Effects of orientation on the fatigue crack growth behaviors of the ZK60 magnesium alloy in air and PBS

Strong anisotropic corrosion and mechanical properties caused by specimen orientations greatly limit the applications of wrought magnesium alloys.To investigate the influences of specimen orientation,the corrosion tests and(corrosion)fatigue crack growth tests were conducted.The rolled and transverse surfaces of the materials show distinct corrosion rate differences in the stable corrosion stage,but the truth is the opposite for the initial stage of corrosion.In air,specimen orientations have a significant influence on the plastic deformation mechanisms near the crack tip,which results in different fatigue fracture surfaces and cracking paths.Compared with R-T specimens,N-T specimens show a slower fatigue crack growth(FCG)rate in air,which can be attributed to crack closure effects and deformation twinning near the crack tip.The corrosion environment will not significantly change the main plastic deformation mechanisms for the same type of specimen.However,the FCG rate in phosphate buffer saline(PBS)is one order of magnitude higher than that in air,which is caused by the combined effects of hydrogen-induced cracking and anodic dissolution.Owing to the similar corrosion rates at crack tips,the specimens with different orientations display close FCG rates in PBS.

Statistical learning prediction of fatigue crack growth via path slicing and re-weighting

Predicting potential risks associated with the fatigue of key structural components is crucial in engineering design.However,fatigue often involves entangled complexities of material microstructures and service conditions,making diagnosis and prognosis of fatigue damage challenging.We report a statistical learning framework to predict the growth of fatigue cracks and the life-to-failure of the components under loading conditions with uncertainties.Digital libraries of fatigue crack patterns and the remaining life are constructed by high-fidelity physical simulations.Dimensionality reduction and neural network architectures are then used to learn the history dependence and nonlinearity of fatigue crack growth.Path-slicing and re-weighting techniques are introduced to handle the statistical noises and rare events.The predicted fatigue crack patterns are self-updated and self-corrected by the evolving crack patterns.The end-to-end approach is validated by representative examples with fatigue cracks in plates,which showcase the digital-twin scenario in real-time structural health monitoring and fatigue life prediction for maintenance management decision-making.

STOCHASTIC MODELLING OF FATIGUE CRACK GROWTH UNDER CONSTANT AMPLITUDE LOADING

Two stochastic models of fatigue crack growth under constant amplitude cyclic loading are proposed and studied by using the stochastic averaging method and total probability theorem to account for high frequency component and low frequency component, respectively, of the irregular nature of fatigue crack growth observed in Virkler's experiment. Particular attention is paid to the prediction performance of the models under a change in the initial crack length. It is shown that the models proposed in the present paper yields better agreement with experimental data than other models available in literature.

Effect of annealing treatment on microstructure and fatigue crack growth behavior of Al–Zn–Mg–Sc–Zr alloy

Al-Zn-Mg-Sc-Zr alloy samples were annealed to four different states （under-aging, peak-aging, over-aging and double-aging） and then thoroughly investigated by means of electron backscatter diffraction （EBSD）, transmission electron microscopy （TEM）, scanning electron microscopy （SEM）, tensile and fatigue crack growth rate tests to explore the influence of annealing treatment on microstmcture and fatigue crack growth behavior. The results indicate that Al3（Sc,Zr） particles can effectively refine grains and enhance tensile properties and fatigue properties. After annealing treatment, the under-aged sample and double-aged sample obtained average grain sizes of 4.9473 and 4.1257 μm, and the maximum value of yield/tensile strength （561 MPa/581 MPa） was obtained in peak-aged state. In the Paris region, fatigue crack growth rate, crack deflection and bifurcation, crack blunting and inter/trans-granular propagation were discussed based on data fitting and Laird model and Griffith theory. And the results show that the under-aged sample possesses the best resistance to fatigue crack propagation and the most tortuous and bifurcated crack path. For all samples, the fatigue crack growth rate in the rupture region was inversely proportional to yield strength.

Effects of precipitates on fatigue crack growth rate of AA 7055 aluminum alloy

The effects of precipitates on the fatigue crack growth rate of AA 7055 Al alloy subjected to different ageing treatments were investigated using transmission electron microscope and fatigue crack growth testing.The results show that the T77 treated samples exhibit the lowest crack growth rate,while the crack growth rate of over-aged samples is the highest.In terms of the model based on the reversibility of dislocation motion within the plastic zone close to the crack tip,the improved crack growth resistance is attributed to many precipitates that are coherent with Al matrix in the under-aged and T77 treated samples.When the precipitate is coherent with the Al matrix,the larger the precipitate is,the slower the fatigue crack grows.The effects of grain boundary precipitates and precipitate free zone on the fatigue crack growth resistance are less significant than those of precipitates within grains of the alloy.

Fatigue Crack Growth Rate of Ti-6Al-4V Considering the Effects of Fracture Toughness and Crack Closure

Fatigue fracture is one of the main failure modes of Ti-6A1-4V alloy,fracture toughness and crack closure have strong effects on the fatigue crack growth（FCG）rate of Ti-6A1-4V alloy.The FCG rate of Ti-6A1-4V is investigated by using experimental and analytical methods.The effects of stress ratio,crack closure and fracture toughness on the FCG rate are studied and discussed.A modified prediction model of the FCG rate is proposed,and the relationship between the fracture toughness and the stress intensity factor（SIF）range is redefined by introducing a correcting coefficient.Notched plate fatigue tests（including the fracture toughness test and the FCG rate test）are conducted to investigate the influence of affecting factors on the FCG rate.Comparisons between the predicted results of the proposed model,the Paris model,the Walker model,the Sadananda model,and the experimental data show that the proposed model gives the best agreement with the test data particularly in the near-threshold region and the Paris region,and the corresponding calculated fatigue life is also accurate in the same regions.By considering the effects of fracture toughness and crack closure,the novel FCG rate prediction model not only improves the estimating accuracy,but also extends the adaptability of the FCG rate prediction model in engineering.

Effect ofαphase morphology on fatigue crack growth behavior of Ti−5Al−5Mo−5V−1Cr−1Fe alloy

Taking a Ti−5Al−5Mo−5V−1Cr−1Fe alloy as exemplary case,the fatigue crack growth sensitivity and fracture features with various tailoredαphase morphologies were thoroughly investigated using fatigue crack growth rate(FCGR)test,optical microscopy(OM)and scanning electron microscopy(SEM).The tailored microstructures by heat treatments include the fine and coarse secondaryαphase,as well as the widmanstatten and basket weave features.The sample with coarse secondaryαphase exhibits better comprehensive properties of good crack propagation resistance(with long Paris regime ranging from 15 to 60 MPa·m1/2),high yield strength(1113 MPa)and ultimate strength(1150 MPa),and good elongation(11.6%).The good crack propagation resistance can be attributed to crack deflection,long secondary crack,and tortuous crack path induced by coarse secondaryαphase.

EFFECTS OF MICROSTRVCTURE ON FATIGUE CRACK GROWTH BEHMIOR IN Ni-BASE SUPERALLOY GH586

Threshold stress values, muging from ～8 to 16MPa·m1/2 can be obtained in a Ni-base alloy GH586 by varying the microstructure through heat treatments. The threshold and low crack growth rate behaviors at room temperature, with varying groin size and γ'-distribution, have been investigated. The results indicate that grain size is an important microstructurol parameter that affects fatigue crack growth threshold and propagation behaviors, as the values of △Kth increase with increasing grain size, but the γ' -distribution also has important effect. Analyses show that the effects of groin size on threshold and low crack-growth rate behavior result from heterogeneous deformation and roughness-induced crack closure due to crystallographic slipping and cracking in coarse microstructure. The higher △Kth and lower fatigue crack growth rate with increasing amounts of fine γ' phases are closely related to less damage accumulation level in deformation zone of crack-tip resulted from heterogeneous deformation due to dislocations' shearing γ' precipitates.

Effects of pre-rolling on mechanical properties and fatigue crack growth rate of 2195 Al-Li alloy

While pre-deformation is often conducted before aging treatment to increase the strength and microhardness of 2195 Al-Li alloy, it often increases the fatigue crack growth(FCG) rate and thus reduces the fatigue life of the alloy.To determine the effects and causes of pre-deformation and heat treatment on the mechanical properties and FCG rate of2195 Al-Li alloy, and to provide a suitable calculation model for the FCG rate under different pre-deformation conditions, 2195 Al-Li alloy specimens with different degrees of pre-rolling(0, 3%, 6%, and 9%) were investigated. The experimental results indicate that with the increase of pre-rolling, the density of the T1phase and the uniformity of the S′distribution and the microhardness, tensile strength, and yield strength of the alloy increase and at the same time the FCG rate increases, and thus the fatigue life is reduced. It was also found that the normalized stress intensity factor of elastic modulus(E) can be applied to correlate the FCG rate of pre-rolled 2195 Al-Li alloy with constant C and K parameters.

Fatigue crack growth behaviour of friction stir welded AA7075-T651 aluminium alloy joints

The aim of the present work is to evaluate the fatigue crack growth behaviour of 12 mm thick AA 7075-T651 aluminium alloy plates joined by FSW. Fatigue crack growth test was carried out on center cracked tensile (CCT) specimens extracted from the FSW joints and unwelded parent metal. Transverse tensile properties of the unwelded parent metal and welded joints were evaluated. Microstructures of the welded joints were analyzed using optical microscopy and transmission electron microscopy. The scanning electron microscope was used to characterize the fracture surfaces. It was found that the ΔKcr of the welded joint is reduced by 10×10-3 MPa·m1/2 in comparison with the unwelded parent metal. Hence, the fatigue life of the friction stir welded AA 7075-T651aluminium alloy joints is appreciably lower than that of the unwelded parent metal, which is attributed to the dissolution of precipitates in the weld region during friction stir welding.

Simple Predicting Method for Fatigue Crack Growth Rate Based on Tensile Strength of Carbon Steel

Three types of fatigue tests for an annealed carbon steel containing carbon of 0.42%were carried out on smooth specimens and specimens with a small blind hole in order to investigate the fatigue crack growth law.A simple predicting method for crack growth rates has been proposed involving strengthσband the relation between cyclic stress and strain.The validity of proposed method has been confirmed by experiments on several carbon steels with different loadings.

Fracture toughness and fatigue crack growth analysis of 7050-T7451 alloy thick plate with different thicknesses

The strength, fracture toughness and fatigue crack growth resistance of 7050-T7451 aluminum alloy plate with different thicknesses （35 mm and 160 ram） were investigated by means of optical microscope, scanning electron microscope and transmission electron microscope. The results show that thicker plate has lower strength and fracture toughness but higher fatigue crack growth resistance, by comparison to the thinner plate. The drop of strength is mainly attributed to grain coarsening in the thicker plate, and the increased degree of recrystallization results in the loss of Kio However, the coarsened grains in the thicker plate make cracks deflected and closure effect enhanced due to surface roughness increased. For both of plates, in the fracture surface subjected plain strain, a transition from transgranular dimpled fracture to intergranular dimpled fracture is observed during the fracture process.

Effects of laser shock peening on fatigue crack growth rate and fracture properties of AA2524 aluminum alloy

In order to prolong the service life of aircraft skin made from AA2524, the effects of laser shock peening(LSP) on fatigue crack growth(FCG) rate and fracture toughness(K_(c)) of AA2524 were investigated. Multiple LSP treatment was performed on compact tension(CT) specimen from single side and double sides. The surface integrity was measured with Vickers hardness tester, X-ray diffractometer and confocal laser scanning microscope, respectively. FCG rate test and fracture toughness test under plane stress were carried out after LSP treatment. The microstructure features of cross-sections were observed with scanning electron microscope. The results showed that the micro-hardness and residual stress of CT specimens were increased dramatically after LSP treatment. Compared to the base metal(BM), the fatigue life was prolonged by 2.4 times and fracture toughness was increased by 22% after multiple LSP.

Fractographic analysis of the overload effect on fatigue crack growth in 2024-T3 and 7075-T6 Al alloys

The effect of single overload on the fatigue crack growth in 2024-T3 and 7075-T6 Al alloys was analyzed.Fatigue tests under constantamplitude loading with overload peak were carried out on V-notched specimens.Fractographic analysis was used as a principal approach to explain the crack growth retardation due to the overload.Scanning electron microscopy(SEM)analyses were conducted on the fractured surface of failed specimens to study the retardation effect.The obtained results show that the overload application generates a plastic zone in both aluminum alloys.The generated plastic zone is three times larger in the case of 2024-T3 compared to 7075-T6,and thus,a significant crack retardation was induced for 2024-T3.The retardation effect due to the overload for 2024-T3 and 7075-T6 lasted for about 10 mm and 1 mm,respectively,from the point of overload application.

Fatigue crack growth behaviors of a new burn-resistant highly-stabilized beta titanium alloy

This article presents the fatigue crack growth （FCG） behaviors of a new bum-resistant highly-stabilized beta Ti40 alloy. The FCG rates were analyzed. The fracture surfaces and the side surfaces of the test samples were explored. The results show that frequency affects the cracking behaviors of Ti40 alloy. Temperature also plays an important role in Ti40 alloy cracking. At room temperature （25℃）, when the frequency increases, the cracking rate changes a little in the range of low stress intensity factor （△K）, while it changes significantly when △K is high. At 500℃, the cracking rate of Ti40 alloy changes significantly during all the course of cracking. The fi＇equency also affects the microstructure patterns of Ti40 alloy. A number of secondary cracks appear in the area more than 200μm from the main crack at a high △K when the frequency is 1 Hz, but only a few secondary cracks exist when the frequency is 10 Hz. Facet image is the main image of the fracture surfaces when the frequency is 1 Hz. While, ductile striation occupies most of the area of fracture surfaces when the frequency is 10 Hz.

Fatigue crack growth mechanism in cast hybrid metal matrix composite reinforced with SiC particles and Al_2O_3 whiskers

The fatigue crack growth(FCG) mechanism of a cast hybrid metal matrix composite(MMC) reinforced with SiC particles and Al2O3 whiskers was investigated. For comparison, the FCG mechanisms of a cast MMC with Al2O3 whiskers and a cast Al alloy were also investigated. The results show that the FCG mechanism is observed in the near-threshold and stable-crack-growth regions.The hybrid MMC shows a higher threshold stress intensity factor range, ?Kth, than the MMC with Al2O3 and Al alloy, indicating better resistance to crack growth in a lower stress intensity factor range, ?K. In the near-threshold region with decreasing ?K, the two composite materials exhibit similar FCG mechanism that is dominated by debonding of the reinforcement–matrix interface, and followed by void nucleation and coalescence in the Al matrix. At higher ?K in the stable- or mid-crack-growth region, in addition to the debonding of the particle–matrix and whisker–matrix interface caused by cycle-by-cycle crack growth at the interface, the FCG is affected predominantly by striation formation in the Al matrix. Moreover, void nucleation and coalescence in the Al matrix and transgranular fracture of SiC particles and Al2O3 whiskers at high ?K are also observed as the local unstable fracture mechanisms.However, the FCG of the monolithic Al alloy is dominated by void nucleation and coalescence at lower ?K, whereas the FCG at higher ?K is controlled mainly by striation formation in the Al grains, and followed by void nucleation and coalescence in the Si clusters.

Modeling of Fatigue Crack Growth Closure Considering the Integrative Effect of Cyclic Stress Ratio,Specimen Thickness and Poisson's Ratio

Key components of large structures in aeronautics industry are required to be made light and have long enough fatigue lives.It is of vital importance to estimate the fatigue life of these structures accurately.Since the FCG process is affected by various factors,no universal model exists due to the complexity of the mechanisms.Most of the existing models are obtained by fitting the experimental data and could hardly describe the integrative effect of most existing factors simultaneously.In order to account for the integrative effect of specimen parameters,material property and loading conditions on FCG process,a new model named integrative influence factor model（IIF） is proposed based on the plasticity-induced crack closure theory.Accordingly to the predictions of crack opening ratio（γ） and effective stress intensity factor range ratio（U） with different material under various loading conditions,predictions of γ and U by the IIF model are completely identical to the theoretical results from the plane stress state to the plane strain state when Poisson＇s ratio equals 1/3.When Poisson＇s ratio equals 0.3,predictions of γ and U by the IIF model are larger than the predictions by the existing model,and more close to the theoretical results.In addition,it describes the influence of R ratios on γ and U effectively in the whole region from-1.0 to 1.0.Moreover,several sets of test data of FCG rates in 5 kinds of aluminum alloys with various specimen thicknesses under different loading conditions are used to validate the IIF model,most of the test data are situated on the predicted curves or between the two curves that represent the specimen with different thicknesses under the same stress ratio.Some of the test data slightly departure from the predictions by the IIF model due to the surface roughness and errors in measurement.Besides,based on the analysis of the physical rule of crack opening ratios,a relative thickness of specimen is defined to describe the influence of material property,specimen thickness and so forth on FCG characteristics conveniently.In conclusion,the relative thickness of specimen simplifies the expression of FCG characteristic and provides a general parameter to analyze the fatigue characteristics of different materials with various thicknesses under different loading conditions.The IIF model describes the integrative effect of existing influence factors explicitly and quantitatively,and provides a helpful tool for fatigue property estimation of practical component and experiment design.

Statistical Analysis Methods of Fatigue Crack Growth Rate

The standard center-cracked tensile specimens M （T） with different widths made of aluminum alloy were designed for fatigue crack growth rate experiments, and the effect of specimen size on the fatigue crack growth rate was discussed. The firing equation and the p-da/dN-△K curve of fatigue crack growth rate （with different confidence and reliability levels） were obtained by one-side tolerance factor analysis. In order to reasonably reflect the dispersion of material properties on the fatigue crack growth rate and fatigue crack propagation life, two novel statistical analysis methods were proposed, which can be used to describe the probability distribution of fatigue crack growth rate. Compared with the traditional statistical analysis method of probabilistic fatigue crack growth rate, the fitted curves from the novel statistical analysis methods yield more objective description on the probability distribution of crack growth rate.

Effect of Pre-loading on Short Fatigue Crack Growth at a Notch

Results indicate that under cyclic tension the growth rate of short fatigue crack from notch root will be lowered greatly by tensile pre-loading,but only a little change by compressive pre-loading. The effect of tensile pre-loading will decrease with the increase of stress ratio.The variation of short fatigue crack growth rate is related to the residual stress distribution around notch root.

Fatigue Crack Growth Behavior of Different Zones in an Annealed Automatic Gas Tungsten Arc Weld Joint of TA16 and TC4 Titanium Alloys

Based on the investigated microstructure of different zones in the annealed automatic gas tungsten arc weld joint of TA16 and TC4 titanium alloys,the mechanical property of them was assessed under fatigue crack growth rate tests.For evaluation of fatigue crack growth rate,three points bending specimens were used.The correlation between the range of stress intensity factor and crack growth rate was determined in different zones of the annealed weld joint.Fatigue crack growth rates were obviously different in different zones of weld joint of dissimilar titanium alloys,due to their different microstructures.Scanning electron microscope examinations were conducted on the fracture surface in order to determine the relevant fracture mechanisms and crack growth mechanisms with respect to the details of microstructure.