Fatigue crack propagation behaviour of an ultra-high strength, silicon-modified AISI 4340 alloy steel (300-M) has been investigated in moist air over an extremely wide range of growth rates from 10−8 to 10−1 mm/cycle. Particular emphasis has been devoted to the influence of microstructure on fatigue-fracture behaviour near the threshold stress intensity, ∆K 0 below which crack growth cannot be detected. By varying microstructure through quench and tempering and isothermal transformations, the threshold stress intensity and near-threshold crack-propagation rates are observed to be influenced by mean stress (load ratio), material strength, grain size, and impurity segregation. The threshold ∆K 0 for crack propagation is found to be inversely related to the strength of the steel, and a relationship between ∆K 0 and cyclic yield stress is observed. It is shown how near-threshold crack -growth resistance can be improved by (i) cyclic softening, (ii) coarsening the prior austenite grain size, and (iii) ...

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Influence of microstructure on near-threshold fatigue-crack propagation in ultra-high strength steel

The role of microstructure and environment in influencing ultra-low fatigue crack propagation rates has been investigated in 7075 aluminum alloy heat-treated to underaged, peak-aged, and overaged conditions and tested over a range of load ratios. Threshold stress intensity range, ΔK0, values were found to decrease monotonically with increasing load ratio for all three heat treatments fatigue tested in 95 pct relative humidity air, with ΔK
 0 decreasing at all load ratios with increased extent of aging. Comparison of the near-threshold fatigue behavior obtained in humid air with the data forvacuo, however, showed that the presence of moisture leads to a larger reduction in ΔK0 for the underaged microstructure than the overaged condition, at all load ratios. An examination of the nature of crack morphology and scanning Auger/SIMS analyses of near-threshold fracture surfaces revealed that although the crack path in the underaged structure was highly serrated and nonlinear, crack face oxidation products were much thicker in the overaged condition. The apparent differences in slow fatigue crack growth resistance of the three aging conditions are ascribed to a complex interaction among three mechanisms: the embrittling effect of moisture resulting in conventional corrosion fatigue processes, the role of microstructure and slip mode in inducing crack deflection, and crack closure arising from a combination of environmental and microstructural contributions.

Mechanisms of Slow Fatigue Crack Growth in High Strength Aluminum Alloys: Role of Microstructure and Environment

This chapter focuses on two kinds of environmental fracture, stress corrosion cracking (SCC) and hydrogen embrittlement, and discusses the role in such failures of a number of metallurgical variables. These include chemical composition; microstructural components such as precipitate type and structure, and grain size and shape; crystallographic texture; heat treatment and its effect on the foregoing variables; and processing, particularly the thermomechanical treatments (TMT), which are attracting increased attention for property optimization. These variables are expected to be of great importance in the development of new engineering materials to meet demanding service conditions.

The Role of Metallurgical Variables in Hydrogen-Assisted Environmental Fracture

This bibliography is comprised of approximately 1,600 reference citations related to four problem areas in the mechanics of failure in aerospace structures. The bibliography represents a search of the literature published in the period 1962-1976, the effort being largely limited to documents published in the United States. Listings are subdivided into the four problem areas: Hydrogen Embrittlement; Protective Coatings; Composite Materials; and Nondestructive Evaluation. An author index is included.

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Bibliography of information on mechanics of structural failure (hydrogen embrittlement, protective coatings, composite materials, NDE)

The fatigue-crack growth (fcg) behaviour of metals and alloys at low stress intensities is considered in terms of load ratio, microstructure, and environment. The behaviour of aluminium and titanium alloys and steels is examined and their mode of fcg reported. The occurrence of microstructurally sensitive fcg is considered and the conditions leading to its occurrence examined. The identity of trans granular facets formed in this region of fcg are tabulated and some of the models proposed for this phenomenon are presented. The importance of K max as a controlling influence on the growth of fatigue cracks even at low stress intensities is conveyed by the results presented.

Fatigue crack growth characteristics at low stress intensities of metals and alloys

Environmental fatigue crack propagation in 2024-T3, 7075-T6, and 7178-T6 has been studied at low levels of cyclic amplitude of stress intensity, ΔK. Both wedge force loading and remote loading techniques were employed to achieve the desired ΔK levels, and preliminary experiments were designed to test their compatibility. Testing was carried out in humid air, distilled water, and 3.5 pct sodium chloride solution, and the observed crack growth rates compared with those in desiccated air. Later studies were also conducted in an inert reference environment with a total water content of less than 2 ppm. When the data are plotted as log ΔK vs log d2a /dN, alloy 2024-T3 exhibits a marked slope transition, alloy 7075-T6 a slight slope transition, and alloy 7178-T6 a rectilinear behavior throughout the whole range of ΔK studied. The basic shape of these curves is discussed in terms of state-of-stress conditions at the crack tip, frequency effects, environmental effects, strain rate sensitivity, and metallurgical structure. An attempt is also made to correlate the rate of fatigue crack propagation in a particular environment and at a particular ΔK level with the fracture topography.

John A. Feeney

Papers

Environmental fatigue crack propagation of aluminum alloys at low stress intensity levels