Open Access
The Effects of Processing Residual Stresses on the Fatigue Crack Growth Behavior of Structural Materials
TLDR
In this article, the effects of quenching residual stresses on fatigue crack propagation behavior of various materials were investigated, and an original residual stress analytical correction to fatigue crack growth data was developed, compared to existing corrective methodologies, and validated using residual stress free data.Abstract:
Residual stresses are a common and often undesired result of material processing, introduced through non-linear deformation and/or phase transformation of material under mechanical or thermo-mechanical loading. These macro stresses alter mechanical properties and the intrinsic fatigue crack growth characteristics of the material. Residual stress artifacts can introduce inconsistencies and significant errors when the true material behavior is needed for material development and optimization and for structural component design. The effects of quenching residual stresses on fatigue crack propagation behavior of various materials were investigated. In parallel, residual stresses similar in magnitude and distribution with the quenching residual stresses were generated using mechanical processes to decouple the effects of residual stresses from microstructural effects. Mechanical residual stress distributions predicted by 3D elastic-plastic finite element analysis showed good agreement with the stresses measured on fatigue crack growth testing specimens using fracture mechanics approaches. Crack propagation characteristics in fields with low and high residual stresses were studied using optical and scanning electron microscopy, and the effects of residual stress on crack path behavior were assessed. An original residual stress analytical correction to fatigue crack growth data was developed, compared to existing corrective methodologies, and validated using residual stress free data. Overall, the work provides tools to understand, control, and correct the effects of processing residual stresses on fatigue crack growth for accurate fatigue critical design and life predictions.read more
Citations
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Experimental and numerical investigation of residual stresses around cold extrusion hole of ultrahigh strength steel
TL;DR: In this paper, a two-dimensional finite element (FE) model was established to simulate the residual stresses associated with the hole extrusion process and the numerical result showed a good agreement with the experimental data.
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Fracture failure analysis of DY08Aluminum alloy elastic coupling
TL;DR: In this article, the failure reasons of a DY08 aluminum alloy elastic coupling connecting the motor of the multi-functional test bench with the experimental device was investigated based on the fact that the lifespan of coupling was not reached.
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Initial Residual Stresses in Hot-Rolled Wide-Flange Shapes: A Computational Technique and Influence on Structural Performances
Shahriar Quayyum,Tasnim Hassan +1 more
TL;DR: In this paper, wide-flange members are hot-rolled to their final shapes and subsequently air-cooled, during which residual stresses are developed due to nonuniform cooling.
Fatigue life prediction models for components subjected to manufacturing induced residual stresses
TL;DR: A comprehensive study of the mechanical fatigue subject is presented, with particular focus on the residual stresses issue, as their impact on the fatigue life expectations, the manufacturing processes behind their formation, their measurement methods and the most preforming way to account them in the fatigueLife estimates.
References
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Journal ArticleDOI
Determination of residual stress distributions from measured stress intensity factors
TL;DR: In this paper, the authors calculate the stress that acted on the corresponding axis in the initial, uncracked state of the body when a crack or machined cut is introduced in a body that contains residual stresses.
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Fracture mechanics analysis for residual stress and crack closure corrections
TL;DR: In this paper, a new methodology is proposed to determine (1) stress intensity factors due to residual stress, Kres, when samples with high residual stress are tested, and (2) effective stress intensity factor, Keff, from corresponding applied stresses when closure contributions are significant.
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The effect of residual stress and its redistribution of fatigue crack growth
Yee Cheong Lam,K.S. Lian +1 more
TL;DR: In this paper, an experimental method for introducing residual stress in a specimen by local plastic deformation and a technique to measure and delineate the residual stress field is discussed, and the role of residual stress redistribution as the crack grows is also discussed.
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An elastic-plastic analytical model for predicting fatigue crack growth in arbitrary edge-cracked two-dimensional geometries with residual stress
TL;DR: In this paper, a two-dimensional, weight-function-based, non-linear elastic-plastic analytical model has been developed for considering fatigue crack propagation in a pre-existing residual stress field.
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Microstructure dependent fatigue crack growth in aged hardened aluminium alloys
TL;DR: In this article, the effects of different dominant closure mechanisms (plasticity-induced closure or roughness-induced closures) on the fatigue crack propagation in AlMgSi1-T6 aluminium alloys with different Mn and Cr contents were investigated.