
tip strain during cyclic loading of a closed crack.
K eff K max K op
17
CRACK CLOSURE
The effect of grain size on fatigue crack
propagation in 1018 steel is shown in Figure
Crack closure can also be introduced by a viscous fluid. The fluid acts as
a wedge between crack faces, somewhat like the oxide mechanism.
19
CRACK CLOSURE
Three of the closure mechanisms illustrated above (roughness,
corrosion product, and viscous fluid) involve crack wedging. That is, the
crack is prevented from closing completely by an obstruction of some
type.
20
A CLOSER LOOK AT CRACK-WEDGING MECHANISMS
Consider an idealized scenario where a rigid wedge is inserted into an
open crack, suppose that the shape of this wedge is such that the crack
perfectly conforms to it when the load is removed.
21
A CLOSER LOOK AT CRACK-WEDGING MECHANISMS
Now assume that the crack contains a single rigid particle, as the load is
removed and the crack faces close, they eventually contact the particle.
There is a small residual K when
the load is removed completely.
22
A CLOSER LOOK AT CRACK-WEDGING MECHANISMS
The following Figure illustrates a more realistic case, where the crack is
filled with particles of various sizes.
As the load is relaxed, the
slope of the load-CMOD
curve gradually changes as
more particles make
contact with the crack.
Eventually, no further
contact occurs and the
CMOD attains a constant
value, assuming the
particles are rigid.
As was the case for the
single-particle scenario,
defining Kop at the point of
initial slope change could
lead to errors.
23
EFFECTS OF LOADING VARIABLES ON CLOSURE
Stress intensity for crack closure (Kop) depends on a number of factors,
which are identified differently by various researchers.
Elber implies the following relationship for Kop (for 2023-T3 aluminum)
1
K op K 0.5 0.4 R
1 R
Most experts believe that the R ratio effects on the threshold are due
to crack closure.
25
THE CLOSURE MODEL FOR THE THRESHOLD
The figure shows a
schematic illustration of
the relationship
between closure
behavior and the R ratio,
assuming Kop is constant.
27
THE CLOSURE MODEL FOR THE THRESHOLD
This Figure is a plot of actual
threshold data for a variety
of steels. For most of the
steels on this plot, R*
appears to be around 0.8
and ∆Kth* is between 2 and
3 MPa.m-1/2.
30
Problem 10.4
Consider a 1T compact specimen that is loaded cyclically at a constant
load amplitude with Pmax = 18 kN and Pmin = 5 kN. Using the fatigue
crack growth data in Problem 10.1, calculate the number of cycles
required to grow the crack from a/W = 0.35 to a/W = 0.60. Plot crack
size vs. cumulative cycles for this range of a/W (Using a computer
program)
dN
where da/dN is in m/cycle and ∆K is in 𝑀𝑃𝑎 𝑚 and ∆σ is in MPa
31