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Article history:
Received 19 June 2013
Received in revised form 11 January 2014
Accepted 14 January 2014
Available online 20 January 2014
Keywords:
Crack growth model
Fatigue crack growth
Overload cycle
Retarded crack length
Retardation parameters
a b s t r a c t
In the present work an attempt has been made to study the simultaneous effect of overload and
low temperature on fatigue crack growth behavior. It is known that overload application retards a
propagating fatigue crack. It has been observed in this study that application of the overload at low
temperature further enhances the magnitude of retardation. Various factors affecting retardation have
been analyzed and crack growth behavior is predicted using a modied exponential model. It is observed
that the proposed model estimates the crack growth rate and life accurately. The theoretically estimated
retardation parameters have been also found to be in good agreement with their experimental values.
2014 Elsevier Masson SAS. All rights reserved.
1. Introduction
Manufacturing, processing and fabrication introduce some defects and aws in engineering materials. The application of cyclic
and uctuating loads may initiate fatigue crack and subsequent
crack extension from these stress concentration sites. Attainment
of a critical length makes the component unreliable and may cause
complete failure of the structure. Estimation of crack growth behavior under such loading conditions is essential for stability and
safety of structure.
The loading condition, operating temperature and material
properties play important role in fatigue initiation and crack
growth behavior. It is known that introduction of spike or band
overload retards a growing fatigue crack resulting in enhancement
of the life of the structure and component. Aircrafts, ships, offshore structures etc. experience such load interactions during their
service. The introduction of overload cycle/s has been studied extensively and it is known to retard a growing fatigue crack [2,5,
14,26,30,31]. The magnitude of overload induced retardation is a
function of overload ratio, position of application of the overload,
material properties and the operating temperature.
Wheeler [30] proposed that retardation is achieved due to the
compressive residual stress eld due to the application of overload
1270-9638/$ see front matter 2014 Elsevier Masson SAS. All rights reserved.
http://dx.doi.org/10.1016/j.ast.2014.01.005
101
Nomenclature
a
ai
aj
aol
ad
aPd
aEd
A, B , C
B
C
da/dN
E
ys
f (g)
K
KC
crack length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
crack length corresponding to the ith step . . . . . .
crack length corresponding to the jth step . . . . . .
crack length at overload . . . . . . . . . . . . . . . . . . . . . . . . . . .
retarded crack length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
retarded (predicted) crack length . . . . . . . . . . . . . . . . .
mm
mm
mm
mm
mm
mm
K IC
K max
B
K max
K ol
K
K eff
l
m
mi j
n
N
Ni
Nj
Nd
N dP
N dE
Table 1
Chemical composition (in wt%).
Al
Cu
Mg
Mn
Fe
Si
Zn
Cr
Others
90.794.7
3.84.9
1.21.8
0.30.9
0.5
0.5
0.25
0.1
0.15
Table 2
Mechanical properties.
Tensile
strength (ut )
(MPa)
Yield
strength (ys )
(MPa)
Modulus of
elasticity (E)
(MPa)
Poissons
ratio ( )
(MPa m)
(MPa m)
Elongation
469
324
73,100
0.33
37.0
95.31
19% over
12.7 mm
GL
2. Experimental procedure
The present study was conducted on 2024-T3 Al-alloy whose
chemical composition and mechanical properties are given in Tables 1 and 2 respectively. Single-edge notched tension (SENT) specimens having a thickness of 6.5 mm were used for conducting
the fatigue tests. The specimens were made in the longitudinal
transverse (LT) direction. The detail geometry of the specimens is
presented in Fig. 1.
The experiments were performed in a servo-hydraulic dynamic
testing machine, Instron-8502, having a load capacity of 250 kN,
interfaced to a computer for machine control and data acquisition.
All the fatigue tests were conducted in air and at room temperature except during overloading. The test specimens were fatigue
precracked under mode-I loading to an a/ w ratio of 0.3 and were
subjected to constant load fatigue test (i.e. progressive increase in
K with crack extension) maintaining a load ratio, R = 0.1. Sinusoidal loads were applied at a frequency of 6 Hz. The crack growth
was monitored with the help of a COD gauge mounted on the face
of the machined notch. The following equation is used to determine stress intensity factor, K [3].
K = f (g)
wB
(1)
where,
+ 30.39(a/ w )4
(2)
102
Table 3
Load scenarios of the tested specimen.
F max
(kN)
F min
(kN)
F max(ol)
(kN)
R ol
ai
(mm)
aol
(mm)
af
(mm)
7.305
0.7305
15.341
2.10
17.75
20.40
32.40
a j = a i emi j ( N j N i )
(3)
where,
ai and a j = crack lengths in ith step and jth step in mm respectively,
N i and N j = Nos. of cycles in ith step and jth step respectively,
mi j = specic growth rate in the interval i j,
i = No. of experimental steps, and j = i + 1.
Fig. 1. Single edge notched specimen geometry.
B
ent temperatures of +25, 0, 28, 43, 53, 83 C, where, K max
is the maximum stress intensity factor for base line test. This is
followed by fatigue cycling under constant amplitude loading condition. Subsequently all the specimens were subjected to fatigue
test in mode-I and at constant load condition. The load scenarios
of the tests are presented in Table 3.
Low temperature was attained by passing liquid nitrogen
through a cooling chamber surrounding the specimen. The cooling
chamber consisted of two inlet ports in lower end and two outlet
ports in upper end connected by blind holes as shown in Figs. 2(a)
and 2(b). A gap of 4 mm was maintained on either sides of the
specimen in order to avoid direct physical contact with cooling
(a)
mi j =
ln( a j )
i
(4)
(N j N i )
(b)
Fig. 2. (a) Photograph of cooling chamber. (b) Schematic diagram of cooling chamber.
103
Table 4
Curve tting constants for R ol = 2.10.
A
B
C
D
103298.41 106
48410.452 106
5340.184 106
173.798 106
Table 5
Experimental and predicted results of the tested specimen at 0 C.
aPd
(mm)
aEd
(mm)
% error
in aPd
N dP 103
cycle
N dE 103
cycle
% error
in N dP
2.244
2.133
5.19
15.817
15.510
1.98
m = A l3 + B l2 + C l + D
(7)
where,
l=
K
K max
KC
KC
ys
E
1/4
(Rt)
(8)
Plane stress fracture toughness value was used in the expression as tests were conducted in that state. The plane stress fracture
toughness (K C ) is calculated from plane strain fracture toughness
(K IC ) using an empirical relation proposed by Irwin [9] as follows,
2
2
K C2 = K IC
1 + 1.4IC
(9)
where,
IC =
Nj =
ln( a j )
i
mi j
+ Ni
(5)
(a j ai )
=
dN
(N j N i )
da
1
B
K IC
ys
(10)
The calculated values of plane stress fracture toughness are presented in Table 2. The different m and l values for post overload
region are tted by a 3rd degree polynomial. The predicted values of m are obtained from Eq. (7) as per the procedure given
elsewhere [16]. The values of the constants A , B , C and D corresponding to the overload ratio 2.1 and the temperature range
+25 C to 83 C are tabulated in Table 4.
The predicted values of m for the specimen overloaded at 0 C
are calculated by putting the values of different constants from the
Table 4 in Eq. (7). Then the predicted values of N are calculated
using Eq. (5).
5. Results and discussion
(6)
104
has been observed that reversed plastic zone produced in the overload region due to Bauschinger effect is responsible for decrease in
the amount of retardation due to application of an overload [8,
22]. The reversed plasticity reduces the effectiveness of retardation caused by monotonic plastic zone [30]. The overload induced
monotonic plastic zone is dictated by K ol whereas K is responsible for inducing reversed plasticity. Application of overload at
low temperature decreases the size of overload-induced plastic
zone, responsible for retardation, due to increased value of yield
105
Fig. 10. Comparison of density of secondary cracks at different conditions of test temperatures. (a) Overloaded at room temperature. (b) Overloaded at 28 C. (c) Overloaded
at 53 C. (d) Overloaded at 83 C.
3. Monotonic and cyclic plastic zones and the size of elastic enclave.
All the above factors make the situation complex and the contribution of each component is dicult to quantify. The delay cycles shown in Fig. 9 reveals the combined effect of all the above
mentioned factors.
6. Conclusions
Fig. 11. Monotonic plastic zone size and respective elastic enclave.
The simultaneous effect of overload and low temperature on fatigue crack growth behavior has been studied and the crack growth
has been predicted by using the exponential model suitably modied to take into account the overload temperature. The model has
been developed by using the crack growth data of 25, 28, 43,
53, 83 C overload temperatures and validated by predicting
the fatigue life for the specimen overloaded at 0 C. Various factors affecting retardation have been analyzed and the results are
concluded as,
1. The application of an overload retards the crack growth rate
resulting in enhanced fatigue life.
2. Overload at low temperature enhances the retardation effect
more than overloading at normal (room) temperature.
3. The presence of a large number of secondary cracks formed in
the overload affected tear zone due to low temperature environment is responsible for enhancing the retardation effect by
reducing the available K for primary crack extension.
4. The enhanced crack extension with lowering of temperature
of overload cycle can also be explained with the help of
Bauschinger effect.
5. The relative increase in magnitude of retardation decreases
with decrease in temperature. This may be explained on the
basis of decrease in the monotonic plastic zone size as well as
106
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