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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Journal ArticleDOI
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.
Journal ArticleDOI
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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Fatigue-Life Prediction Methodology Using a Crack-Closure Model
TL;DR: In this article, the capabilities of a plasticity-induced crackclosure model and life-prediction code, FASTRAN, to predict fatigue lives of metallic materials using small-crack theory were reviewed.
Book ChapterDOI
An Evaluation of the Adjusted Compliance Ratio Technique for Determining the Effective Stress Intensity Factor
JK Donald,GH Bray,RW Bush +2 more
Book ChapterDOI
Effect of residual stress on fatigue crack growth rate measurement
TL;DR: In this article, the influence of residual stress leads to erroneous interpretation of fatigue crack growth rate measurements made in accordance with ASTM Method E 647-78T, and guidelines for minimization of their effect on fracture property measurement are suggested.