Lec 19: Fatigue

Saturday, 5 November 2016 10:31 AM

 Fatigue
○ A form of failure that occurs in structures subjected to dynamic and fluctuating stresses
○ e.g. bridges, aircraft, and machine components
○ Under these circumstances, it is possible for failure to occur at a stress level considerably lower
than the tensile or yield strength for a static load
○ Used because this type of failure normally occurs after a lengthy period of repeated stress or
strain cycling
○ Causes 90% of all metallic failures
○ Polymers and ceramics (except for glasses) are also susceptible to this type of failure
○ Catastrophic and insidious, occurring very suddenly and without warning
○ Brittlelike in nature even in normally ductile metals, hence, very little, if any, gross plastic deformation
associated with failure
○ Process occurs by the initiation and propagation of cracks, and ordinarily the fracture surface is
perpendicular to the direction of an applied tensile stress

8.7 CYCLIC STRESSES

 Applied stress may be axial (tension-compression), flexural (bending), or torsional (twisting) in nature
 Three fluctuating stress-time modes:

1. REVERSED STRESS CYCLE

○ Fig. 9.23a
○ Represented schematically by a regular and sinusoidal time dependence
Amplitude is symmetrical about a mean zero stress level

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 ○ Amplitude is symmetrical about a mean zero stress level
○ e.g. alternating from a maximum tensile stress ( ) to a minimum compressive stress ( )
of equl magnitude
2. REPEATED STRESS CYCLE
○ Fig. 9.23b
○ The maxima and minima are asymmetrical relative to the zero stress level
3. RANDOM STRESS CYCLE
○ Fig. 9.23c
○ Stress level may vary randomly in amplitude and frequency
 Parameters used to characterize the fluctuating stress cycle

1. Mean stress,
○ Where the stress amplitude alternates
○ Average of the maximum and minimum stresses in the cycle
○
2. Range of stress,
○ Difference between and
○
3. Stress amplitude,
○ One-half of this range of stress

4. Stress ratio, R
○ Ratio of minimum and maximum stress amplitudes

8.8 The S-N Curve

 Fatigue properties of materials can be determined from laboratory simulation tests
 Test apparatus should be designed to duplicate as nearly as possible the service stress conditions
○ e.g. stress level, time frequency, stress pattern
 Rotating-bending test apparatus

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 ○

○ Used for fatigue testing

○ The compression and tensile stresses are imposed on the specimen as it is simultaneously bent and
rotated
○ May use an alternating uniaxial tension-compression stress cycle
○ Tests are done by subjecting a specimen to the stress cycling at a relatively large maximum stress
amplitude ( ) (i.e. on the order of 2/3 of the static tensile strength then the number of cycles to
failure is counted
○ Then repeated on other specimens at progressively decreasing maximum stress amplitudes
○ Plot: stress S vs. the logarithm of the number N of cycles to failure for each of the specimens
○ S - stress amplitude,
○ S- or values may be used
 Types of S-N behavior and Domains
○ The higher the magnitude of the stress, the smaller the number of cycles the material is capable of
sustaining before failure.
1. Fatigue Limit
 Aka Endurance limit
 Defined as a limiting stress level wherein the S-N curve becomes horizontal at higher N values
below which fatigue failure wil not occur

 Represents the largest value of fluctuating stress that wil not cause failure for essential y an
infinite number of cycles
 For steels, it is between 35% and 60% of the tensile strength
 Domain: LOW-CYCLE FATIGUE
□ Associated with relatively high loads that produce not only elastic strain but also some
plastic strain during each cycle
□ Fatigue lives are relatively short
□ Occurs at less than about 104 to 105 cycles

2. Fatigue Strength
 For most nonferrous alloys (e.g. Al, Cu, Mg) do not have fatigue limit
 The S-N curve continues its downward trend at increasingly greater N values. Thus, fatigue
wil ultimately occur regardless of the magnitude of the stress
 It is defined as the stress level at which failure wil occur for some specified number of
cycles.
□ e.g. 107 cycles

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 □

 Domain: HIGH-CYCLE FATIGUE

□ Lower stress levels wherein deformations are totally elastic, longer lives result
□ Relatively large numbers of cycles are required to produce fatigue failure
□ Associated with fatigue lives greater than about 104 to 105 cycles
 Fatigue life, Nf
○ Another important parameter that characterizes a material's fatigue behavior
○ It is the number of cycles to cause failure at a specified stress level.
○ See Fig. 9.25b
○ There always exists considerable scatter in fatigue data.
 A variation in the measured N value for a number of specimens tested at the same stress
level that wil lead to significant design uncertainties when fatigue life and/or fatigue limit
(strength) are being considered
 A consequence of the fatigue sensitivity to a number of test and material parameters that are
impossible to control precisely
□ Parameters: specimen fabrication and surface preparation, metallurgical variables,
specimen aligment in the apparatus, mean stress and test frequency
 Fig. 9.25 represent best fit curves that have been drawn through average-value data points
□ Approximately 1/2 of the specimens tested actually failed at stress levels lying nearly
25% below the curve
 Several statistical techniques have been developed to specify fatigue life and fatigue limit in
terms of probabilities.
□ e.g. Series of constant probability curves

 P represents the probability of failure

 Example: At a stress of 200 MPa, we would expect a 1% of the specimens to
fail at about 106 cycles.
8.9 Crack Initiation and Propagation
 Process of fatigue failure
1. Crack initiation
 A small crack forms at some point of high stress concentration

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  A small crack forms at some point of high stress concentration
 Cracks associated with fatigue failure almost always initiate (or nucleate) on the surface of a
component at some point of stress concentration
 Crack nucleation sites: surface scratches, sharp fil ets, keyways, threads, dents
 Cyclic loading can produce microscopic surface discontinuities resulting from dislocation slip
steps that may also act as stress raisers, and therefore as crack initiation sites
2. Crack propagation
 Crack advances incrementally with each stress cycle
 Region of a fracture surface that formed during the crack propagation step may be
characterized by TWO types of MARKINGS:
□ Both indicate the position of the crack tip at some point in time and appear as concentric
ridges that expand away from the crack initiation sites, frequently in a circular or
semicircular pattern
□ Have similar appearances but they are stil different, both in origin and size
1. Beachmarks
 Also called "clamshell marks"
 Of macroscopic dimensions that may be observed with the unaided eye

 Found for components that experienced interruptions during the crack

propagation stage
◊ Example: a machine that operated only during normal work-shift hours
 Found for components that experienced interruptions during the crack
propagation stage
2. Striations
 Microscopic in size and subject to observation with the electron microscope either
TEM or SEM

 Each striation is thought to represent the advance distance of a crack front

during a single load cycle
 Striation width = f(increasing stress range)
Striation width Stress range

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  Striation width Stress range
□ There may be thousands of striations within a single beachmark.
□ The presence of beachmarks and/or striations on a fracture surface confirms that the
cause of failure was fatigue. Nevertheless, the absence of either or both does not
exclude fatigue as the cause of failure.
□ Beachmarks and striations wil not appear on that region over which the rapid failure
occurs.
 Rather, the rapid failure may either be ductile or brittle; presence of plastic
deformation for ductile and absent for brittle

3. Final failure
 Occurs very rapidly once the advancing crack has reached a critical size

8.10 Factors that affect Fatigue Life

1. Mean Stress
○ Dependence of fatigue life on stress amplitude
 Taken for constant mean stress, often for the reversed cycle ( )
○ Increasing the mean stress level leads to a decrease in fatigue life

2. Surface Effects
○ The maximum stress within a component or structure occurs at its surface. Consequently, most
cracks leading to fatigue failure originate at surface positions, specifically at stress amplification sites.
Therefore, fatigue life is especial y sensitive to the condition and configuration of the component
surface.
3. Design Factors
○ Any notch or geometrical discontinuity can act as a stress raiser and fatigue crack initiation site
 Examples: grooves, holes, keyways, threads
 The sharper the discontinuity (i.e. the smaller the radius of curvature), the more severe the
stress concentration.
 Preventive measure: avoiding when possible these structural irregularities, making design
modifications whereby sudden contour changes leading to sharp corners are eliminated
□ Example: using rounded fil ets with large radii of curvature at the point where there is a
change in diameter for a rotating shaft

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 change in diameter for a rotating shaft

4. Surface Treatments
○ During machining operations small scratches and grooves are invariably introduced into the workpiece
surface by cutting tool action that limit fatigue life
○ Preventive measure: improving the surface finish by polishing wil enhance fatigue life significantly
 Imposing residual compressive stresses within a thin outer surface layer
□ Surface tensile stress of external origin wil be partial y nullified and reduced in magnitude
by the residual compressive stress
□ Net effect: reduction of crack formation and fatigue failure
□ Introduced into ductile metals mechanically by localized plastic deformation within the
outer surface region
 Shot peening
◊ Small, hard particles (shot) having diameters within the range of 0.1 to 1.0
mm are projected at high velocities onto the surface to be treated
◊ The resulting deformation induces compressive stresses to a depth of
between one-quarter and one-half of the shot diameter

 Case hardening
□ A technique by which both surface hardness and fatigue life are enhanced for steel
alloys
□ A carburizing or nitriding process whereby a component is exposed to a carbonaceous
or nitrogenous atmosphere at elevated temperature
□ A C- or N-rich outer surface layer (or "case") is introduced by atomic diffusion from
the gaseous phase
 In the order of 1 mm deep and is harder than the inner core of material
□ Results: increased hardness within the case, desired residual compressive stresses the
formation of which attends the carburizing or nitriding process

 Knoop microhardness indentations - dark and elongated diamond shapes

 The upper indentation, lying within the carburized layer is smaller than the core
indentation

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 indentation
8.11 Environmental Effects
1. Thermal fatigue
○ Normally induced at elevated temperatures by fluctuating thermal stresses; mechanical stresses from
an external source need not be present
○ Origin of thermal stresses - restraint to the dimensional expansion and/or contraction that would
normally occur in a structural member with variations in temperature
○ Thermal stress

 Thermal stress wil not arise if this mechanical restraint is absent
○ Preventive measure
 Reduce the restraint source
 Allowing unhindered dimensional changes with temp variations
 Choose materials with appropriate physical properties
2. Corrosion fatigue
○ Failure that occurs by the simultaneous action of a cyclic stress and chemical attack
○ Corrosive environment produce shorter fatigue lives
○ Even normal ambient atmosphere wil affect the fatigue behavior of some materials
 Small pits
□ may form as a result of chemical reactions between the environment and material
□ Serve as points of stress concentration and therefore as crack nucleation sites
□ Crack propagation rate is enhanced as a result of the corrosive environment
○ The nature of the stress cycles wil influence the fatigue behavior.
 Lowering the load application frequency leads to longer periods during which the opened crack
is in contact with the environment and to a reduction in the fatigue life
 Preventive measure: apply protective surface coatings, select a more corrosion-resistant
materials, and reduce the corrosiveness of the environment
 Reduce the applied tensile stress level and impose residual compressive stresses on the
surface of the member

Reference: Callister, Jr., W. D. (2007). Materials Science and Engineering - An Introduction. New York: John Wiley &
Sons, Inc.

Prepared by: AGMOngkiko

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