Hostname: page-component-cd9895bd7-gbm5v Total loading time: 0 Render date: 2024-12-23T11:35:57.309Z Has data issue: false hasContentIssue false

Micromechanical modeling of fatigue crack initiation in polycrystals

Published online by Cambridge University Press:  17 October 2017

Martin Boeff
Affiliation:
Interdisciplinary Centre for Advanced Materials Simulation, Ruhr-Universität Bochum, Bochum 44801, Germany
Hamad ul Hassan*
Affiliation:
Interdisciplinary Centre for Advanced Materials Simulation, Ruhr-Universität Bochum, Bochum 44801, Germany
Alexander Hartmaier
Affiliation:
Interdisciplinary Centre for Advanced Materials Simulation, Ruhr-Universität Bochum, Bochum 44801, Germany
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

Fatigue is an important mechanism for the failure of components in many engineering applications and a significant proportion of the fatigue life is spent in the crack initiation phase. Although a large number of research work addresses fatigue life and fatigue crack growth, the problem of modeling crack initiation remains a major challenge in the scientific and engineering community. In the present work, a micromechanical model is developed and applied to study fatigue crack initiation. In particular, the effect of different hardening mechanisms on fatigue crack initiation is investigated. To accomplish this, a model describing the evolution of the particular dislocation structures observed under cyclic plastic deformation is implemented and applied on randomly generated representative microstructures to investigate fatigue crack initiation. Finally, a method is presented to calculate the S–N curve for the polycrystalline materials. With this work, it is demonstrated how the micromechanical modeling can support the understanding of damage and failure mechanisms occurring during fatigue.

Type
Articles
Copyright
Copyright © Materials Research Society 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Contributing Editor: Mathias Göken

References

REFERENCES

Mughrabi, H.: Microstructural fatigue mechanisms: Cyclic slip irreversibility, crack initiation, non-linear elastic damage analysis. Int. J. Fatigue 57, 28 (2013).Google Scholar
Miller, K.J.: The short crack problem. Fatigue Fract. Eng. Mater. Struct. 5(3), 223232 (1982).Google Scholar
Tokaji, K., Ogawa, T., Harada, Y., and Ando, Z.: Limitations of linear elastic fracture mechanics in respect of small fatigue cracks and microstructure. Fatigue Fract. Eng. Mater. Struct. 9(1), 114 (1986).Google Scholar
Christ, H-J. and Mughrabi, H.: Cyclic stress-strain response and microstructure under variable amplitube loading. Fatigue Fract. Eng. Mater. Struct. 19(2–3), 335348 (1996).Google Scholar
Miller, K.J.: The three thresholds for fatigue crack propagation. In Fatigue and Fracture Mechanics, Vol. 27, Piascik, Robert S., Newman, James C. Jr., and Dowling, Norman E., eds. (ASTM International, Conshohocken, Pennsylvania, 1997), pp. 267286.Google Scholar
Bathias, C. and Paris, P.C.: Gigacycle Fatigue in Mechanical Practice, Vol. 185 (CRC Press, Boca Raton, Florida, 2004).Google Scholar
Mughrabi, H.: On the life-controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime. Fatigue Fract. Eng. Mater. Struct. 22(7), 633641 (1999).Google Scholar
Mughrabi, H.: On multi-stage fatigue life diagrams and the relevant life-controlling mechanisms in ultrahigh-cycle fatigue. Fatigue Fract. Eng. Mater. Struct. 25(8–9), 755764 (2002).Google Scholar
McDowell, D.L., Gall, K., Horstemeyer, M.F., and Fan, J.: Microstructure-based fatigue modeling of cast A356-T6 alloy. Eng. Fract. Mech. 70(1), 4980 (2003).Google Scholar
McDowell, D.L.: Multiaxial small fatigue crack growth in metals. Int. J. Fatigue 19(93), 127135 (1997).Google Scholar
Lankford, J. and Kusenberger, F.N.: Initiation of fatigue cracks in 4340 steel. Metall. Trans. 4(2), 553559 (1973).Google Scholar
Mughrabi, H.: Cyclic slip irreversibilities and the evolution of fatigue damage. Metall. Mater. Trans. B 40(4), 431453 (2009).Google Scholar
Tokaji, K. and Ogawa, T.: The growth behaviour of microstructurally small fatigue cracks in metals. Short Fatigue Cracks, ESIS 13, 8599 (1992).Google Scholar
Suresh, S.: Fatigue of Materials (Cambridge University Press, Cambridge, United Kingdom, 1998).CrossRefGoogle Scholar
Bennett, V. and McDowell, D.L.: Polycrystal orientation effects on microslip and mixed-mode behavior of microstructurally small cracks. In Mixed-mode Crack Behavior, Miller, K.J. and McDowell, D.L., eds. (ASTM International, Conshohocken, Pennsylvania 1999), pp. 203228.Google Scholar
Simonovski, I., Nilsson, K-F., and Cizelj, L.: The influence of crystallographic orientation on crack tip displacements of microstructurally small, kinked crack crossing the grain boundary. Comput. Mater. Sci. 39(4), 817828 (2007).Google Scholar
Groh, S. and Zbib, H.M.: Advances in discrete dislocations dynamics and multiscale modeling. J. Eng. Mater. Technol. 131(4), 41209 (2009).Google Scholar
Künkler, B., Düber, O., Köster, P., Krupp, U., Fritzen, C-P., and Christ, H-J.: Modelling of short crack propagation—Transition from stage I to stage II. Eng. Fract. Mech. 75(3), 715725 (2008).Google Scholar
Mughbrabi, H., Ackermann, F.u., and Herz, K.: Persistent slipbands in fatigued face-centered and body-centered cubic metals. In Fatigue Mechanisms, Fong, Jeffrey T., ed. (ASTM, Philadelphia, Pennsylvania 1979), pp. 6995.Google Scholar
Wang, R. and Mughrabi, H.: Secondary cyclic hardening in fatigued copper monocrystals and polycrystals. Mater. Sci. Eng. 63(2), 147163 (1984).Google Scholar
Castelluccio, G.M.: A Study on the Influence of Microstructure on Small Fatigue Cracks. PhD thesis, George W. Woodruff School of Mechanical Engineering, Georigia Institute of Technology, Atlanta, Georgia, 2012.Google Scholar
Sharaf, M.A.M.: The Microstructure Influence on Fatigue Life Variability in Structural Steels. PhD thesis. RWTH Aachen University, Aachen, Germany, 2015.Google Scholar
McDowell, D.L. and Dunne, F.P.E.: Microstructure-sensitive computational modeling of fatigue crack formation. Int. J. Fatigue 32(9), 15211542 (2010).Google Scholar
Dunne, F.P.E., Wilkinson, A.J., and Allen, R.: Experimental and computational studies of low cycle fatigue crack nucleation in a polycrystal. Int. J. Plast. 23(2), 273295 (2007).Google Scholar
Przybyla, C.P. and McDowell, D.L.: Microstructure-sensitive extreme value probabilities for high cycle fatigue of {Ni}-base superalloy {IN100}. Int. J. Plast. 26(3), 372394 (2010).Google Scholar
Krupp, U., Düber, O., Christ, H-J., Künkler, B., Schick, A., and Fritzen, C-P.: Application of the EBSD technique to describe the initiation and growth behaviour of microstructurally short fatigue cracks in a duplex steel. J. Microsc. 213(3), 313320 (2004).Google Scholar
Tanaka, K. and Mura, T.: A dislocation model for fatigue crack initiation. J. Appl. Mech. 48(1), 97103 (1981).Google Scholar
Boeff, M.: Micromechanical modelling of fatigue crack initiation and growth. PhD thesis, Department of Mechanical Engineering, Ruhr Universität Bochum, Bochum, Germany, 2016.Google Scholar
Kröner, E.: Allgemeine Kontinuumstheorie der Versetzungen und Eigenspannungen. Arch. Ration. Mech. Anal. 4(1), 273334 (1959).Google Scholar
Lee, E.H. and Liu, D.T.: Finite-strain elastic–plastic theory with application to plane-wave analysis. J. Appl. Phys. 38(1), 1927 (1967).Google Scholar
Lee, E.H.: Elastic–plastic deformation at finite strains. J. Appl. Mech. 36(1), 16 (1969).Google Scholar
Bonet, J. and Wood, R.D.: Nonlinear Continuum Mechanics for Finite Element Analysis (Cambridge University Press, 2008).Google Scholar
Koester, A., Ma, A., and Hartmaier, A.: Atomistically informed crystal plasticity model for body-centered cubic iron. Acta Mater. 60(9), 38943901 (2012).Google Scholar
Roters, F., Eisenlohr, P., Hantcherli, L., Tjahjanto, D.D., Bieler, T.R., and Raabe, D.: Overview of constitutive laws, kinematics, homogenization and multiscale methods in crystal plasticity finite-element modeling: Theory, experiments, applications. Acta Mater. 58(4), 11521211 (2010).Google Scholar
Rice, J.R.: Inelastic constitutive relations for solids: An internal-variable theory and its application to metal plasticity. J. Mech. Phys. Solids 19(6), 433455 (1971).Google Scholar
Hutchinson, J.W.: Bounds and self-consistent estimates for creep of polycrystalline materials. Proc. R. Soc. London, Ser. A 348(1652), 101127 (1976).Google Scholar
Mughrabi, H.: The long-range internal stress field in the dislocation wall structure of persistent slip bands. Phys. Status Solidi 104(1), 107120 (1987).Google Scholar
Mayama, T. and Sasaki, K.: Investigation of subsequent viscoplastic deformation of austenitic stainless steel subjected to cyclic preloading. Int. J. Plast. 22(2), 374390 (2006).Google Scholar
Evrard, P., Alvarez-Armas, I., Aubin, V., and Degallaix, S.: Polycrystalline modeling of the cyclic hardening/softening behavior of an austenitic-ferritic stainless steel. Mech. Mater. 42(4), 395404 (2010).Google Scholar
Evrard, P., Aubin, V., Degallaix, S., and Kondo, D.: Formulation of a new single crystal law for modeling the cyclic softening. Mech. Res. Commun. 35(8), 589594 (2008).Google Scholar
Manonukul, A. and Dunne, F.P.E.: High-and low-cycle fatigue crack initiation using polycrystal plasticity. Proc. R. Soc. London, Ser. A 460(2047), 18811903 (2004).Google Scholar
Boeff, M., Gutknecht, F., Engels, P.S., Ma, A., and Hartmaier, A.: Formulation of nonlocal damage models based on spectral methods for application to complex microstructures. Eng. Fract. Mech. 147, 373387 (2015).Google Scholar
Sandia National Laboratories, CUBIT 13.2., 2013.Google Scholar
Inal, K., Lebrun, J.L., and Belassel, M.: Second-order stresses and strains in heterogeneous steels: Self-consistent modeling and X-ray diffraction analysis. Metall. Mater. Trans. A 35(8), 23612369 (2004).Google Scholar
Mahmoody, S.: Micromechanical Modeling of Dual-Phase Steel Using a Rate-Dependet Crystal Plasticity Model (McGill University, Montreal, Canada, 2007).Google Scholar