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Printed in Great Britain. @ 1983 Petgamon Press Ltd.
XIULINZHENGt
Department of Material Engineering, North-Western Polytechnical University, Xian, Shaanxi, The Peoples
Republic of China
MANFRED
A. HIRT
Department of Civil Engineering, ICOM, Swiss Federal Institute of Technology, Lausanne, Switzerland
Abstract-From previous investigations of the mechanisms of both fracture and fatigue crack propagation,
the static fracture model proposed by Lal and Weiss may be thought as reasonable for describing fatigue
crack propagation in metals at both low and interm~iate stress intensity factor ranges AK. Recent progress
in fatigue crack propagation indicates that it is not only possible, but also necessary, to modify this static
fracture model. Based on the modified static fracture model, the effective stress intensity factor range
A&, which is defined as the difference between AK and the fatigue crack propagation threshold value
A&, is taken as the governing parameter for fatigue crack propagation. Utilising the estimates of the
theoretical strengths of metals employed in industry, a new expression for fatigue crack propagation, which
may be predicted from the tensile properties of the metals, has been derived. The correlation between the
fatigue crack propagation rate and the tensile properties is thus revealed. The new expression lits the test
results of fatigue crack propagation of steels below lo- mm~cycleand indicates well the effect of stress
ratio on the fatigue crack propagation rate.
1. INTRODUCTION
THESTUDY of fatigue crack propagation (FCP) examines how a fatigue crack grows under cyclic load.
This topic is cu~ently the subject of considerable research, mainly dealing with the development of
various models to best explain the crack propagation phenomenon. Most of these models, which are
based on different theoretical assumptions, are summarized by Yokobori[l] and by Bathias and
Bailon[2]. Fatigue crack propagation is, paradoxically, both simple and difficult. The problem is simple in
the sense that, considering only region B of the fatigue crack propagation curve (Fig. l), it can often be
successfully resolved by using the basic Pariss equation[3]. It is, however, diticult in that it may require
many parameters and bring together different physical mechanisms verging, in some unfavorable
g [mm/cycle]
KC
Final fracture
1o-2
1o-3
10-4
1r5
10-6
AK [MPa $iij
Fig. 1. Schematic representation of fatigue crack propagation rate da/dPI versus stress intensity factor
range AKon a log-log scale.
tProf. Zheng was a visiting professor at ICOM, at the Swiss Federal Institute of Technology, Lausanne, from January 1980to March
1982.
965
EFM Vol. 18, No. S-u
966 XIULIN ZHENG and MANFRED A. HIRT
situations, toward impossibility. It is clear, for example, that the governing mechanisms of fatigue crack
propagation in region C are quite different from those in regions A and B [4, S]. Hence, with present
knowledge, any attempt to explain the fatigue crack propagation curve empirically and in its entirety has
no physical basis. This also explains why Pariss equation fails in regions A and C. The majority of the
existing models predict values of the exponent M in Pariss equation to be a constant of either 2 or 4 [2,
61. However, the value of m, determined by experiment, varies between 1.4 and 9.66 [7,8]. Fatigue crack
propagation may be assumed to occur due to the plastic deformation and fracture of material elements
located immediately ahead of a crack tip. Thus, fatigue crack propagation must be related to some other
material property parameters. Several attempts have been made to find an appropriate correlation
between the fatigue crack propagation and the said material property parameters although little progress
has been made to date [5, 6, 9, 101. This indicates clearly that the existing fatigue crack propagation
(FCP) models cannot perfectly account for the phenomenon in metals. From studies into the subject of
FCP and fracture [ 1l-141, the static fracture model proposed by La1 and Weiss [lo] gives a good insight into
the problem in regions A and B of fatigue crack growth. However, even here the model needs some
modifications.
Recent progress [15-171 has gone a considerable way in solving some of the physical constraints
of fatigue crack propagation. This paper presents modifications made to La1 and Weisss model in order
to develop a new FCP expression. The intention of ?he new expression is to incorporate the important
feature of the correlation between fatigue crack propagation and the metal property parameters. Several
tests results on various steels are then used to check the validity of the new expression.
Fatigue element
Fig. 2. Schematic illustration of the fatigue element along the potential crack path.
Fatigue crack propagation in steels %7
Fig. 3. Schematic illustration of the assumption of the amount of incremental fatigue crack propagation [17].
which is the same as Lal and Weisss assumption. Thus, if the stress distribution ahead of the crack tip
and the critical fracture stress are known, it is then easy to derive a mathematical expression for FCP.
(2)
XIUCPJ ZHENG and MANFRED A. HIRT
f
Off
L i
_--_-_-..-_--I,
0
0" x
cl)
~
1
Y Y
+
I 1
Off uff
j 0 0
I L!
--
,,=~J-------~ --_---_Lt
0' X 0" x
Cl e)
~ ~
Y
t
Y
4
t
Off
Q
k
__-_-_--),
0" X
f)
~
--_--_a
9)
LOAD P
0
a 9
Fig. 4. Schematic illustration of the static fracture model for fatigue crack propagation.
Since the effective stress intensity factor is the governing parameter for FCP, it should be used in eqn (2)
in place of &. So when x becomes xr = da/dN, eqn (2) can be rewritten as:
The criterion for the crack initiation at the notch tip is given by Ref. 1171as:
where K, is the theoretical stress conce~~ation factor, 5 is the nominal stress applied to the notched
Fatigue crack propagation in steels 969
element, E is Youngs modulus and ur and ef are the materials fracture strength and fracture ductility,
respectively.
Having accepted qEoref as the theoretical strength of the metallic materials [19], it is then possible
to explain the physical si~ificance of eqn (4). The material at the notch root will fracture to initiate a
crack if the fictitious elastic stress K,S exceeds the theoretical strength of metals. If the bluntened crack
is taken as a sharp notch, the stress (r at the crack tip should then be equal to KS. When crack
propagation at the crack tip is stopped, the stress u is considered to be not more than q/Eor~+ Hence, it
can be deduced that the theoretical strength of metals may be taken as equal to the critical fracture
stress in La1 and Weisss model. Then taking:
+1 (8)
27rEure;
Equation (7) is the mathematics expression for FCP at the stress ratio of R = 0. When a crack
propagates according to the static fracture model, the FCP coefficient B is a constant related to the
tensile properties of metals.
where AKthOis the crack propagation threshold value for the stress ratio R = 0, and y is a constant which
varies from zero to unity (111. It can be seen from eqns (7) and (9) that AKe, becomes smaller as R
increases and hence the FCP rate increases. However, the variation of AKth has a greater effect on the
FCP rate at lower values of AK (region A) and less effect at higher values of AK (region B).
Tensile properties and the corresponding numerical values of AKti, at various stress ratios are given
by Ritchie[21]. It is then easy to write the expression for FCP based on eqns (7) and (8):
The curves for FCP predicted by eqns (10) and (11) are in good agreement with the test results shown in
Fig. 5. However, it should be pointed out that, due to different definitions, the above values of AK,, are
smaller than those determined experimentally [2]. In actual fact, the AKti, values obtained from tests are
defined at about du/dN = 10m6to lo- mm/cycle [ll]. In eqn (7), the theoretical value is defined as the
value of AK for du/dN = 0.
970 XIULIN ZHENG and MANFRED A. HIRT
A = 0.05
300 M alloy steel l
R = 0.70
-6 _
10
2 4 6 0 10 20 40 60
Fig. 5. Predicted curves and test results showing the influence of stress ratio on FCP for 300M alloy steel,
austenitized at 87oC,oil-quenched and tempered at 3WC 1211.
4. EXPERIMENTALRESULTS
4.1 Methods for the analysis of test data
After log~~mi~ ~ansformation, eqn (7) becomes:
da
log do = log B + 2log(AK - AK,,,), (12)
which represents a straight line with slope 2 when da/dN versus (AX - A&J is plotted on a logarithmic
scale. Using a trial and error approach, a computer program for linear regression analysis can be written
to obtain the values of B and A&, given the condition that the slope is within the range of 2 k 0.004.
Table 1. Tensile properties and test results of the FCP for two steels
oU u RA R [MPa+]
AKth
MATERIAL Y R r s
EMPa] [%I EXPERIMENT PREDICTED [MPa w]
HSLA steel [22] 591 452 65.0 0.1 6.6?~.10-~~ 7.55.1O-'O 10.10 0.979 0.08
30CrMnSiNi2A [ZS] 1703 1357 45.7 0.2 6.51+10-'" 5.36*10-lo 1.61 0.985 0.051
-8
10
10 50 100 5 10 50
Fig. 6. Regression analysis of test data of fatigue crack propagation according to eqn (7). (a) High-strength,
low-alloy steel [22]. (b) High-strength martensite steel [23].
times in the value of B, it is not possible to say the same thing for some pearlite-ferrite steels or for some
quenched-tempered steels. Why this difference appears is still not clear and supplementary research is
needed. However, it should be pointed out that the FCP is a highly localized phenomenon and the
microstructure has thus a great influence on the FCP rate.
In his work, Pelloux[32] suggested that the FCP in an aluminium alloy is controlled principally by the
matrix properties when the plastic zone width is smaller than the interparticle spacing of the inclusions.
From this, it may be suggested that the differing values of B for those steels will be more dependent
upon the tensile properties of the matrix rather than those of the steels. If it is assumed that 0.1 E is the
critical fracture stress, or theoretical strength, of the steel matrix phase [6], the value of B according to
eqn (8) will become 3.97 * lo-. This value is closer to that of B for those steels previously mentioned.
5. DISCUSSION
The modified static fracture model is still based on the tensile stress failure criterion. According to
this hypothesis, the maximum stress at the crack tip in all cases should be either equal to, or below, the
critical fracture stress of the metal employed. Consequently, the crack tip must be bluntened during
loading in order to relieve the stress at the crack tip. This is actually required by the equilibrium between
the applied stress and the resistance of the metal. Hence, the higher the applied stress, the bigger the
crack tip radius.
Table 2. Tensile properties and reanalysed results of the FCP for various steels
0 ci RA I B fMPa-2] T
i I i
6. CONCLUSIONS
1. During loading, the bluntening phenomenon at the crack tip has been taken into account in the
new static fracture model for the FCP developed in the present paper. It is clearly necessary to maintain
mechanical equi~brium at the crack tip.
2. Considering the existence of the FCP threshold A&,, the effective stress intensity factor range
A&, which is defined as the difference AK -A&,, is thought to be the governing parameter in FCP.
3. Based on the new FCP model, a new expression for FCP has been derived:
-&=~(AK - AK,,J2.
where B is a material constant and can be predicted from the tensile properties. This expression for FCP
can be applied to give a good description of the fatigue crack propagation at various stress ratios below
da/dN rs W3 mm/cycle.
4. This study has introduced a very simple and useful relationship between the coefficient B and the
tensile properties of metals leading, consequently, to their correlation with fatigue crack propagation.
5. ,I\&, is a very important parameter affecting the FCP rate, in particular at the lower values of AK,
in region A. The required value of AK,,, may be determined from the test results of FCP by a trial and
error approach using linear regression analysis and thus without any additional testing.
6. A final important conclusion is that the model includes the most essential crack propagation
parameters such as AK, A&,, material properties and the stress ratio.
Finally, although the existing experimental results justify the use of the new expression, more test
results with different types of steels are necessary to show its range of applicability.
Acknowledgements-We are grateful to Prof. J.-C. Badoux, director of the Institute for Steel Construction of the Federal Institute of
Technology in Lausanne, Switzerland, for his support of our work. Appreciation is also expressed to Messrs. F. Celebi, B. Kerridge
and M. Fiaux for their help in preparing this paper.
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