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Lecture 6
Fatigue Failure
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Part A
Preliminary Discussion
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Basic Definition
Definition of fatigue
ASTM E1823
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Basic Definition
Progressive
Fatigue process occurs over a period of time or usage
Localized
Fatigue process operates at local areas rather than throughout the
entire component or structure
Permanent
The structural change due to fatigue is an irreversible process
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Basic Definition
Fluctuating
Fatigue process involves stresses and strains that are cyclic in
nature and requires more than just a sustained load
Cracks
The ultimate cause of fatigue failure is that a crack has grown, due
to cyclic loading, to a point at which the remaining material can no
longer tolerate the stresses and strains
Fracture
The last stage of the fatigue process is separation of a component
or structure into two or more parts
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Fatigue of Metals
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Fatigue of Metals
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Beachmarks
(clamshell marks)
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Slip step
Static stress
Slip band
extrusion
Cyclic stress
Slip band
intrusion
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
1 1 1
2 2 2
3 3 3
4 4 4
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Crack path
Stage II
Crack profile of transgranular (transcrystalline) fatigue crack growth
in aluminum-lithium alloy
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Cyclic Stress
Random stress cycle Asymmetrical stress cycle Symmetrical (reversed) stress cycle
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Example 1
Question
A cylindrical fatigue specimen is subjected to a cyclic stress
loading on the form:
(t ) = 10 + 50 sin (t ) MPa
where is the angular velocity and t is time. Compute the mean
stress, stress amplitude, stress range and stress ratio
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
f = I + II : Number of cycles
I
= f (stress level, loading history, residual stresses, material properties, geometry)
II
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Fatigue Analysis
(Estimation of lifetime in service)
I >>> II I <<< II
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Part B
Fatigue Crack Nucleation
Approach
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Introduction
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Fatigue Testing
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Fatigue Testing
m = 0
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
m = 0 m = 0
(Aluminum)
(Steel)
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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m = 0
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Fatigue Strength
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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a = A ( f )B = 'f (2 f )b
f
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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( , )
f
a
SF = SF =
(safety factors in stress) (safety factor in lifetime)
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Example 2
Question
For the AISI 4340 steel, a stress amplitude of 500 MPa will be applied in service
for 2000 cycles. What are the safety factors in stress and in lifetime
a
a = A ( f )B
(500,2000)
f
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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S-N Curve
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Haigh Diagram
Lifetime decreases
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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u Tensile strength
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
1 Goodman line
a m
u + =1
Tensile strength
Sf u
~ fB True fracture strength
2 2 Gerber parabola
2
a
3 + m =1
S f u
3 Morrow line
1 a
+ ~m = 1
Sf fB
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Example 3
Question
A cylindrical 4340 steel bar is subjected to a fluctuating axial load that
varies from a maximum of 330 kN tension to a minimum of 110 kN
compression. Using the Goodman line, determine the minimum bar
diameter to give infinite fatigue life. The mechanical properties of the
steel are:
u = 1090 MPa S f = 204 MPa
a m
+ =1
Sf u
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Part C
Fatigue Crack Propagation
Approach
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Introduction
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Beach marks
(clamshell marks) Fatigue striations
10 m
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Fatigue Testing
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Fatigue Testing
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Geometry independence
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Region I
Below a threshold value Kth, no
observable fatigue crack growth
Kth occurs at crack propagation
rates of the order of 0.25 nm/cycle
or less
Region II
Represents an essentially linear
relationship between log da/dN and
log K
da
log log(K )
d
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Region III
Region of accelerated crack growth
Kmax approaches the fracture
toughness of the material KIC
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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Mathematical Representation
Paris Law
da
= C (K )
m
d
K = K max K min
= Y max a Y min a
C, m: Material parameters
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
Example 4
Question
Show that for the Paris Law, number of cycles to failure Nf required for
crack to propagate from initial length a0 to final length af , is given by
the following relation:
(a )
m m
(a0 )
1 1
2 2
da r = max min
= C (K ) f =
f
m
m
d C
m
r
m/2
Y 1
m
KQA 7007 / KXGB 6301 / KXGM 6310 Assoc. Prof. Dr. A. Andriyana
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