Lecture 14

Fatigue & Creep in Engineering

Materials
(Chapter 8)

Chapter 8 - 1
 Fatigue
Fatigue = failure under applied cyclic stress.
specimen compression on top

motor counter
bearing bearing

flex coupling
t
tension
i on b
bottom
tt

Stress varies with time.

max
S m, and
-- key parameters are S,
S
cycling frequency m
min time

Key points: Fatigue...

--can cause part failure, even though max < y.
--responsible
ibl ffor ~ 90% off mechanical
h i l engineering
i i ffailures.
il
Chapter 8 - 2
 Fatigue: Definitions
Asymmetric
Symmetric

Random
d

Chapter 8 - 3
Fatigue: Definitions

Chapter 8 - 4
 Types of Fatigue Behavior

S = stress amplitude
Fatigue limit, Sfat: case for
--no fatigue if S < Sfat unsafe steel (typ.)
Sfat

safe

10 3 10 5 10 7 10 9
N = Cycles to failure

S = stress aamplitude
For some materials, case for
there is no fatigue unsafe Al (typ.)
limit!
safe

10 3 10 5 10 7 10 9
N = Cycles to failure
Chapter 8 - 5
Ex: Fatigue in 7075-T6 Aluminum
Alloy

Chapter 8 - 6
 Rate of Fatigue Crack Growth
Crack grows incrementally
typ. 1 to 6
da
K
m
dN
~ a
increase in crack length per loading cycle
crack origin
Failed rotating shaft
-- crack grew even though
Kmax < Kc
-- crack grows faster as
increases
crack gets longer
loading freq. increases.

Chapter 8 - 7
Fatigue Failure in Ductile Materials
(Aluminum)

Chapter 8 - 8
Fatigue Failure in Brittle Material

Chapter 8 - 9
Importance of Mean Stress

Chapter 8 - 10
 Improving Fatigue Life

amplitude
1. Impose compressive Adapted from
surface stresses Fig. 8.24, Callister &
Rethwisch 8e8e.

S = stress a
(to suppress surface near zero or compressive m
cracks from growing) moderate tensile m
Larger tensile m

N = Cycles to failure

--Method 1: shot peening --Method 2: carburizing

shot
C-rich
C rich gas
putt
surface
into
compression

2. Remove stress bad better

concentrators. Adapted from
Fig. 8.25, Callister &
bad better Rethwisch 8e.

Chapter 8 - 11
Effect of Surface Compressive
Stresses

Chapter 8 - 12
 Effect of Surface Compressive
Stresses
Hardened
Case depth by
Carburization (or
Nitriding)

In compression Micro-indentation
marks

Chapter 8 - 13
 Environmental Effects

Thermal cycle..stress cycle..Thermal fatigue.

Chapter 8 - 14
 Creep
Sample deformation at a constant stress () vs. time

0 t

Primary Creep: slope (creep rate)

decreases with time.
Secondary Creep: steady-state
i.e., constant slope /t)
Adapted from
Tertiary Creep: slope (creep rate) Fig. 8.28, Callister &
Rethwisch 8e.
increases with time, i.e. acceleration of rate.
Chapter 8 - 15
 Creep: Temperature Dependence
Occurs at elevated temperature, T > 0.4 Tm (in K)

tertiary

primary
secondary

elastic

Chapter 8 - 16
 Secondary Creep
Strain rate is constant at a given T,
-- strain hardening is balanced by recovery
stress exponent (material parameter)
Qc
s K 2 exp
n
activation energy for creep
strain rate RT ( t i l parameter)
(material t )
material const. applied stress

S
Strain rate 200
427C
s (MPa)

increases 100
538C
g
with increasing 40
Stress

T, 20
649C
10

10 -2 10 -1 1
Steady state creep rate s (%/1000hr)
Chapter 8 - 17
 A better & more informative
Material constant Creep Equation
depending on Activation energy
gy for
creep mechanism
h i
Self-diffusion

Grain size Applied stress

m & b depend on the creep mechanism

Chapter 8 - 18
 Mechanisms of Creep
The mechanism of creep depends on temperature and
stress. The various methods are:

Bulk diffusion (Nabarro-Herring creep)

Dislocation climb -here the strain is actually

accomplished by climb

Climb-assisted glide here the climb is an enabling

mechanism,, allowingg dislocations to gget around obstacles

Grain boundary diffusion (Coble creep)

Thermally activated glide e.g., via cross-slip

Chapter 8 - 19
 Mechanisms of Creep
p
Things to know

Dislocations related creep.. m = 4-6, and b = 0. It has a strong

dependence on the applied stress and no grain size dependence.
Nabarro Herring Creep (Bulk
Nabarro-Herring (B lk Diffn)..m
Diffn) = 1,
1 and b = 2.
2 Atoms
At
diffuse through the lattice causing grains to elongate along the stress axis; it
creep has a weak stress dependence and a moderate grain size dependence.
Coble Creep (Grain boundary diffusion).
diffusion) m = 1, 1 and b = 3.
3 Atoms diffuse
along grain boundaries to elongate the grains along the stress axis. This causes
Coble creep to have a stronger grain size dependence than Nabarro-Herring
creep.
p Here,, Q(g
Q(grain boundaryy diffusion)
ff ) < Q(self
Q( f diffusion),
ff ), Coble creepp
occurs at lower temperatures than Nabarro-Herring creep.

Thermally activated glide e.g., via cross-slip

Chapter 8 - 20
 Creep Failure
Failure: along grain boundaries.

g.b. cavities

applied
stress

Chapter 8 - 21
Creep Failure in S-590 Alloy

fig_08_31
Chapter 8 -
 Prediction of Creep Rupture Lifetime
Estimate rupture time
S-590 Iron, T = 800C, = 20,000 psi

100 Ti
Time to
t rupture,
t tr
T (20 log t r ) L

Strress (103 psi)

20 function of
temperature
10 applied stress
time to failure (rupture)

data for
S-590 Iron

12 16 20 24 28
1 (1073 K )(20 log t r ) 24 x103
103 L (K-h)

Ans: tr = 233 hr
Chapter 8 - 23
 Estimate the rupture time for
S 590 Iron,
S-590 750C = 20,000
Iron T = 750C, 20 000 psi
Solution:

Time to rupture, tr 100

psi)
T (20 log t r ) L

ess (103 p
20
temperature function of
applied stress 10

Stre
time to failure
fail re (rupture)
(r pt re)
data for

(1023 K )(20 log

g t r ) 24 x10 3 S-590 Iron
1
12 16 20 24 28
103 L (K-h)
Ans: tr = 2890 hr

Chapter 8 - 24
 To Increase Creep
p Rupture
p
Resistance:

1) Use large grain size material, highly

directions g
grains or a single
g crystal.
y
2) Use heavy alloying (grain boundary
g dislocation drag
drag, g etc.))
3) Use high melting point material
4)) Use high
g modulus of elasticityy
material

Make sure its justifiable ($$$$$...)

Chapter 8 - 25
 SUMMARY
Engineering materials not as strong as predicted by theory
Flaws act as stress concentrators that cause failure at
stresses lower than theoretical values.
Sharp corners produce large stress concentrations
andd premature
t failure.
f il
Failure type depends on T and :
For simple fracture (noncyclic and T < 0.4Tm), failure stress
-For
decreases with:
- increased maximum flaw size,
- decreased T,,
- increased rate of loading.
- For fatigue (cyclic :
- cycles
y to fail decreases as increases.
- For creep (T > 0.4Tm):
- time to rupture decreases as or T increases. Chapter 8 - 26
 ANNOUNCEMENTS

Reading: Study chapter 8 thoroughly. Study the

solutions of Chapter 8 problems very well. Do not
memorize but try understanding the concepts
behind the solutions

Chapter 8 - 27