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10-10
10-8
10-6
10-4
10-2
100
102
Understand the physics on this scale Model the physics on this scale Use the models on this scale
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N = 10,000
Fatigue, How and Why
N = 40,000
Nf = 170,000
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Ewing, J.A. and Humfrey, J.C. The fracture of metals under repeated alterations of stress, Philosophical Transactions of the Royal Society, Vol. A200, 1903, 241-250
2009 Darrell Socie, All Rights Reserved
Crack Nucleation
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Polak, J. Cyclic Plasticity and Low Cycle Fatigue Life of Metals, Elsevier, 1991
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Loading
Fatigue, How and Why
Unloading
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Slip Bands
Ma, B-T and Laird C. Overview of fatigue behavior in copper sinle crystals II Population, size, distribution and growth Kinetics of stage I cracks for tests at constant strain amplitude, Acta Metallurgica, Vol 37, 1989, 337-348
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N = 60
N = 240
N = 300
N = 1200
Fatigue, How and Why
N = 2000
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Crack at Particle
Material: BS L65 Aluminum Loading: 63 ksi, R=0 for 500,000+ cycles, followed by 68 ksi, R=0 to failure. Cracks found during 68 ksi loading.
S. Pearson, Initiation of Fatigue Cracks in Commercial Aluminum Alloys and the Subsequent Propagation of Very Short Cracks, RAE TR 72236, Dec 1972.
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10 m James & Morris, ASTM STP 811 Fatigue Mechanisms: Advances in Quantitative Measurement of Physical Damage, pp. 46-70, 1983.
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S. Pearson, Initiation of Fatigue Cracks in Commercial Aluminum Alloys and the Subsequent Propagation of Very Short Cracks, RAE TR 72236, Dec 1972.
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Langford and Kusenberger, Initiation of Fatigue Cracks in 4340 Steel, Metallurgical Transactions, Vol 4, 1977, 553-559
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Y. Murakami, Metal Fatigue: Effects of Small Defects and Nonmetallic Inclusions, 2002
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0.35
500
1000
1500
2000
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Surface Damage
surface surface bulk
10 m
100 m
20-25 austenitic steel in symmetrical push-pull fatigue (20C, p/2= 0.4%) : short cracks on the surface and in the bulk
From Jacques Stolarz, Ecole Nationale Superieure des Mines Presented at LCF 5 in Berlin, 2003
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free surface
Stage I
Fatigue, How and Why
Stage II
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Stage I crack is strongly affected by slip characteristics, microstructure dimensions, stress level, extent of near tip plasticity
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N = 900
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Crack Length, mm
0.5
Cycles
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E D
10-7 A B C
0.03 0.025 0.02 0.015 0.01 0.005 0 0.005 0.01 0.015 0.02 0.025 Crack Length, mm
Akiniwa, Y., Tanaka, K., and Matsui, E.,Statistical Characteristics of Propagation of Small Fatigue Cracks in Smooth Specimens of Aluminum Alloy 2024-T3, Materials Science and Engineering, Vol. A104, 1988, 105-115
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Strain-Life Data
10m
Crack size
2 Strain Amplitude
0.1
101
102
103
104
105
106
107
Reversals, 2Nf Most of the life is spent in microcrack growth in the plastic strain dominated region
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Plastic zone size is much larger than the material microstructure so that the microstructure does not play such an important role.
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Material strength does not play a major role in fatigue crack growth
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Crack Closure
a b c
S=0
Fatigue, How and Why
S = 175
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S = 250
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Mode I Growth
5 m
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Mode II Growth
shear stress
slip bands
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Tension
10
10
10
10
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0.8
f
0.6 0.4
0.2 0 1 10 10
2
Shear Nucleation 10
3
10
10
10
10
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Characterization
Stress Life Curve
Fatigue Limit
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Bending Fatigue
stress amplitude stress
F Bending stress:
Mc = I
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SN Curve
500
Monel Alloy
400 300 200 500 400 300 200 105 0 1x108 2x108 3x108 4x108 5x108
Cycles to Failure
106
107
108
109
1 hour
1 day
1 month
1 year
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Fatigue Strength
Fatigue Life
Alloy 2014-T4 2024-T4 6061-T6 7075-T6 105 290 297 186 276 106 235 214 152 200 107 186 166 117 166 108 152 145 104 152 109 138 138 90 145
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Sharpe et. al. Fatigue Design of Aluminum Components and Structures , 1996
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S b = S'f (Nf ) 2
1000
fatigue limit
100 102
103
104
105
106
107
108
109
Cycles The fatigue limit is usually only found in steel laboratory specimens
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internal inclusions
100 103
104
105
106
107
108
109
1010
Cycles
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Fatigue Damage
Stress Amplitude, MPa 10000
S b = S'f (Nf ) 2
1 10
1000
100 100
101
102
105
106
107
S Nf = ' 2S f
1 b
Damage S10
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0.35
500
1000
1500
2000
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SN Materials Data
10000 93 steels 17 aluminums Stress Amplitude, MPa
1000
100
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p
Fatigue, How and Why
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Strain-Life Data
600
Stress Amplitude 2
= + 2 K' 2 2E
1/ n'
2 During cyclic deformation, the material deforms on a path described by the cyclic stress strain curve Strain Amplitude
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0.004
0.008
0.012
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Strain-Life Data
2
1 0.1 0.01 0.001 10-4 10-5 100
- 2Nf
Strain Amplitude
101
102
103
104
105
106
107
Reversals, 2Nf
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Plastic
0.1 0.01
Strain Amplitude
Elastic
101
102
103
104
105
106
107
Reversals, 2Nf
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Strain-Life Curve
2
1 0.1 0.01 0.001 10-4 10-5 100 101 102 103
'f
c
Strain Amplitude
'f E
2Nt
104 105 106 107
Reversals, 2Nf
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N Materials Data
10 93 steels Strain Amplitude 1 17 aluminums
0.1 10-2 10-3 10-4 1 10 102 103 104 105 106 107
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K T = 1+ 2
KT ~ 2000
Traditional material properties like tensile strength are not very useful for cracked structures
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K = a
K characterizes the magnitude of the stresses, strains, and displacements in the neighborhood of a crack tip Two cracks with the same K will have the same behavior
2a
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a2 a1
da dN
2a
Cycles
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Kc
da = C K m dN
m~3
10
100
KTH
Fatigue, How and Why
K,MPa m
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Threshold Region
a K TH > a f w
operating stresses
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K TH ac = 0.63
K TH ac = 2.52 u
Fatigue, How and Why
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Crack Size, mm
K TH = 5 MPa m
0.8 0.6 0.4 0.2 0 0 500 1000 1500 2000
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Kc
da = C K m dN
10
100
KTH
Fatigue, How and Why
K,MPa m
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Ferritic-Pearlitic Steel: da = 6.9 10 12 K MPa m dN Martensitic Steel: da = 1.4 10 10 K MPa m dN Austenitic Stainless Steel:
3.0
10-7
2.25
da = 5.6 10 12 K MPa m dN
3.25
Barsom, Fatigue Crack Propagation in Steels of Various Yield Strengths Journal of Engineering for Industry, Trans. ASME, Series B, Vol. 93, No. 4, 1971, 1190-1196
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Sharp, Nordmark and Menzemer, Fatigue Design of Aluminum Components and Structures, 1996
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Crack Length, mm
Virkler, Hillberry and Goel, The Statistical Nature of Fatigue Crack Propagation, Journal of Engineering Materials and Technology, Vol. 101, 1979, 148-153
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Fatigue Analysis
Material Data
Analysis
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Life Estimation
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P
Stress Amplitude, MPa 10000
1000
100 100
101
102
105
106
107
The Similitude Concept states that if the instantaneous loads applied to the test structure (wing spar, say) and the test specimen are the same, then the response in each case will also be the same and can be described by the materials S-N curve.
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Material Data
Kf
Analysis
S , Sm
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Stress-Life
Major Assumptions:
Most of the life is consumed nucleating cracks Elastic deformation Nominal stresses and material strength control fatigue life Accurate determination of Kf for each geometry and material
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Stress-Life
Advantages:
Changes in material and geometry can easily be evaluated Large empirical database for steel with standard notch shapes
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Stress-Life
Limitations:
Does not account for notch root plasticity Mean stress effects are often in error Requires empirical Kf for good results
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100
The Similitude Concept states that if the instantaneous loads applied to the test structure (welded beam on a bulldozer, say) and the test specimen (standard fillet weld) are the same, then the response in each case will also be the same and can be described by one of the standard BS 7608 Weld Classification S-N curves.
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Weld Classifications
D E
F2
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Material Data
Weld SN curve
Class
Analysis
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BS 7608
Major Assumptions:
Crack growth dominates fatigue life Complex weld geometries can be described by a standard classification Results independent of material and mean stress for structural steels
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BS 7608
Advantages:
Manufacturing effects are directly included Large empirical database exists
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BS 7608
Limitations:
Difficult to determine weld class for complex shapes No benefit for improving manufacturing process
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101
102
105
106
107
The Similitude Concept states that if the instantaneous strains applied to the test structure (vehicle suspension, say) and the test specimen are the same, then the response in each case will also be the same and can be described by the materials e-N curve. Due account can also be made for stress concentrations, variable amplitude loading etc.
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Material Data
Kf
Analysis
S , Sm
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Strain-Life
Major Assumptions:
Local stresses and strains control fatigue behavior Plasticity around stress concentrations Accurate determination of Kf
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Strain-Life
Advantages:
Plasticity effects Mean stress effects
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Strain-Life
Limitations:
Requires empirical Kf Long life situations where surface finish and processing variables are important
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10-6 Crack Growth Rate, m/cycle 10-7 10-8 10-9 10-10 10-11 10-12 1
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Material Data
da/dN curve
Analysis
S , Sm
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Crack Growth
Major Assumptions:
Nominal stress and crack size control fatigue life Accurate determination of initial crack size
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Crack Growth
Advantage:
Only method to directly deal with cracks
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Crack Growth
Limitations:
Complex sequence effects Accurate determination of initial crack size
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Design Philosophy
Safe Life Damage Tolerant
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Safe Life
500
400
300
99 90
50
10
Percent Survival
106
107
108
109
Fatigue Life
Choose an appropriate risk and replace critical parts after some specified interval
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Damage Tolerant
Inspection
Crack size a2 a1
Inspection
A Boeing 777 costs $250,000,000 A new car costs $25,000 For every $1 spent inspecting and maintaining a B 777 you can spend only 0.01 on a car
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Similitude
Failure mechanism Size Scale
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www.FatigueCalculator.com
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Finders
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Deterministic Analysis
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Probabilistic Analysis
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