Fatigue

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Definition of fatigue: evolution of properties occurring in a material subjected to repeated application of stresses or strains. Notes:

Fatigue affects a variety of applications Distinct materials have distinct damage mechanisms and distinctive fatigue 5/23/12 properties.

The Tensile Curve

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Example of Cyclic Loading

Consider spokes on a motorcycle wheel. Will failure occur if (t) and if max < y ?

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Sources of Fatigue Damage

Microstructural inhomogeneity Physical damage Stress concentrations

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Types of Fatigue

Mechanical Fatigue Multiaxial Fatigue Thermal Fatigue Creep-Fatigue Thermomechanical Fatigue Corrosion Fatigue
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Contact Fatigue

Material or component is subjected to isothermal mechanical cycling at room or elevated temperature conditions Mechanical strain rate is designed to avoid time dependent deformation (e.g. creep)
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Examples of Mechanical Fatigue

Stages of Fatigue

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Stages of Fatigue Example

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Safe-Life Design

Def: Safe-Life Design is an approach which designs components with no tolerance for failure during the course of the life of the part

Notes: Used on very critical parts or on

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those which cannot be inspected

Standards

Def: Standard - an accepted guide that governs concepts, procedure, definitions, etc. Ex: ASTM E606 Standard Practice for Strain-Controlled Fatigue Testing Ex: ISO 1099:2006 5/23/12 Metallic

materials --

Fatigue Journals

International Journal of Fatigue Engineering Materials & Structures Engineering Failure Analysis Materials Science and Engineering Journal of Mechanical Sciences

Fatigue and Fracture of

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Fatigue Texts

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Fatigue Analysis
can be used to determine each of the following:

Number of cycles to failure Effect of altering the component (e.g., material, processing, geometry) Effect of environment and temperature Effect of presences of stress concentrations and cracks on fatigue 5/23/12

Founders of Fatigue

Poncelet (1824) Rankine (1842) Wohler (1860s) Bauschinger (1885) Ewings and Humpries (1903) Coffin and Manson (1954) Paris (1961)
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Jean-Victor Poncelet

Coined the term fatigue Used the term to refer to tired metals that had been worn down via cyclic loading

Studied waterwheels
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and turbines

August Wohler

Systematically examined steel railway axles Sought to determine the existence of the endurance limit below the endurance limit of the material Developed S-N curves Concluded that cyclic stress range is more important than peak stress.
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August Wohler

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Ewings and Humphries

Using micrographs, they determined fatigue crack initiation is related to the evolution of the crystal structure

Discovered the progression of slip

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bands and slip steps

Disasters Attributed to Fatigue

Versailles train crash (1842) Boston Molasses Disaster (1915) Liberty Ships of WWII (1940s) De Havilland Comet Jets (1953, 1954) The Point Pleasant/Silver Bridge Disaster (1967) China Airlines Flight 611 (2002) And more 5/23/12

Versailles train crash

Caused by fatigue failure of a locomotive axle at a sharp cornered shoulder

Notes: Occurred on May 8th, 1842 Carriages behind piled into the wrecked engines and caught fire
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Problem solved with better axles

De Havilland Comet

Three plane crashes caused by repeated

pressurization of the metallic fuselage skin at sharp corners near windows

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Disaster Summary

Fatigue damage affects Fatigue failure caused by a variety of factors: Stress concentrations Corrosion fatigue Prior damage

Fatigue damage can be deadly Current fatigue methods stop these 5/23/12

Stages of Fatigue Crack Growth (FCG)

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Stages of Fatigue Crack Growth (FCG)

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Beach Marks

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FCG Surfaces: Uniaxial

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FCG Surfaces: Bending

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FCG Surfaces: Reversed Bending

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Rotating Bending and Torsion

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Mechanical Cycling

Notes:

Cyclic stress (or strain) leads to fatigue failure The resistance of a material (or a component) to fatigue is measured in cycles, denoted by Nf, and connoted by fatigue life
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Notes:

Example Cycles

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Determining Stress Histories

Consider a critical location in component Consider the mechanical (and thermal) loads experienced by that component

Use Solid Mechanics

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analysis or FEA to convert

Fatigue Regimes

Def: High Cycle Fatigue (HCF) when

the number of cycles to fatigue failure, Nf , is in the range of 103 to 106.

Def: Low Cycle Fatigue (LCF) - when Nf is in the range of 101 to 103. Def: Infinite Life - when Nf is above 5/23/12 106.

Stress History Nomenclature Defs:

Stress amplitude a = (max min)/2 Mean stress m = (max + min)/2 Stress range = (max - min) Stress ratio R = min/max Amplitude ratio A = a/m
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Stress-Life Approach

Assumptions: High cycle fatigue regime

Strain range is dominated by elastic rather than plastic strain Peak and valley stresses are constant Only one component of loading 5/23/12 (e.g., axial,

Typical S-N Curve for Steel

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S-N Curves for Al Alloys

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Endurance Limit for Nonferrous Alloys

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S-N Curves for Polymers

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S-N Curves for Filled Thermosets

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Modeling S-N Data

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Rotating Bending Rig

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Used to conduct experiments on small samples

Rotating Bending Fatigue Testing System

Usually new materials for which little to no data exist

System cost $20K Speed: 500 to 10K

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Relationship of Su and Se: Steel

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Su and Se: Wrought & Cast Iron

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Su and Se: Aluminum Alloys

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Su and Se: Copper Alloys

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Relationship of Su and Se

Fatigue strength data come from rotating bending experiments

Small and polished specimens At high tensile

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strengths, fatigue

Typical Endurance Limits

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Endurance Limit Modifiers

The endurance limit is impacted by each of the following: Surface condition Presence of notches Fabrication defects Absolute size Environment Cyclic Rate 5/23/12

Correction factors are used to account for various

Endurance Limit Modifiers

effects on the endurance limit

The unmodified endurance limit, Se, is based on the rotating bending tests Marin factors are unitless, positive, and have a
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maximum value of unity.

Surface Condition Factor, CSurf

Unmodified endurance limit determined from highly polished samples

Data is typically quite scattered Small variation

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Surface Condition Factor, CSurf

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Surface Condition Factor, CSurf

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Special Cases for R and A

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Size Factor, CSize

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Size Factor, CSize

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Type of Load

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Environment, Cenv

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Reliability Factor, CR

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Miscellaneous Factor, Cm

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Cyclic Rate

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Modeling S-N Curve Near 103

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Temperature Factor, CTemp

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Effect of Mean Stress

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Stress Ratio Effect

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Master Fatigue Diagram

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Master Fatigue Diagram

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Fatigue Failure Theories for Fluctuating Stress

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Fatigue Failure Theories

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Fatigue Failure Theories

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Discussion of Methods

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Finite Life

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Important Stress-Life Concepts

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Fatigue Design Considerations

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Summary

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Stress Concentrations

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