The effect of corrosion location relative to local stresses on the fatigue life of geometrically-complex, galvanically corroded AA7075-T6

CORROSION ◽  
10.5006/3908 ◽  
2021 ◽  
Author(s):  
Carly Cocke ◽  
Rebecca Marshall ◽  
Charles Sprinkle ◽  
Adam Goff ◽  
Robert Kelly ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Stress Field ◽  
Crack Formation ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
High Stress ◽  
Corrosion Damage ◽  
Relative Impact ◽  
Fastener Hole ◽  
Macro Scale

Aluminum components used in aerospace structures are commonly coupled with stainless-steel fasteners. These through-hole geometries on the aluminum substrate cause a concentrated stress field. The high-stresses at the fastener sites can preferentially initiate coating damage allowing for moisture ingress which can lead to the formation of a galvanic couple between the aluminum alloy and the stainless-steel fastener. Corrosion damage is known to favorably initiate fatigue cracks thus severely reducing the total life of the component. This work aims to understand the relative impact and interaction of fastener hole geometry induced stress concentrations and corrosion damage on the fatigue crack initiation behavior. Specifically, by imparting various levels of corrosion severities at different locations within the macro-scale stress field, the relative impact of each on the initiation process can be determined. This work demonstrated a dominant role of the macro-scale stress field on the crack formation location. Specifically, crack formation was found to preferentially occur at high stress regions in lieu of forming at lower stress regions, regardless of corrosion severity. Critically, the findings of this work will inform the means by which coatings are evaluated and will serve as a controlled validation of experiments for fracture mechanics modeling.

Fatigue Life Prediction of Microstructures

2012 ◽  
Author(s):  
Gustavo M. Castelluccio ◽  
David L. McDowell
Keyword(s):  
Grain Size ◽  
Life Prediction ◽  
High Cycle Fatigue ◽  
Crack Formation ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
Modeling Framework ◽  
Small Cracks ◽  
Engineering Alloys ◽  
Bimodal Grain Size

The formation and early growth of fatigue cracks in the high cycle fatigue regime is influenced by microstructuctural features such as grain size and morphological and crystallographic texture. However, most fatigue models do not predict the influence of the microstructure on early stages of crack formation, or they employ parameters that should be calibrated with experimental data from specimens with microstructures of interest. These post facto strategies are adequate to characterize materials, but they are not fully appropriate to aid in the design of fatigue-resistant engineering alloys. This paper presents a modeling framework that facilitates relative assessment of fatigue resistance among different microstructures. The scheme employs finite element simulations that explicitly render the microstructure and a methodology that estimates transgranular fatigue growth for microstructurally small cracks on a grain-by-grain basis, including consideration of growth within grains (embedded analytically) and stress redistribution as the cracks extend. The methodology is implemented using a crystal plasticity algorithm in ABAQUS and calibrated to study fatigue crack initiation of a bimodal grain size distribution found in RR1000 powder processed Ni-base superalloys for turbine disk applications.

Nondestructive detection of fatigue cracks in PM 304 stainless steel by internal friction and elasticity

1993 ◽  
Vol 8 (9) ◽  
pp. 2216-2223 ◽  
Author(s):  
S.M. McGuire ◽  
M.E. Fine ◽  
O. Buck ◽  
J.D. Achenbach
Keyword(s):  
Stress Intensity Factor ◽  
Stainless Steel ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Internal Friction ◽  
Crack Growth ◽  
Fatigue Cracks ◽  
Mechanical Vibration ◽  
Fatigue Crack Initiation ◽  
304 Stainless Steel

A resonant frequency mechanical vibration method was used to nondestructively detect fatigue crack initiation in notched 304 stainless steel samples prepared by powder metallurgy. This method allowed the determination of an effective elastic modulus and the direct measurement of internal friction. Changes in the modulus and internal friction were found to correlate well with the presence of 50 μm long fatigue cracks. The length of the through cracks initiated at the notch was measured using surface replicas, which were examined in a scanning electron microscope. Small crack growth rate data were also obtained and plotted versus the stress intensity factor. The crack growth rates were compared with long crack data performed on compact tension samples of this material. The short cracks grew at intensity factors below the long crack threshold stress intensity factor.

Prediction of Fatigue Crack Initiation and Growth During Thermal Cycling

2015 ◽  
Author(s):  
Guiyi Wu ◽  
David Smith ◽  
David Tanner
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Crack Initiation ◽  
Thermal Cycling ◽  
Dwell Time ◽  
Thermal Loading ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
Stress And Strain ◽  
Finite Element Analyses

Conventional approaches to assess fatigue under combined thermal and mechanical loading often utilize a fatigue design curve. In this paper models based on the physics and mechanics for the initiation and growth of fatigue cracks in stainless steel are first explained. The models are based on experimental evidence gathered for the initiation and growth of small cracks created during strain controlled laboratory tests. This evidence is then linked with data for the growth of large fatigue cracks in stainless steel. In the paper these models are coupled with finite element analyses to explore the fatigue initiation and growth of cracks in stainless steel pipes subjected to thermal cycling. It is assumed that the material behaviour is elastic-perfectly plastic, rate independent and fatigue occurs in air. The stress and strain fields for pipes subjected to a range of thermal loading conditions are explored. The fields are shown to be sensitive to parameters such as the Biot and Fourier numbers that include pipe dimensions, physical properties, dwell time and thermal conditions. Of particular interest is the temperature range and dwell time during thermal loading. Finite element analyses are then used to determine the stress and strain ranges created by thermal loading and these ranges are used in the crack initiation and growth models to estimate fatigue life.

Observation of Dislocation Microstructures and Simulation of Stress Field during Fatigue Crack Initiation in a Copper Single Crystal

2006 ◽  
Vol 312 ◽  
pp. 71-76
Author(s):  
J.H. Yang ◽  
Xiao Ping Zhang ◽  
Yiu Wing Mai ◽  
W. Yan
Keyword(s):  
Single Crystal ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
High Stress ◽  
Dislocation Dynamics ◽  
Copper Single Crystal ◽  
Internal Stresses ◽  
Shear Stresses ◽  
The Matrix ◽  
Simulation Results

How a crack initiates from the smooth surface of single crystals subjected to uniaxial cyclic loading is unclear. Experiments were conducted to observe in detail the dislocation microstructures during the saturation stage of cyclic deformation in a copper single crystal using scanning electron microscopy and the electron channeling contrast (SEM–ECC) technique. Some dark zones were found in the dislocation microstructures, which were located either at the edge region of the specimen or within the persistent slip bands (PSBs) at the matrix/PSB interfaces. Hence, fatigue cracks will initiate at these sites with high stress concentrations, i.e., the dark zones. Also, dislocation dynamics (DD) simulation was adopted to calculate internal stress distributions induced by dislocations, and finite element analysis (FEA) used to obtain stress distribution at the matrix/PSB interfaces and neighboring micro-regions caused by an externally applied load. Simulation results show that the external shear stresses distribute uniformly in all specimens; while near the free-surface regions, the maximum value of internal stresses not only occurs at interfaces between PSBs and dislocation matrix, but also at locations where these interfaces cross the freesurface. Consequently, the interfaces are most probable sites for nucleated cracks. Finally, the simulation results agree well with experimental observations.

scholarly journals Analysis of Corrosion of Hastelloy-N, Alloy X750, SS316 and SS304 in Molten Salt High-Temperature Environment

Energies ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 543
Author(s):  
Ketan Kumar Sandhi ◽  
Jerzy Szpunar
Keyword(s):  
Weight Loss ◽  
Stainless Steel ◽  
Corrosion Resistance ◽  
Molten Salt ◽  
Corrosion Damage ◽  
Nickel Superalloy ◽  
Triple Junctions ◽  
Salt Corrosion ◽  
Molten Fluoride ◽  
Stainless Steel 316

Nickel superalloy Hastelloy-N, alloy X-750, stainless steel 316 (SS316), and stainless steel 304 (SS304) are among the alloys used in the construction of molten salt reactor (MSR). These alloys were analyzed for their corrosion resistance behavior in molten fluoride salt, a coolant used in MSR reactors with 46.5% LiF+ 11.5% NaF+ 42% KF. The corrosion tests were run at 700 °C for 100 h under the Ar cover gas. After corrosion, significant weight loss was observed in the alloy X750. Weight loss registered in SS316 and SS304 was also high. However, Hastelloy-N gained weight after exposure to molten salt corrosion. This could be attributed to electrochemical plating of corrosion products from other alloys on Hastelloy-N surface. SEM–energy-dispersive X-ray spectroscopy (EDXS) scans of cross-section of alloys revealed maximum corrosion damage to the depth of 250 µm in X750, in contrast to only 20 µm on Hastelloy-N. XPS wide survey scans revealed the presence of Fe, Cr, and Ni elements on the surface of all corroded alloys. In addition, Cr clusters were formed at the triple junctions of grains, as confirmed by SEM–EBSD (Electron Back Scattered Diffraction) analysis. The order of corrosion resistance in FLiNaK environment was X750 < SS316 < SS304 < Hastelloy-N.

scholarly journals Fatigue Crack Initiation and Propagation at High Temperature of New-Generation Bearing Steel

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 25
Author(s):  
Zhiwei Wu ◽  
Maosheng Yang ◽  
Kunyu Zhao
Keyword(s):  
Fracture Surface ◽  
Failure Mode ◽  
Electron Backscatter Diffraction ◽  
Fatigue Cracks ◽  
Fatigue Crack Initiation ◽  
Optical Microscope ◽  
Bearing Steel ◽  
Fatigue Properties ◽  
New Generation ◽  
Scanning Electron

The new generation of bearing steel has good comprehensive properties, which can satisfy most of the requirements of bearing steel in a complex environment. In the presented work, fatigue properties of 15Cr14Co12Mo5Ni2 bearing steel have been investigated by means of rotating bending fatigue tests on smooth bar specimens after carburization and heat treatment. Optical microscope, scanning electron microscopy, electron backscatter diffraction, and Image-Pro Plus software were used to analyze the fracture, microstructure, and carbides. The results suggest that the fatigue strength at room temperature and 500 °C is 1027 MPa and 585 MPa, respectively. Scanning electron micrographic observations on the fracture surface of the fatigue specimens at 500 °C show that fatigue cracks usually initiate from voids in the carburized case and oxide layer on the surface of steel. The failure mode in the carburized case is a quasi-cleavage fracture, and with the increase of crack propagation depth, the failure mode gradually changes to fatigue and creep-fatigue interaction. With the increase of the distance from the surface, the size of the martensite block decreases and the fracture surface shows great fluctuation.

Low-Cycle Fatigue Behaviour of Gas Turbine Alloys

1974 ◽  
Vol 188 (1) ◽  
pp. 321-328 ◽  
Author(s):  
W. J. Evans ◽  
G. P. Tilly
Keyword(s):  
Low Cycle Fatigue ◽  
Fatigue Cracks ◽  
High Stress ◽  
Cyclic Creep ◽  
Fatigue Curve ◽  
Fatigue Behaviour ◽  
Material Surface ◽  
Tension Stress ◽  
Cycle Fatigue ◽  
Stress Tests

The low-cycle fatigue characteristics of an 11 per cent chromium steel, two nickel alloys and two titanium alloys have been studied in the range 20° to 500°C. For repeated-tension stress tests on all the materials, there was a sharp break in the stress-endurance curve between 103 and 104 cycles. The high stress failures were attributed to cyclic creep contributing to the development of internal cavities. At lower stresses, failures occurred through the growth of fatigue cracks initiated at the material surface. The whole fatigue curve could be represented by an expression developed from linear damage assumptions. Data for different temperatures and types of stress concentration were correlated by expressing stress as a fraction of the static strength. Repeated-tensile strain cycling data were represented on a stress-endurance diagram and it was shown that they correlated with push-pull stress cycles at high stresses and repeated-tension at low stresses. In general, the compressive phase tended to accentuate cyclic creep so that ductile failures occurred at proportionally lower stresses. Changes in frequency from 1 to 100 cycle/min were shown to have no significant effect on low-cycle fatigue behaviour.

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