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AM 11/03 1
Single primary slip system
S
S
II Fatigue Mechanisms
AM 11/03 2
Current Theory of Fatigue
3. Intrusions,extrusions
2. Persistent slip bands
4. Stage I (shear) fatigue crack
5. Stage II fatigue crack
1. Cyclic slip
AM 11/03 3
Outline
n 1. Cyclic slipn 2. Persistent slip bands (PSB)n 3. Intrusions and extrusionsn 4. Stage I crack growthn 5. Stage II crack growth
AM 11/03 4
Process of fatigue
3. Intrusions,extrusions
2. Persistent slip bands
4. Stage I (shear) fatigue crack
5. Stage II fatigue crack
1. Cyclic slip
AM 11/03 5
1. Cyclic slip
First cycle
Many cycles later - cyclic hardening
Cyclic slip occurs within a grain and therefore operates on an atomic scale and are thus is controlled by features seen at that scale.
AM 11/03 6
1. Cyclic slip
d =G b2 b3( )
2π γ
Material γ Stacking Fault Energy ergs cm-2
Aluminum 250
Iron 200
Nickel 200
Copper 90
Gold 75
Silv er 25
Stainl ess Steel <10
α Brass <10
n Planar or wavy slip?
AM 11/03 7
1. Cyclic slip
Planarslip inCu-Al
Wavy slip in steel
Cu-Al alloys, Cu-Zn, Aust. SS
Ni, Cu, Al Fe
n Stacking-fault energy effects
AM 11/03 8
1. Cyclic slipWavy slip materials Planar slip materials
n Planar and wavy slip materials
AM 11/03 9
1. Cyclic slip
γ = 10-3
γ =10-5
Dislocation cell structuresin copper
n Development of cell structures
AM 11/03 10
Example
5µm
60 cycles
1,000 cycles
5,000 cycles
20,000 cycles
80,000 cycles (failure)
OM surface OM etch pit
TEM
Stress range = ±25 ksi.
n Fatigue of an Fe single crystal
AM 11/03 11
Outline
n 1. Cyclic slip
n 2. Persistent slip bands (PSB)
n 3. Intrusions and extrusionsn 4. Stage I crack growthn 5. Stage II crack growth
AM 11/03 12
2. Persistent slip bands (PSB)
•Development of cell structures (hardening)•Increase in stress amplitude (under strain control)•Break down of cell structure to form PSBs•Localization of slip in PSBs
PSB
Cyclic hardening Cyclic softening
AM 11/03 13
Outline
n 1. Cyclic slipn 2. Persistent slip bands (PSB)
n 3. Intrusions and extrusionsn 4. Stage I crack growthn 5. Stage II crack growth
AM 11/03 14
3. Intrusions and extrusions
Intrusions and extrusions on thesurface of a Nispecimen
AM 11/03 15
3. Intrusions and extrusions
Cyclically hardened material
Extrusion
Cyclically hardened material
Intrusion
Cyclically hardened material
AM 11/03 16
3. Intrusions and extrusions
Fatigue crack initiation at an inclusionCyclic slip steps (PSB)Fatigue crack initiation at a PSB
AM 11/03 17
Outline
n 1. Cyclic slipn 2. Persistent slip bands (PSB)n 3. Intrusions and extrusions
n 4. Stage I crack growthn 5. Stage II crack growth
AM 11/03 18
4. Stage I crack growth
Single primary slip system
individual grain
near - tip plastic zone
S
S
Stage I fatigue cracks are the size of the grains and are thus controlled by features seen at that scale: grain boundaries, mean stresses, environment.
AM 11/03 19
4. Stage I crack growth
rc =1π
∆KI
2σy'
2
Cyclic plastic zone is the region ahead of a growing fatigue crack in which slip takes place. Its size relative to the microstructure determines the behavior of the fatigue crack, i.e.. Stage I andStage II behavior.
AM 11/03 20
4. Stage I crack growth
n Short Cracks, Long Cracks
AM 11/03 21
Cracks growing from notches don’t know that that stress field they are experiencing is confined to the notch root.
4. Stage I crack growth
n Crack Growth at a Notch
AM 11/03 22
4. Stage I crack growth
Here the ?K is the remote stress intensity factor based on remote stresses….
n Growth of Small Cracks
AM 11/03 23
Outline
n 1. Cyclic slipn 2. Persistent slip bands (PSB)n 3. Intrusions and extrusionsn 4. Stage I crack growth
n 5. Stage II crack growth
AM 11/03 24
5. Stage II crack growth
Plexiglas
Stage II fatigue cracks much larger than the grain size and are thus sensitive only to large scale microstructural features - texture, global residual stresses, etc.
AM 11/03 25
Example
n Stage II fatigue crack in a weldment
AM 11/03 26
5. Stage II crack growth
Scanning electronmicroscope image -striations clearly visible
Schematic drawing ofa fatigue fracturesurface
AM 11/03 27
5. Stage II crack growth
Plastic wake New plastic deformation
S
S
Rem
ote
Stre
ss, S
Time, t
Smax
S , Sop cl
S
S
Rem
ote
Stre
ss, S
Time, t
Smax
S , Sop cl
a.
b.
S = 0
S = Sop
AM 11/03 28
5. Stage II crack growth
Plastic wake New plastic deformation
S
S
Rem
ote
Stre
ss, S
Time, t
Smax
S , Sop cl
S
S
Rem
ote
Stre
ss, S
Time, t
Smax
S , Sop cl
c.
d.
S = Smax
S = 0
AM 11/03 29
Elastic stresses near a crack tipS
c
σx
σy
σxy
x
y
R
θ
σx =S πc
2πRcos
θ2
1− sinθ2
sin3θ2
=
KI2πR
f1 θ( )
σy =S πc
2πRcos
θ2
1+ sinθ2
sin3θ2
=
KI2πR
f2 θ( )
τxy =S πc
2πRcos
θ2
sinθ2
cosθ2
sin3θ2
=
KI2πR
f3 θ( )
The magnitude stress field near a crack tip depends upon the stress intensity factor (KI). Wouldn’t it be nice if this quantity correlates with the speed with which fatigue cracks grow? Let’s see if it works! Rather, let’s see if we can MAKE it work!
∆K ≡ Y∆S πaRange of stress intensity factor
AM 11/03 30
Geometry correction factor (Y)
2c
2c 2c
c
SS
S S
S
SS
S
Y=1
Y=1.12
Y=2/p
W
Y = secπcW
Infinite width center cracked panel
Finite width center cracked panel
Edge cracked panel
Disc shaped crack in an infinite body
B
AM 11/03 31
Crack growth rate (da/dN) is related to the crack tip stress field and is thus strongly correlated with the range of stress intensity factor: (? K=Y? Svpa).
dadN
= C ∆K( )n
Paris power law
5. Stage II crack growth
AM 11/03 32
5. Stage II crack growth
n Crack Closure Mechanisms
AM 11/03 33
5. Stage II crack growth
dadn
= C ∆K( )m K max( )p ExtrinsicIntrinsic
AM 11/03 34
Example
•Orientation of microstructural texture•Grain size •Strength•Environment
n Aluminum - crack growth
AM 11/03 35
5. Stage II crack growth
A. Dissolution of crack tip.
B. Dissolution plus H+ acceleration.
C. H+ acceleration
D. Corrosion products may retard crack growth at low ?K.
A B
C Dn Effects of
Environment
AM 11/03 36
The fatigue crack growth rates for Al and Ti are much more rapid than steel for a given ?K. However, when normalized by Young’s Modulus all metals exhibit about the same behavior.
Example
n Crack Growth Rates of Metals
AM 11/03 37
Summary
n Fatigue is a complex process involving many steps but it may be broken down into the initiation and growth of fatigue cracks.
n The growth of fatigue cracks is often considered to be the most important feature of fatigue from an engineering perspective.