STRESS - LIFE (S-N) BEHAVIOR

Smax

Smax

FATIGUE LIMIT (ENDURANCE LIMIT)

Smax
R = Smin/Smax = constant

LIFE, Nf, CYCLES

STRESS - LIFE (S-N) BEHAVIOR

Smax

Smax

FATIGUE LIMIT (ENDURANCE LIMIT)

Smax
R = Smin/Smax = constant

LIFE, Nf, CYCLES

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FATIGUE CRACK CLOSURE MECHANISMS

Plastic wake Oxide debris

(a) Plasticity-induced (b) Roughness-induced closure closure

Elber, 1968

(c) Oxide/corrosion productinduced closure

Paris et.al., 1972 Suresh and Ritchie, 1981

Beevers, 1979 Suresh and Ritchie, 1982

FATIGUE CRACK CLOSURE MECHANISMS

Plastic wake Oxide debris

(a) Plasticity-induced (b) Roughness-induced closure closure

Elber, 1968

(c) Oxide/corrosion productinduced closure

Paris et.al., 1972 Suresh and Ritchie, 1981

Beevers, 1979 Suresh and Ritchie, 1982

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Chapter 1 Introduction

Historical Overview of Fatigue, Fatigue Crack Growth and Fracture Mechanical Failure Modes Importance of Fatigue Considerations in Design
Presentation slide are from: Metal Fatigue in Engineering, Ali Fatemi, University of Toledo Mechanical Behavior of Materials, Norman Dowling, Virginia Tech and James C. Newman, Jr., Mississippi State University
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Atoms to Autos

TM

TM C Center f Ad for Advanced Vehicular Systems (CAVS) d V hi l S

Mechanical Behavior of Materials: Engineering Methods for Deformation, Fracture, and Fatigue, Third Edition, by Norman E. Dowling. ISBN 0-13-186312-6. 2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved

Mechanical Failure Modes

Mechanical failure involves a complex interaction of load, , ( , p ) time, and environment (i.e., temperature and corrosion).

Loads may be monotonic, steady, variable, uniaxial or multi-axial. lti i l Loading duration may range from centuries to y g y g years, , as in steel bridges, or to seconds or milliseconds, as in firing a handgun. Temperatures can vary from cryogenic with rocket motor fuels, to over a thousand degrees Celsius, with gas turbine engines. T i Temperatures may be i th t b isothermal or variable. l i bl
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Mechanical Failure Modes (cont.)

Corrosive environments can range from severe attack with automobile engine exhaust or salt water spray, as in the Space Shuttle airframe, to essentially no attack, in vacuum or inert gas. (Note: Lab air is aggressive.) gas aggressive ) Interaction of load, time and environment along with material selection, structural configuration, processing, and residual stresses create a wide range of possible failure modes in all fields of engineering. The following slide provides a list of some possible structural failure modes in metals metals.
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Fracture x Log crack length a Crack growth

Crack nucleation at micro-structural feature Elapsed Cycles, N

Fatigue

Fatigue failures are due to repeated (cyclic) loading. At least one-half of all mechanical failures are due to fatigue. Many books and articles have suggested that between 50 to 90% of all mechanical failures are caused by cyclic loading and environments (corrosion). Most f th M t of these failures are unexpected and many cause f il t d d extensive damage and fatalities. They include simple items, such as door springs and electrical light bulbs, to complex components and structures involving ground vehicles ships aircraft vehicles, ships, aircraft, and human body parts.
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Different Aspects of Fatigue p g

Fatigue crack nucleation g Fatigue crack growth (small- and large-cracks) Constant Constant- or variable amplitude loading variable-amplitude Uniaxial or multi-axial loading Corrosion fatigue Fretting fatigue Creep-fatigue Creep fatigue (isothermal or thermo mechanical) thermo-mechanical) Fracture Combinations of th above C bi ti f the b
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Phases of Fatigue Life and Relevant Factors

Modified from Schijve, 1974

Crack nucleation

Micro-crack growth

Macro-crack growth

Failure

Nucleation KT , K , K Stress and strain concentration, notch constraint

Crack growth

Fracture KIc , K c , J Ic , CTOD Constraint

K , K max , K eff , J eff and CTOD

Microstructure, geometry, loading, crack-front constraint

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Stages of the Fatigue Process

Mark Stage I Stage II Inclusion or void Stage II Scratch Burr Stage II

Slipband cracking (a)

(b)
Influence of inclusions or voids

(c)
Influence of service-induced or manufacturing defects

Stages of fatigue process

(Forsyth, 1962)

(Morris, Buck and Marcus, 1976)

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Chapter 1 Introduction

Historical Overview of Fatigue, Fatigue Crack Growth and Fracture Mechanical Failure Modes Importance of Fatigue Considerations in Design

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Importance of Fatigue Considerations in D i i Design

A comprehensive study of the cost of fatigue and fracture in the United States indicated $119 billion (in 1982 dollars) cost occurred in only 1978 (National Bureau of Standards, now National Institute of Standards Technology, NIST) This was about 4% of the gross national product. The study emphasized that this cost could be significantly reduced by using proper and current fatigue design technology.

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Importance of Fatigue Considerations in D i i Design (cont.) ( t)

Motor vehicles & parts Aircraft & parts Construction residences Construction Non-residential buildings Fabricated products Non-ferrous products Petroleum refining Structural metals
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Importance of Fatigue Considerations in D i i Design (cont.) ( t)

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Importance of Fatigue Considerations in D i i Design (cont.) ( t)

Proper fatigue design involves synthesis, analysis & testing. p g g y , y g Fatigue testing alone is not a proper fatigue design procedure, since it should be used for product durability determination, and not for product development. Analysis alone is also insufficient, since current fatigue life models incl ding soft are programs are not models, including software programs, adequate for safety critical parts. Both analysis and testing are required to develop components of good fatigue design. The closer the analysis and testing simulates the real y g component loading, configuration and environments, the greater the confidence in the final design.
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Importance of Fatigue Considerations in D i i Design (cont.) ( t)

Many fatigue design approaches exist. They can be simple, inexpensive approaches, or they may be extremely complex and expensive. A more complete fatigue design procedure may be initially more expensive, b t i th l i but in the long run it may b th l be the least t expensive. Current product liability laws have placed special emphasis on explicitly documented design decisions.

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Importance of Fatigue Considerations in D i i Design (cont.) ( t)

Safety factors are often used in conjunction with or without proper fatigue design. Safety factors too high may lead to non-competitive products in the global market, while values too low can contribute to unwanted failures. Safety factors are not replacements for proper fatigue design procedures, nor should they be an excuse to offset poor fatigue design procedures.

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Some Examples of Fatigue Failures

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Some Simple Rules in Fatigue Design

Do consider material processing, surface quality, and stress concentrations in fatigue design design. Dont rely on safety factors to attempt to overcome poor design procedures. Do consider that fatigue durability testing should be used as a design verification tool, rather than as a design development tool. Dont overlook the additive or synergistic effects of load, environment, configuration, residual stress, ti i t fi ti id l t time, and d material microstructure on fatigue design.

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