Analysis of Fatigue Crack Paths in Cold Drawn Pearlitic Steel.
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ABSTRACT: In this paper, a fracto-metallographic analysis was performed on the cracked specimens of cold drawn pearlitic steel subjected to fatigue tests. Fatigue cracks are transcollonial and exhibit a preference for fracturing pearlitic lamellae, with non-uniform crack opening displacement values, micro-discontinuities, branchings, bifurcations and frequent local deflections that create microstructural roughness. At the micro-level, the cold drawn pearlitic steel exhibits higher micro-roughness than the hot rolled bar (this is a consequence of the manufacturing process by cold drawing), so that the actual fractured surface in the cold drawn wire is greater than that in the hot rolled bar, due to the fact that the crack deflection events are more frequent and with higher angle in the former (the heavily drawn prestressing steel wire). These findings show the relevant role on the manufacturing process by cold drawing in the fatigue crack propagation in pearlitic steel.
Project description:Fatigue properties and cracking behavior of cold-drawn commercially pure aluminum wires (CPAWs) widely used as the overhead transmission conductors were investigated. It was found that the fracture surface of the CPAWs shows an obvious four-stage fracture characteristic, i.e., crack initiation, planar crack propagation, 45°-inclined crack propagation and final rapid fracture. The crack growth mechanisms for the CPAWs were found quite different from those for the conventional coarse-grained materials. The cracks in the CPAWs firstly grow along the grain boundaries (Stage I crack growth), and then grow along the plane of maximum shear stress during the last stage of cycling (Stage II crack growth), leading to the distinctive fracture surfaces, i.e., the granular surface in the planar crack propagation region and the coarse fatigue striations in the 45°-inclined crack propagation region. The grain boundary migration was observed in the fatigued CPAWs. The increase in fatigue load enhances the dislocation recovery, increases the grain boundary migration rate, and thus promotes the occurrence of softening and damage localization up to the final failure.
Project description:In order to investigate the methods to heal fatigue cracks in metals, tubular specimens of 1045 steel with axial and radial fatigue cracks were treated under the eddy current. The optical microscope was employed to examine the change of fatigue cracks of specimens before and after the eddy current treatment. The results show that the fatigue cracks along the axial direction of the specimen could be healed effectively in the fatigue crack initiation zone and the crack tip zone under the eddy current treatment, and the healing could occur within a very short time. The voltage breakdown and the transient thermal compressive stress caused by the detouring of eddy current around the fatigue crack were the main factors contributing to the healing in the fatigue crack initiation zone and the crack tip zone, respectively. Eddy current treatment may be a novel and effective method for crack healing.
Project description:This Data in Brief article presents crystallographic data collected along chloride-induced stress corrosion cracks (CISCC) in a gas tungsten arc welded (GTAW) austenitic stainless steel (AuSS) 304L. The experimental setup involved a welded stainless steel 304L coupon of dimensions 105 mm × 18.5 mm × 3 mm, loaded in a 4-point bending fixture with a maximum tensile stress of 380 MPa. The fixtured specimen was immersed in boiling magnesium chloride (MgCl2) solution until a through-crack was observed on the specimen surface after 17 hours of boiling. The cross-section was subsequently polished, and 37 cracks of interest in the heat affected zone (HAZ) and weld zone (WZ) were selected for crystallographic characterization. Scanning electron microscopy (SEM) based electron backscatter diffraction (EBSD) was used to map the grain orientations along and surrounding each crack path. The obtained orientation imaging microscopy (OIM) datasets were post-processed using EDAX OIM V8 proprietary software to generate inverse pole figures (IPF), image quality (IQ) figures, detector signal (SEM) images, and to determine the Taylor factor and Schmid factor of mapped grains. This dataset can be used to understand CISCC crack initiation, propagation, and termination behaviors, as has been reported in the accompanying original research article. This data article providing the raw EBSD OIM datasets and processed images formatted for accessibility in future studies. This comprehensive EBSD dataset can further be used to extract grain boundary misorientation information; benchmark comparative studies of SCC/CISCC in AuSS and other Fe or Ni alloys; and provide critical validation data on grain morphology, misorientation, and crystallography for GTAW and CISCC models.
Project description:This paper deals with the effect of several residual stress profiles on the fatigue crack propagation in prestressing steel wires subjected to tension loading or bending moment. To this end, a computer program was developed to evaluate the crack front evolution on the basis of the Walker law. Results demonstrate that the absence of residual stresses makes the crack propagate towards a preferential crack path. When surface residual stresses are tensile and, correspondingly, core residual stresses are compressive, the fatigue crack fronts rapidly converge towards a quasi-straightshape. When surface residual stresses are compressive, with their corresponding tensile stresses in the core area, a preferential crack path also appears.
Project description:Fretting fatigue experiments and finite element analysis were carried out to investigate the influence of cylindrical-on-flat contact on crack nucleation, crack path and fatigue life of medium-carbon steel. The location of crack nucleation was predicted using the maximum shear stress range criterion and the maximum relative slip amplitude criterion. The prediction using the maximum relative slip amplitude criterion gave the better agreement with the experimental result, and should be used for the prediction of the location of crack nucleation. Crack openings under compressive bulk stresses were found in the fretting fatigues with flat-on-flat contact and cylindrical-on-flat contacts, i.e., fretting-contact-induced crack openings. The crack opening stress of specimen with flat-on-flat contact was lower than those of specimens with cylindrical-on-flat contacts, while that of specimen with 60-mm radius contact pad was lower than that of specimen with 15-mm radius contact pad. The fretting fatigue lives were estimated by integrating the fatigue crack growth curve from an initial propagating crack length to a critical crack length. The predictions of fretting fatigue life with consideration of crack opening were in good agreement with the experimental results.
Project description:The unexpected failures of structural materials in very high cycle fatigue (VHCF) regime have been a critical issue in modern engineering design. In this study, the VHCF property of a Cr-Ni-W gear steel was experimentally investigated under axial loading with the stress ratio of R = -1, and a life prediction model associated with crack initiation and growth behaviors was proposed. Results show that the Cr-Ni-W gear steel exhibits the constantly decreasing S-N property without traditional fatigue limit, and the fatigue strength corresponding to 10⁸ cycles is around 485 MPa. The inclusion-fine granular area (FGA)-fisheye induced failure becomes the main failure mechanism in the VHCF regime, and the local stress around the inclusion play a key role. By using the finite element analysis of representative volume element, the local stress tends to increase with the increase of elastic modulus difference between inclusion and matrix. The predicted crack initiation life occupies the majority of total fatigue life, while the predicted crack growth life is only accounts for a tiny fraction. In view of the good agreement between the predicted and experimental results, the proposed VHCF life prediction model involving crack initiation and growth can be acceptable for inclusion-FGA-fisheye induced failure.
Project description:The fatigue strength, effects of a notch on the fatigue strength, and fatigue crack growth rate of Ti-15Zr-4Nb-4Ta alloy were compared with those of other implantable metals. Zr, Nb, and Ta are important alloying elements for Ti alloys for attaining superior long-term corrosion resistance and biocompatibility. The highly biocompatible Ti-15Zr-4Nb-4Ta alloy exhibited an excellent balance between strength and ductility. Its notched tensile strength was much higher than that of a smooth specimen. The strength of 20% cold-worked commercially pure (C.P.) grade 4 Ti was close to that of Ti alloy. The tension-to-tension fatigue strength of an annealed Ti-15Zr-4Nb-4Ta rod at 107 cycles was approximately 740 MPa. The fatigue strength of this alloy was much improved by aging treatment after solution treatment. The fatigue strengths of C.P. grade 4 Ti and stainless steel were markedly improved by 20% cold working. The fatigue strength of Co-Cr-Mo alloy was markedly increased by hot forging. The notch fatigue strengths of 20% cold-worked C.P. grade 4 Ti, and annealed and aged Ti-15Zr-4Nb-4Ta, and annealed Ti-6Al-4V alloys were less than those of the smooth specimens. The fatigue crack growth rate of Ti-15Zr-4Nb-4Ta was the same as that of Ti-6Al-4V. The fatigue crack growth rate in 0.9% NaCl was the same as that in air. Stainless steel and Co-Cr-Mo-Ni-Fe alloy had a larger stress-intensity factor range (ΔK) than Ti alloy.
Project description:Data-driven models based on deep learning have led to tremendous breakthroughs in classical computer vision tasks and have recently made their way into natural sciences. However, the absence of domain knowledge in their inherent design significantly hinders the understanding and acceptance of these models. Nevertheless, explainability is crucial to justify the use of deep learning tools in safety-relevant applications such as aircraft component design, service and inspection. In this work, we train convolutional neural networks for crack tip detection in fatigue crack growth experiments using full-field displacement data obtained by digital image correlation. For this, we introduce the novel architecture ParallelNets-a network which combines segmentation and regression of the crack tip coordinates-and compare it with a classical U-Net-based architecture. Aiming for explainability, we use the Grad-CAM interpretability method to visualize the neural attention of several models. Attention heatmaps show that ParallelNets is able to focus on physically relevant areas like the crack tip field, which explains its superior performance in terms of accuracy, robustness, and stability.
Project description:A technique to heal a fatigue crack in austenitic stainless steel SUS316 by applying a controlled, high-density pulsed current was developed. A surface-activated pre-coating (SAPC), which eliminates the oxide layer and coats a Ni film on the crack surface, was used to improve the adhesion between crack surfaces. Cracks were observed by scanning electron microscopy before and after the application of high-density electropulsing. To evaluate the healing effect of the SAPC during crack propagation, fatigue tests were conducted under a constant stress intensity factor. The fatigue crack treated with the SAPC was found to be effectively healed as a result of electropulsing, and also showed a slower rate of crack propagation.
Project description:Soft materials fail by crack propagation under external loads. While fracture toughness of a soft material can be enhanced by orders of magnitude, its fatigue threshold remains insusceptible. In this work, we demonstrate a crack tip softening (CTS) concept to simultaneously improve the toughness and threshold of a single polymeric network. Polyacrylamide hydrogels have been selected as a model material. The polymer network is cured by two kinds of crosslinkers: a normal crosslinker and a light-degradable crosslinker. We characterize the pristine sample and light-treated sample by shear modulus, fracture toughness, fatigue threshold, and fractocohesive length. Notably, we apply light at the crack tip of a sample so that the light-sensitive crosslinkers degrade, resulting in a CTS sample with a softer and elastic crack tip. The pristine sample has a fracture toughness of 748.3 ± 15.19 J/m2 and a fatigue threshold of 9.3 J/m2. By comparison, the CTS sample has a fracture toughness of 2,774.6 ± 127.14 J/m2 and a fatigue threshold of 33.8 J/m2. Both fracture toughness and fatigue threshold have been enhanced by about four times. We attribute this simultaneous enhancement to stress de-concentration and elastic shielding at the crack tip. Different from the "fiber/matrix composite" concept and the "crystallization at the crack tip" concept, the CTS concept in the present work provides another option to simultaneously enhance the toughness and threshold, which improves the reliability of soft devices during applications.