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Fatigue and Fracture Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . 681 Infinite-Life Criterion (S-N Curves) . . . . . . . . . . . . . . . . . . . . . . 681 Finite-Life Criterion (-N Curves) . . . . . . . . . . . . . . . . . . . . . . . 682 Fracture Mechanics Approach . . . . . . . . . . . . . . . . . . . . . . . . . . 683 Fatigue, Creep Fatigue, and Thermomechanical Fatigue Life Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686 Process of Fatigue Crack Initiation and Early Growth . . . . . . . . 686 Fatigue Testing Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688 Ancillary Equipment and Specimens . . . . . . . . . . . . . . . . . . . . . . 690 Electronic Test Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698 Baseline Isothermal Fatigue Testing . . . . . . . . . . . . . . . . . . . . . . 700 Testing for Effects of Variables on Fatigue Resistance . . . . . . . . 704 Creep-Fatigue Interaction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708 Thermomechanical Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Helpful Guidelines for Fatigue Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Ultrasonic Fatigue Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Historical Perspective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Strain Rates, Frequency, and Time Compression . . . . . . . . . . . . 717 Testing Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Testing Equipment and Methods . . . . . . . . . . . . . . . . . . . . . . . . . 719 Test Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728 Fretting Fatigue Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Fretting and Fretting Fatigue Mechanisms . . . . . . . . . . . . . . . . . 731 Typical Systems and Specific Remedies . . . . . . . . . . . . . . . . . . . 732 Testing, Modeling, and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 734 Variables Investigated during Fretting Fatigue Tests . . . . . . . . . 735
Prevention or Improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737 Fatigue Crack Growth Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 Fracture Mechanics in Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 Test Methods and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 Specimen Selection and Preparation . . . . . . . . . . . . . . . . . . . . . . 743 Crack-Length Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746 Loading Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Analysis of Crack Growth Data . . . . . . . . . . . . . . . . . . . . . . . . . . 751 Appendix: High-Temperature Fatigue Crack Growth Testing . . 753 Fatigue Testing and Behavior of Plastics . . . . . . . . . . . . . . . . . . . 758 Fatigue Crack Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 Fatigue Crack Propagation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761 Factors Affecting Fatigue Performance of Polymers. . . . . . . . . . 763 Fractography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766 Fatigue Testing of Brittle Solids . . . . . . . . . . . . . . . . . . . . . . . . . . 768 Fatigue Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768 Fatigue Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769 Strength-Based Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . 769 Fracture Mechanics Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 Comparison of Indirect and Direct Methods . . . . . . . . . . . . . . . . 775 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775 Multiaxial Fatigue Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779 Stress States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779 Testing of Cylindrical Specimens . . . . . . . . . . . . . . . . . . . . . . . . 780 Testing of Specimens Containing Notches or Cracks . . . . . . . . . 780 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
ASM Handbook, Volume 8: Mechanical Testing and Evaluation H. Kuhn, D. Medlin, editors, p681685 DOI: 10.1361/asmhba0003313
Stress-life (S-N) Strain life (-N) Fracture mechanic crack growth (da/dN K)
These three types of fatigue properties each play a role in engineering, and each property is used in the context of an underlying fatigue design philosophy as follows:
Principal testing data description
(often called the short crack or small crack phase) Crack growth rates that can be characterized by either linear elastic fracture mechanics, elastic-plastic fracture mechanics, or fully plastic fracture mechanics Final instability
Design philosophy
Design methodology
S-N -N da/dN K
This definition of the stages in the fatigue process is roughly equivalent to the first, except that crack propagation is expressed in terms of crack growth rates, and nucleation is meant to
The S-N and -N techniques are usually appropriate for situations where a component or
Fig. 1
What was the temperature? Was an environment other than lab air em What was the specimen orientation in the Does the line represent minimum, mean, or How many samples were tested? What was the scatter? If the plot is based on constant-amplitude
data, what were the frequency and waveform? Was testing performed using variable-amplitude loading? What was the spectrum? What was the failure criterion? If there were runouts, how were they handled and represented? median response? original material? ployed?
man representation as a means of approximating actual response through the model of the behavior. For materials that do not have a fatigue limit, or for finite-life estimates of materials that do, the fatigue strength at a given number of cycles can be substituted for the intercept on the stress-amplitude axis. Examples of the Haigh and constant-life diagrams are provided in Fig. 2 and 3. Figure 3 is of interest also because of its construction in terms of a percentage of ultimate tensile strength for the strength ranges included.
What were the coupon size and geometry? Was there a stress concentration?
If the data found describe a thin sheet response, it is the wrong data. If the product form is correct, but the plot represents testing done at R = 0.3 and fully reversed data are required, the plot may be helpful, but it is not what is desired. An example of what should be considered important as supporting facts can be found in ASTM E 468, Presentation of Constant Amplitude Fatigue Test Results for Metallic Materials. It provides guidelines for presenting information other than just final data. S-N Data Presentation. Stress is the controlling quantity in this method. The most typical formats for the data are plots of the log number of cycles to failure (sample separation) versus either stress amplitude (Sa), maximum stress (Smax), or perhaps stress range (S). Mean stress influences are also very important, and each design approach must consider them. According to Bannantine et al. (Ref 5), the archetypal mean (Sm) versus amplitude (Sa) presentation format for displaying mean stress effects in the safe-life, infinite-life regime was originally proposed by Haigh. The Haigh diagram can be a plot of real data, but it requires an enormous amount of information for substantiation. A slightly more involved, but also more useful, means of showing the same information incorporates the Haigh diagram with Smax and Smin axes to produce a constant-life diagram. Examples of these are provided subsequently. For general consideration of mean stress effects, various models of the mean-amplitude response have been proposed. A commonly encountered representation is the Goodman line, although several other models are possible (e.g., Gerber and Soderberg). The conventional plot associated with this problem is produced using the Haigh diagram, with the Goodman line connecting the ultimate strength on Sm, and the fatigue limit, corrected fatigue limit, or fatigue strength on Sa. This line then defines the boundary of combined mean-amplitude pairs for anticipated safe-life response. The Goodman relation is linear and can be readily adapted to a variety of manipulations. In many cases Haigh or constant-life diagrams are simply constructs, using the Good-
50
30
Goodman line
200
Fig. 2
A synthetically generated Haigh diagram for an alloy steel (620 MPa, or 90 ksi, ultimate tensile strength) based on typically employed approximations for the axes intercepts and using the Goodman line to establish the acceptable envelope for safe-life, infinite-life combinations. The Goodman line represents an unconnected 106 estimate at 50% failure (criterion: separation).
40
A constant-life diagram for alloy steels that provides combined axes for more ready interpretation. Note the presence of safe-life, finite-life lines on this plot. This diagram is for average test data for axial loading of polished specimens of AISI 4340 steel (ultimate tensile strength, UTS, 860 to 1240 MPa, or 125 to 180 ksi) and is applicable to other steels (e.g., AISI 2330, 4130, 8630). Source: Ref 6
Fig. 3
where is the notch-tip radius, is the range of applied nominal stress, and k t is the stress-concentration factor. Fatigue-crack-initiation behavior of various steels is presented in Fig. 4 (Ref 8) for specimens subjected to zero-to-tension bending stress and containing a smooth notch that resulted in a stress-concentration factor of about 2.5. The data show that KI/ , and, therefore, max is the primary parameter that governs fatigue-crack-initiation behavior in regions of
Fig. 4
K/, MPa
K/, ksi
where a is crack length, N is number of cycles, and A and n are constants. Extensive fatigue-crack-growth-rate data for various steels show that the primary parameter affecting growth rate in region 2 is the stress-
intensity-factor range, and that the mechanical and metallurgical properties of these steels have negligible effects on the fatigue-crackgrowth rate in a room-temperature air environment. The data for martensitic steels fall within a single band, as shown in Fig. 7 (Ref 8), and the upper bound of scatter can be obtained (Ref 8) from:
da = 0.66 10 8 ( K I ) 2 . 25 dN (Eq 5)
102
for
R + 0.1 (Eq 3a)
da/dN, mm/cycle
104
da/dN = C (K)n
and
Kth = 5.5 for R < +0.1 (Eq 3b)
where Kth is in ksi in. Equation 3 indicates that the fatigue-crackpropagation threshold for steels is primarily a function of the stress ratio and is essentially independent of chemical or mechanical properties. The behavior in region 2 (Fig. 6) represents the fatigue-crack-propagation behavior above
Fig. 6
Schematic illustration of variation of fatigue-crack-growth rate, da/dN, with alternating stress intensity, K, in steels, showing regions of primary crack-growth mechanisms. Source: Ref 11
3 2 102 8 6 4 3 2 10 8 6 4 3 2 1.0 12Ni steel 10Ni steel HY-130 steel HY-80 steel
da dN
da dN
107
3 4
6 8 106
6 8 105
3 4
6 8 104
3 4
6 8 103
Fig. 5
Fig. 7
40
20
where a is in inches and KI is in ksi in. The stress ratio and mean stress have negligible effects on the rate of crack growth in region 2. Also, the frequency of cyclic loading and the wave form (sinusoidal, triangular, square, or trapezoidal) do not affect the rate of crack propagation per cycle of load for steels in benign environments (Ref 8). The acceleration of fatigue-crack-growth rates that determines the transition from region 2 to region 3 appears to be caused by the superposition of a brittle or a ductile-tearing mechanism onto the mechanism of cyclic subcritical crack extension, which leaves fatigue striations on the fracture surface. These mechanisms occur when the strain at the tip of the crack reaches a critical value (Ref 8). Thus, the fatigue-rate transition from region 2 to region 3 depends on the maximum stress-intensity factor, on the stress ratio, and on the fracture properties of the material (Ref 8).
Fig. 8
ACKNOWLEDGMENT
Sections of this article were adapted from several ASM Handbook articles, in particular those cited as Ref 1 4 and 7.
REFERENCES
1. M.E. Fine and Y.-W. Chung, Fatigue Fail-
ure in Metals, Fatigue and Fracture, Volume 19, ASM Handbook, ASM International, 1996, p 63 72 2. D.W. Hoeppner, Industrial Significance of Fatigue Problems, Fatigue and Fracture, Vol 19, ASM Handbook, ASM International, 1996, p 3 4 3. E. Krempl, Design for Fatigue Resistance, Materials Selection and Design, Vol 20, ASM Handbook, ASM International, 1997, p 516 532 4. D.W. Cameron and D.W. Hoeppner, Fatigue Properties in Engineering, Fatigue and Fracture, Vol 19, ASM Handbook, ASM International, 1996, p 15 26 5. J.A. Bannantine, J.J. Comer, and J.L. Handrock, Fundamentals of Metal Fatigue Analysis, Prentice-Hall, 1990 6. R.C. Juvinall, Engineering Considerations of Stress, Strain, and Strength, McGrawHill, 1967, p 274
7. J.M. Barsom, Fracture Mechanics Fatigue and Fracture, Metals Handbook Desk Edition, 1985, p 32-2 to 32-7 8. S.T. Rolfe and J.M. Barsom, Fracture and Fatigue Control in Structures Applications of Fracture Mechanics, 3rd ed., ASTM, 1999 9. M.E. Taylor and J.M. Barsom, Effect of Cyclic Frequency on the CorrosionFatigue Crack-Initiation Behavior of ASTM A 517 Grade F Steel, Fracture Mechanics: Thirteenth Conf., STP 743, ASTM, 1981 10. R. Roberts, J.M. Barsom, J.W. Fisher, and S.T. Rolfe, Fracture Mechanics for Bridge Design, FHWA-RD-78-69, Federal Highway Administration, Office of Research and Development, July 1977 11. R.O. Ritchie, Near-Threshold FatigueCrack Propagation in Steels, Int. Met. Rev., Vol 24 (No. 5, 6), 1979