Numerical Simulation and Experimental Studies on Elastic-Plastic Fatigue Crack Growth

A elastic-plastic fatigue crack growth(FCG)finite element model was developed for predicting crack growth rate under cyclic load.The propagation criterion for this model was established based on plastically dissipated energy.The crack growth simulation under cyclic computation was implemented through the ABAQUS scripting interface.The predictions of this model are in good agreement with the results of crack propagation experiment of compact tension specimen made of 304 stainless steel.Based on the proposed model,the single peak overload retardation effect of elastic-plastic fatigue crack was analyzed.The results shows that the single peak overload will reduce the accumulation rate of plastic energy dissipation of elements at crack tip plastic zone,so that crack growth will be arrested.The crack growth rate will not recover until the crack tip exceed the affected region.Meanwhile,the crack growth rate is mainly determined by the amplitude rather than the mean load under the condition of small scale yielding.The proposed model would be helpful for predicting the growth rate of mode I elastic-plastic fatigue crack.

EXPERIMENTAL AND THEORETICAL STUDY ON NUMERICAL DENSITY EVOLUTION OF SHORT FATIGUE CRACKS

Fatigue testing was performed using a kind of triangular shaped specimen to obtain the characteristics of numerical density evolution for short cracks at the primary stage of fatigue damage. The material concerned is a structural alloy steel. The experimental results show that the numerical density of short cracks reaches the maximum value when crack length is slightly less than the average grain diameter, indicating grain boundary is the main barrier for short crack extension. Based on the experimental observations and related theory, the expressions for growth velocity and nucleation rate of short cracks have been proposed. With the solution to phase space conservation equation, the theoretical results of numerical density evolution for short cracks were obtained, which were in agreement with our experimental measurements.

Influence of Rare Earth Element on Short Fatigue Crack Threshold for Al－Li Alloy 2090

Curves of △Kth vs.△ath and △Kcl·th vs.△ath for aluminum-lithium alloy 2090 have been determined and compared with those for traditional aluminum alloy 2024.The growth resistance of short fatigue cracks for aluminum-lithium alloy 2090 is quantitatively evaluated.The essential reason resulting in stronger short cracks effect has been ascertained.Influence of cerium on the growth behavior of short fatigue cracks for aluminum-lithium alloy 2090 was investigated.The results show that by adding cerium into this alloy a significant improvement in △Ki can be achieved and at the same time △Kcl·th is increased.Consequently,the essential factor resulting in lower growth resistance of short fatigue cracks for this alloy is removed and the growth resistance of long and short fatigue cracks is increased.

Density Evolution of the Surface Short Fatigue Cracks of 1Cr18Ni9Ti Pipe-Weld Metal

The evolutionary density and the scatter of densities of the short fatigue cracks on the surface of 1Cr18Ni9Ti pipe-weld metal were observed by local and overall viewpoints, respectively. The local viewpoint, which is in accordance with a so-called "effectively short fatigue crack criterion", paid attention to the dominant effective short fatigue crack (DESFC) initiation zone and the zones ahead of the DESFC tips. The overall viewpoint focused on the whole test piece of specimen. The results revealed that the density and scatter evolution exhibited a significant character of microstructural short crack and physical short crack stages. The evolutionary behavior by the local viewpoint was sensitive to the increase of DESFC size and tip location. The mechanism of the short crack growth associated with the general test observations that the DESFC acted gradually as a long crack and the scatter of DESFC growth rates tended gradually to that of a long crack was well revealed. Intrinsic causes of the random cyclic strain-life relations and stress-strain responses are appropriately given. In contrast, the evolutionary behavior by the overall viewpoint was non-sensitive and violated the general test observations. Therefore, the intrinsic localization and randomization of material evolutionary fatigue damage should be more appropriately revealed from the observations by the local viewpoint.

SHORT FATIGUE CRACK BEHAVIOUR IN ISO-STRESS SPECIMENS

Fatigue tests were made on a vibration machine using specially designed specimens to investi- gate the initiation and propagation features of short fatigue cracks in a weld metal.The spec- imens were triangular in shape so that when loaded as a cantilever beam the surface tensile stress is constant.Test results show that short fatigue cracks mainly originate from slip bands within ferrite grains.The development of short fatigue cracks is marked by a gradual increase in crack density with fatigue cycles.Coalescence of short cracks leads to crack propagation and the crack path is predominantly transgranular.

GROWTH BEHAVIOR OF SHORT FATIGUE CRACKS FOR ALUMINUM- LITHIUM ALLOY 8090

The growth behaviors of short through cracks (0.2 < △a < 2.2mm) and long cracks are compared using CT type specimens in aluminum-lithium alloy 8090 T651. It is found that the short cracks grow much more than long ones and are observed to grow at the stress intensity ranges far below the long crack threshold. The distinction of growth bahavior between short and long cracks is attributed to the difference of their crack closure effect. The growth behavior of short cracks can be rationalized with that of long ones in terms of effective stress intensity ranges. The upper demarcation value of short through cracks for aluminum-lithium alloy 8090 is presented.

THRESHOLD OF SHORT FATIGUE CRACK FOR Al-Li ALLOY 8090

Threshold of fatigue for short through cracks for Al-Li alloy 8090 was evaluated to be lower than that of long cracks,and to decrease with the shortening of the crack length.The correla- tion among the threshold,crack wake,and crack tip shielding of the short fatigue cracks was discussed.The super demarcation length and lowest theoretical threshold of short through fa- tigue cracks were presented.

Influence Mechanism of Cerium on the Threshold of Short Fatigue Crack for Aluminum-lithium Alloy 2090

The thresholds of short fatigue cracks for aluminum-lithium alloys 2090 and 2090+Ce are quantitatively evaluated. The essential reason resulting in stronger short crack effect has been ascertained. Influence of cerium on the threshold of short fatigue cracks for aluminum-lithium alloy 2090 was investigated. The results show that, by adding Ce into this alloy, DeltaK(i) and DeltaK(Cl.th) are increased. The influence mechanism of Ce on the threshold of short fatigue crack for alloy 2090 was explored fi om the bound energy, T, phase, the energy of anti-phase boundary, the energy of super-lattice intrinsic stacking fault and the electron bonds. By adding Ce into alloy 2090, the bound energy of Cu atom in this alloy is increased; the effect of thinning and dispersing T, phase is obtained; the effect of increasing the energy of anti-phase boundary and decreasing the energy of super-lattice intrinsic stacking fault for delta ' phase can be achieved.

Size Evolution of the Surface Short Fatigue Cracks of 1Cr18Ni9Ti Weld Metal

Size evolution of the surface short fatigue cracks of lCrl8Ni'9Ti weld metal was investigated. A local viewpoint is applied to be agreement with a so-called 'effectively short fatigue crack criterion'. Attention was paid to the dominant effectively short fatigue crack (DESFC) initiation zone and the zones ahead of the DESFC tips. The results revealed that the evolutionary size shows a significant character of microstructural short crack (MSC) and physical short crack (PSC) stages. In the MSC stage, fatigue damage is due to mainly the initiation and irregular growth of the effectively short fatigue cracks (ESFCs). In the PSC stage, the damage is conversely due to mainly the DESFC growth and partially, the growth of the ESFCs and the coalescence of the ESFCs themselves with the DESFC. The process involves from a non-ordered/chaotic state in the initiation of MSC stage, gradually to an independently random state at the transition point between the MSC and PSC stages and then, to an ordered/history-dependent random state. Interactive effect of the collective cracks is stronger and shows an increase in the MSC stage, it reaches a maximum value at the transition point and then, tends to a decrease in the PSC stage. The DESFC acts as a result of the interactive cracks and thus, is deemed suitable to describe the behaviour of collective cracks.

GROWTH OF SHORT CRACKS OF A537CLI STEEL UNDER FATIGUE LOADING IN 3.5% NaCl SOLUTION

The effects of environmental media,both in atmosphere and in 3.5% NaCl aqueous solution, on the growth of short cracks in comparison with the long ones have been investigated under fatigue loading on the specimens of single-edge crack about 0.05—0.15 mm for A537CLI steel.The growth rate of short cracks is faster than those of long ones around the threshoht stress intensity.The threshold stress intensity for short crack growth decreases with de- creasing crack length.The acceleration effect of the salt water,as compared with atmosphere environment,on the growth of short cracks under fatigue is much greater than that on the growth of long cracks.

A Statistical Study on the Initiation and Growth Lives of Short Fatigue Cracks

In order to clarify the physical background of the scatter in fatigue behaviour, rotary bending fatigue tests are carried out using smooth speciments of a medium carbon steel with two kinds of grain sizes. The statistical characteristics of short carck initiation and growth lives are investigated by a new definition of short fatigue crack initiation. Detailed analysis reveals that the distribution of short crack initiation life can be expressed by two or threeparameter Weibull distribution, and the threeparameter Weibull distribution is well fitted to the distribution of short crack growth life, and the grain size and stress level have a great influence on the statistical characteristics of crack initiation and growth life.

STUDY ON FATIGUE SHORT CRACK GROWTH LAW AND FATIGUE LIFE FOR MEDIUM CARBON STEELS

The fatigue crack initiation from notch root and the short-crack growth laws of two medium carbon alloying structural steels—35CrMo and 42CrMo are investigated under the different stress ratios R =0.1, 0.3) and three-point bending condition. The relationships between the maximum stress range at the notch root Δ σ max and the number of cycles before fatigue crack initiation N i are determined. The threshold stresses of fatigue crack initiation (Δ σ max ) th are got, and the smallcrack growth laws are obtained for these steels. An effective and convenient method is proposed for predicting the fatigue life of the notch specimens.

A STATISTICAL INVESTIGATION OF THE BEHAVIOR OF SHORT FATIGUE CRACK IN MEDIUM CARBON STEELS

Rotary bending fatigue tests were carried out by using smoothspecimens of medium car- bon steel with two ferrite grain sizes. Inorder to clarify the physical background of the scatter in fa- tiguebehavior, the statistical characteristics of the initiation andgrowth of short fatigue crack were in- vestigated. Results show thatthe short crack initiation and growth life distribution can beexpressed by two-or three-parameter Weibull distribution. The Weibulldistribution of the mixed type is well fitted to the crack lengthdistribution for both steels. The knee values of Weibull plots arerelated to the grain size.

Nonequilibrium Statistical Modeling of Fatigue Crack Growth Behaviour

In order to study the influence of microstructural texture on the growth of short fatigue cracks in metals, the nonequilibrium statistical theory of fatigue fracture correlating a microscopic mechanism with the macroscopic properties is modified to take into consideration the microstructural features of a material, thereby allowing a rationalisation of the experimental data of short fatigue crack growth and long fatigue crack growth. The nonequilibrium statistical theory thus developed relates the growth of cracks with a dislocation mechanism to simulate short fatigue crack growth with the long fatigue crack growth behaviour and predicts the fatigue crack growth rates throughout the fatigue lifetime. The results is finally compared with that of other fatigue theories.

Optimization of Preventive Grinding of Backup Roll against Contact Fatigue Cracking

In order to optimize the current grinding procedure of the backup roll of 2050 continuously variable crown (CVC) mills, the behavior of rolling contact fatigue (RCF) cracking was investigated. Two RCF short cracks, including vertical short crack and ratcheting short crack initiated from ratcheting, were observed. The behavior of both RCF cracks was analyzed in detail. Then a modified grinding procedure was proposed according to the behavior of RCF cracks and the preventive grinding strategy.

钢桥复杂构造疲劳裂纹跨尺度扩展与寿命预测

针对传统宏观唯像学方法无法描述钢桥疲劳损伤由微观到宏观的多尺度演化过程的问题,建立了可描述钢桥复杂构造疲劳裂纹跨尺度扩展与寿命预测方法.首先,结合微观晶体塑性本构模型,建立了以能量耗散理论为基础的微观短裂纹成核与扩展模型.同时,结合线弹性断裂力学,建立了宏观长裂纹扩展模型.在此基础上,以钢桥典型的纵肋与顶板焊接构造细节为研究对象,结合既有疲劳试验,模拟并验证了微观短裂纹的成核、扩展,以及宏观长裂纹扩展全过程.数值模拟结果与试验结果基本一致,表明所提出的疲劳裂纹跨尺度扩展与寿命预测方法对于钢桥复杂构造细节疲劳损伤演化与评估具有较好的适用性.

基于FRANC3D和LSTM的桥梁钢桁架裂纹寿命预测

为了对裂纹疲劳寿命进行快速准确预测,针对常用的疲劳实验和数值仿真实验中各自存在的实验条件受限、计算步骤繁琐、计算过程耗时较长等问题,以大型桥梁钢桁架中的裂纹为研究对象,提出一种结合裂纹分析软件FRANC3D和长短期记忆(long short term memory,简称LSTM)网络模型的裂纹疲劳寿命预测方法。首先,建立钢桁架的有限元模型,通过裂纹分析软件FRANC3D进行疲劳裂纹扩展分析并建立相关数据集;其次,通过疲劳裂纹的扩展仿真数据关注裂纹的扩展状况,收集裂纹特征信息对裂纹疲劳寿命进行预测。实验结果表明,所提出的方法具有较高的预测准确性,同时极大地提升了训练速度,可为裂纹疲劳寿命预测提供参考。

晶粒分布形态对焊趾短裂纹疲劳行为影响的模拟

焊接结构的疲劳裂纹常常萌生于焊趾局部。在复杂的冶金物理作用下,焊趾局部的微观晶粒尺寸及其分布形态呈现明显差异性。为了探究晶粒分布形态对焊趾短裂纹疲劳行为的影响,针对十字焊接接头试件,对焊趾局部的不同区域进行了金相检验,获得粗晶区和细晶区的平均晶粒尺寸,构建了虑及晶粒分布形态的二维代表性体积单元(RVE)模型,基于FIP参量和McDowell模型实现了不同晶粒分布形态对焊趾短裂纹的成核与疲劳扩展行为的模拟,结果表明,微观晶粒尺寸和取向是焊趾短裂纹成核行为的重要影响因素;晶粒分布形态对短裂纹的早期行为影响较小,但在裂纹扩展至某个阈值长度之后,影响逐渐显著;一般情况下,细晶到粗晶的过渡方式可降低短裂纹的扩展速率。

基于显微DIC的谐振疲劳短裂纹尖端变形场演化规律

为研究疲劳短裂纹扩展机理,提出一种基于显微数字图像相关(DIC)的塑性金属材料谐振疲劳短裂纹尖端位移场、应变场和塑性区的测量方法,并对其演化规律进行研究。通过显微摄像系统采集疲劳裂纹扩展过程中谐振载荷最大点试件短裂纹图像;采用DIC方法获得裂纹尖端区域位移场和应变场的数据。通过虚拟引伸计技术结合位移场演化数据获得短裂纹扩展过程中裂纹尖端坐标,进而根据von Mises屈服准则和应变场数据确定裂纹尖端塑性区尺寸及演化规律并与Irwin模型的理论尺寸进行对比验证;采用电子背散射衍射(EBSD)技术测量典型塑性金属材料316不锈钢疲劳裂纹尖端的晶粒尺寸分布,进一步研究谐振载荷作用下疲劳短裂纹尖端区域沿晶粒尺度的位移和应变的演化规律。研究结果表明:提出的方法成功获取了短裂纹微米级变形场演化数据,为塑性金属材料疲劳短裂纹扩展特性的进一步研究和疲劳寿命预测提供了实验和理论支持。

具有不同梯度晶粒组织的粉末高温合金疲劳小裂纹扩展原位观察

采用扫描电子显微镜原位观察的方法对某第三代粉末高温合金不同微观组织的疲劳裂纹萌生和小裂纹扩展行为进行了研究,揭示了双性能粉末涡轮盘轮缘(粗晶组织)、轮心(细晶组织)及晶粒过渡区(梯度结构组织)的微观组织对疲劳小裂纹扩展的影响规律。结果表明:缺口处的一次强化相易成为裂纹萌生位置,其中梯度结构组织呈现出从晶界处开裂的多裂纹萌生特征。对于梯度结构试样,室温下的小裂纹扩展行为受微观结构影响显著,疲劳裂纹扩展速率波动较大。在应力强度因子范围较低时,粗晶试样的裂纹扩展速率高于细晶;随着应力强度因子范围逐渐增大,细晶试样的疲劳裂纹扩展速率增加更快,并高于粗晶试样;这与较长的滑移路径、增强的滑移可逆性和较少的晶界阻碍、减弱的不连续度之间的竞争机制相关。