The Effect of Fatigue Crack Growth on Mechanical Residual Stress Redistribution

Document Type : Original Article

Authors

• Mohammad Noghabi
• Iradj Sattarifar
• Hossein Hosseini Todeshki

AmirKabir University of Technology

10.22067/fum_mech.v27i2.38657

Abstract

In this study, the effect of fatigue loading on the redistribution of mechanical residual stresses in compact tension specimens has been investigated. Fatigue crack growth experimental tests were conducted in accordance with E647 standard for specimens with and without initial residual stress. To investigate the crack tip plastic zone and fracture mechanics parameters finite element analysis using ABAQUS was used. The results showed that the initial residual stress redistributed after a few cycles of fatigue loading. Redistribution depends on the amplitude of cyclic loading. Near crack tip plastic zone area also decrease after a few cycles and reaches a stable value. In experimental tests, the fatigue life of specimens with mechanical residual stresses was lower than specimen having no residual stresses.

Keywords

• Fatigue crack Growth
• Crack Tip Plastic Zone
• Redistribution of Residual Stress
• J Integral

---

References

1. Bucci, R.J., "Effect of residual stress on fatigue crack growth rate measurement", ASTM STP, Vol. 743, pp. 28–47, (1981).

2. McClung, R.C., "A literature survey on the stability and significance of residual stresses during fatigue", Fatigue Fract. Engng. Mater. Struct., Vol. 30, pp. 173–205, (2007).

3. Vaidya, W.V., Staron, P. and Horstmann, M., "Fatigue crack propagation into the residual stress field along and perpendicular to laser beam butt-weld in aluminium alloy AA6056", Fatigue Fract Engng Mater Struct, Vol. 35, 399–411, (2011).

4. Maddox, S.J., "Fatigue strength of welded structures", Abington Publishing; (1991).

5. Withers, P.J., "Residual stress and its role in failure", Rep Prog Phys, Vol. 70, pp. 2211–2264, (2007).

6. Barsoum, Z., Barsoum, I., "Residual stress effects on fatigue life of welded structures using LEFM", Engineering Failure Analysis, Vol. 16, pp. 449–467, (2009).

7. LaRue, J.E. and Daniewicz, S.R., "Predicting the effect of residual stress on fatigue crack growth", International Journal of Fatigue, Vol. 29, pp. 508–515, (2007).

8. Servetti, G. and Zhang, X., "Predicting fatigue crack growth rate in a welded butt joint: The role of effective R ratio in accounting for residual stress effect", Engineering Fracture Mechanics, Vol. 76, pp. 1589–1602, (2009).

9. Ghidini, T. and Dalle Donne, C., "Fatigue crack propagation assessment based on residual stresses obtained through cut-compliance technique", Fatigue Fract Engng Mater Struct, Vol. 30, pp.

214–222, (2006).

10. Bussu, G. and Irving, P.E., "The role of residual stress and heat affected zone properties on fatigue crack propagation in friction stir welded 2024-T351 aluminum joints", International Journal of Fatigue, Vol. 25, pp. 77–88, (2003).

11. Farrahi, G.H., Majzoobi, G.H., Hosseinzadeh, F. and Harati, S.M., "Experimental evaluation of the effect of residual stress field on crack growth behaviour in C(T) specimen", Engineering Fracture Mechanics, Vol. 73, pp. 1772–1782, (2006).

12. Wenman, M.R., Price, A.J., Steuwer, A., Chard-Tuckey, P.R. and Crocombe, A., "Modelling and experimental characterisation of a residual stress field in a ferritic compact tension specimen", International Journal of Pressure Vessels and Piping, Vol. 86, pp. 830–837, (2009).

13. Semari, Z., Aid, A., Benhamena, A., Amrouche, A., Benguediab, M., Sadok, A. and Benseddiq, N., "Effect of residual stresses induced by cold expansion on the crack growth in 6082 aluminum alloy", Engineering Fracture Mechanics, Vol. 99, pp. 159–168, (2013).

14. Wahab, M.A., Rohrsheim, G.R. and Park, J.H., "Experimental study on the influence of overload induced residual stress field on fatigue crack growth in aluminium alloy", Journal of Materials Processing Technology, Vol. 153–154, pp. 945–951, (2004).

15. Stuart, D.H., Hill, M.R. and Newman, J.C., "Correlation of one-dimensional fatigue crack growth at cold-expanded holes using linear fracture mechanics and superposition", Engineering Fracture Mechanics, Vol. 78, pp. 1389–1406, (2011).

16. Lammi, C.J. and Lados, D.A., "Numerical predictions and experimental measurements of residual", Engineering Fracture Mechanics, Vol.78, pp. 1114–1124, (2011).

17. Parker, A.P., "Stress intensity factors, crack profiles, and fatigue crack growth rates in residual stress fields". In: Residual stress effects in fatigue, ASTM STP 776, American Society for Testing and Materials, p. 13–31, (1982).

18. Itoh, Y.Z., Suruga, S. and Kashiwaya, H., "Prediction of fatigue crack growth rate in welding residual stress field", Engineering Fracture Mechanics, pp. 397–407, (1989).

19. Beghini, M., Bertini, L. and Vitale, E., "Fatigue crack growth in residual stress fields: experimental results and modeling, Fatigue Fract Engng Mater Struct", Vol. 17, pp. 1433–1444, (1994).

20. Liljedahl, C.D.M, Tan, M.L., Zanellato, O., Ganguly, S., Fitzpatrick, M.E. and Edwards, L., "Evolution of residual stresses with fatigue loading and subsequent crack growth in a welded aluminum alloy middle tension specimen", Engineering Fracture Mechanics, Vol. 75, pp. 3881–3894, (2008).

21. EN 13445-3, Unfired pressure vessels part 3: Design, European Standard, (2002).

22. ASTM E647-00, Standard test method for measurement of fatigue crack growth rates, Annual Book of ASTM Standards, Vol. 03.01, pp. 603–644, (2002).

23. Anderson, T.L., "Fracture Mechanics Fundamentals and Applications", Third Edition, Boca Raton: Tylor & Francis Group, (2005).

24. Abaqus, D.S., Ver, 6.12. Dassault Systèmes Simulia Corp., Providence, RI, USA, 2012.

25. Abdelaziz, Y., Benkheira, S., Rikioui, T. and Mekkaoui, A., "A double degenerated finite element for modeling the crack tip singularity", Applied Mathematical Modelling, Vol. 34, pp. 4031–4039, (2010).

26. Mirzaee-Sisan, A., Truman, C.E., Smith, D.J. and Smith, M.C., "Interaction of residual stress with mechanical loading in an austenitic stainless steel", Fatigue Fract Engng Mater Struct, Vol. 31, pp. 223–233, (2007).

27. Solanki, K., Daniewicz, S.R. and Newman, J.C., "Finite element analysis of plasticity induced fatigue crack closure: an overview", Engineering Fracture Mechanics, Vol. 71, pp. 149–171, (2004).

28. Solanki, K., Daniewicz, S.R. and Newman, J.C., "Finite element modeling of plasticity-induced crack closure with emphasis on geometry and mesh refinement effects", Engineering Fracture Mechanics, Vol. 70, No. 12, pp. 1475-1489, (2003).

29. ASTM E1820-01, Standard test method for measurement of fracture toughness, Annual Book of ASTM Standards, Vol. 03.01, pp. 1031–1076, (2001).

30. Benedetti, M., Fontanari, V., Scardi, P., Ricardo, C.L.A. and Bandini, M., Reverse bending fatigue of shot peened 7075-T651 aluminium alloy: The role of residual stress relaxation, "International Journal of Fatigue", Vol. 31, pp. 1225–1236, (2009).

31. Zhuang, W.Z. and Halford, G.R., "Investigation of residual stress relaxation under cyclic load", International Journal of Fatigue, Vol. 23, pp. 31–37, (2001).