Investigating the Interaction between Persistent Slip Bands and Surface Hard Coatings via Crystal Plasticity Simulations

Fatigue cracks often initiate from the surface extrusion/intrusions formed due to the operation of persistent slip bands (PSBs). Suppression of these surface topographical features by hard surface coatings can significantly extend fatigue lives under lower stress amplitudes (i.e., high cycle fatigue), while cracks initiate early in the coating or in the coating–substrate interface under higher stress amplitudes (i.e., low cycle fatigue), deteriorating the fatigue performance. However, both beneficial and detrimental effects of the coatings appear to be affected by the coating–substrate material combination and coating thickness. A quantitative understanding of the role of these factors in the fatigue performance of materials is still lacking. In this study, crystal plasticity simulations were employed to elucidate the dependence of the coating’s effects on two factors—i.e., the coating thickness and loading amplitudes. The results revealed that the thicker coatings more effectively suppress the operation of the PSBs, but generate higher tensile and shear stresses, normal and parallel to the interfaces, respectively, promoting interfacial delamination. The tensile stresses parallel to the interface within the coating, which favors coating fracture, are not sensitive to the coating thickness.

The heterogeneity of persistent slip band nucleation and evolution in metals at the micrometer scale

Fatigue damage in metals manifests itself as irreversible dislocation motion followed by crack initiation and propagation. Characterizing the transition from a crack-free to a cracked metal remains one of the most challenging problems in fatigue. Persistent slip bands (PSBs) form in metals during cyclic loading and are one of the most important aspects of this transition. We used in situ microfatigue experiments to investigate PSB formation and evolution mechanisms, and we discovered that PSBs are prevalent at the micrometer scale. Dislocation accumulation rates at this scale are smaller than those in bulk samples, which delays PSB nucleation. Our results suggest the need to refine PSB and crack-initiation models in metals to account for gradual and heterogeneous evolution. These findings also connect micrometer-scale deformation mechanisms with fatigue failure at the bulk scale in metals.

On the Evidence of Thermodynamic Self-Organization during Fatigue: A Review

In this review paper, the evidence and application of thermodynamic self-organization are reviewed for metals typically with single crystals subjected to cyclic loading. The theory of self-organization in thermodynamic processes far from equilibrium is a cutting-edge theme for the development of a new generation of materials. It could be interpreted as the formation of globally coherent patterns, configurations and orderliness through local interactivities by “cascade evolution of dissipative structures”. Non-equilibrium thermodynamics, entropy, and dissipative structures connected to self-organization phenomenon (patterning, orderliness) are briefly discussed. Some example evidences are reviewed in detail to show how thermodynamics self-organization can emerge from a non-equilibrium process; fatigue. Evidences including dislocation density evolution, stored energy, temperature, and acoustic signals can be considered as the signature of self-organization. Most of the attention is given to relate an analogy between persistent slip bands (PSBs) and self-organization in metals with single crystals. Some aspects of the stability of dislocations during fatigue of single crystals are discussed using the formulation of excess entropy generation.

Changing Mechanisms of Surface Relief and the Damage Evaluation of Low Cycle Fatigued Austenitic Stainless Steel

To quantitatively investigate the cause of the changes in arithmetic mean roughness Ra and arithmetic mean waviness Wa of austenitic stainless steel under low-cycle fatigue loading, precise observation focusing on persistent slip bands (PSBs) and crystal grain deformations was conducted on SUS316NG. During the fatigue tests, the specimen’s surface topography was regularly measured using a laser microscope. The surface topographies were analysed by frequency analysis to separate the surface relief due to PSBs from that due to grain deformation. The height caused by PSBs and that by grain deformation were measured respectively. As a result, both of the heights rose with the increase of usage factor (UF). The amount of increase in the heights with respect to UF increased with strain range. The trend of development of both heights was similar with the trend of Ra and Wa. A comparison between Ra and the height caused by PSBs showed that these values strongly correlated with each other. A comparison between Wa and the height caused by grain deformation also showed that these values strongly correlated with each other. Consequently, the surface texture parameters Ra and Wa represent the changes in the heights of surface reliefs due to PSBs and grain deformation.