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In the past, the disagreement of near-threshold fatigue-crack growth (FCG) rate data generated from constant Kmax tests, high load ratio (minimum to maximum load) constant R tests, and ΔKeff based data was a mysterious issue. Because of the disagreement, a variety of test or analysis methods were created to correlate FCG rate data. It was suspected that the ASTM threshold test method using load reduction was inducing remote crack closure due to plastically deformed material, which caused elevated thresholds and slower rates than steady-state behavior. The first goal of this study was the development of a test method to eliminate remote closure during threshold testing. In order to avoid/minimize remote closure effect, compression-precracking methods were used to initiate a crack from a starter notch on compact specimens. Two materials with different fatigue crack surface profiles (flat or very rough) were tested and the results generated from the conventional ASTM precracking method and the compression-precracking test method were compared. In order to understand the disagreement of near-threshold data, crack-opening load measurements were performed from locally (near crack tip) installed strain gages instead of the remote gage (i.e., back face gage). Some careful specimen preparations were performed to avoid out-of-plane bending, to maintain straight crack fronts, and to ensure testing system linearity. It was known that remote gages, such as crack-mouth- opening-displacement-gages were insensitive to measuring load-strain records near threshold. By using local gages, the crack closure effects were clearly observed even in high load ratio (R) tests, like or higher than R = 0.7, and constant Kmax tests, which were believed to be crack closure free. By measuring load-reduced-strain records from local gages, crack-opening loads were able to correlate FCG rate data and showed that ΔKeff-rate data was unique for a wide variety of materials. By comparing (ΔKeff)th values, it may provide reasonable guidance for the material resistance against FCG. Because of “high R crack closure”, some theories considered in the past may need to be reconsidered. First, constant Kmax tests are not entirely crack-closure free. Second, there is no critical load ratio, Rc, to indicate the transition from crack-closure affected to crack-closure free data, and Kmax effects that appear in ΔKth-Kmax relations. Research has shown that the three dominate crack-closure mechanisms (plasticity-, roughness- and debris-induced crack closure) FCG rate behavior in the threshold regime from low to high load ratios.

[pt] Após identificar que uma trinca de fadiga permanecia fechada durante parte do ciclo, Elber assumiu que o dano era induzido apenas pela fração do carregamento acima da carga necessária para abrir a trinca. Diversos modelos foram propostos utilizando o Delta Keff como força motriz da propagação, como os modelos da faixa plástica (strip-yield), que são amplamente utilizados para prever vida residual de componentes trincados. Embora o fenômeno do fechamento da trinca esteja provado, sua real importância na propagação da trinca de fadiga ainda é controversa. Outros mecanismos, além do fechamento da trinca, foram utilizados na tentativa de explicar os efeitos de sequência do carregamento na propagação em amplitude variável como o campo de tensão residual à frente da trinca. Mesmo após mais de 50 anos de pesquisas desde a proposição da primeira regra de propagação por Paris ainda não há consenso nem sobre o mecanismo nem sobre a modelagem. Esse trabalho tem como objetivo apresentar uma modelagem para prever propagação da trinca de fadiga com base na hipótese de que o dano acumulado por deformação plástica seria a força motriz para propagação. A modelagem proposta se diferença de outros modelos de acúmulo de dano por permitir que o contato existente entre as superfícies da trinca exerça influência sobre as deformações plástica à frente de sua ponta. Os resultados mostram que a modelagem proposta possui capacidade de reproduzir curvas de propagação semelhante ao modelo strip-yield. / [en] After identify that a fatigue crack remains closed during part of the load cycle, Elber assumed the damage was induced only by the cycle part over the load required to open the crack. Several models were developed based on Delta Keff as the strip-yield ones, which are widely used to predict residual lives of cracked components. Although the crack closure phenomenon is well proven its actual significance for the propagation is still controversial. Others mechanisms, beyond the crack closure, were used in trying to explain the sequence effects on variable amplitude crack propagation like the residual stress field ahead of the crack tip. However even after more than 50 years of research since the first propagation rule proposed by Paris there is no neither about the mechanism neither about modelling. This work has the aim of present a modelling to predict fatigue crack growth based on the hypothesis that the damage accumulated by cyclic plastic strain would be propagation the drive force. The modelling proposed differs from others damage accumulation models by allowing the existed contact between the crack surfaces to exercise its influence on plastic strain ahead of the crack tip. The results show that the proposed model is able to reproduce propagation curves similar to the model strip-yield.

The integrity of nearly all engineering structures are threatened by the presence of cracks. Structural failure occurs if a crack larger than a critical size exists. Although most well designed structures initially contain no critical cracks, subcritical cracks can grow to failure under fatigue loading, called fatigue crack growth (FCG). Because it is impossible or impractical to prevent subcritical crack growth in most applications, a damage tolerant design philosophy was developed for crack sensitive structures. Design engineers have taken advantage of the FCG threshold concept to design for long fatigue lives. FCG threshold (DKth) is a value of DK (crack-tip loading), below which no significant FCG occurs. Cracks are tolerated if DK is less than DKth. However, FCG threshold is not constant. Many variables influence DKth including microstructure, environment, and load ratio. The current research focuses on load ratio effects on DKth and threshold FCG. Two categories of load ratio effects are studied here: extrinsic and intrinsic. Extrinsic load ratio effects operate in the crack wake and include fatigue crack closure mechanisms. Intrinsic load ratio effects operate in the crack-tip process zone and include microcracking and void production. To gain a better understanding of threshold FCG load ratio effects (1) a fatigue crack closure model is developed to consider the most likely closure mechanisms at threshold, simultaneously, and (2) intrinsic load ratio mechanisms are identified and modeled. An analytical fatigue crack closure model is developed that includes the three closure mechanisms considered most important at threshold (PICC, RICC, and OICC). Crack meandering and a limited amount of mixed-mode loading are also considered. The rough crack geometry, approximated as a two-dimensional sawtooth wave, results in a mixed-mode crack-tip stress state. Dislocation and continuum mechanics concepts are used to determine mixed-mode crack face displacements. Plasticity induced crack closure is included by modifying an existing analytical model, and an oxide layer in the crack mouth is modeled as a uniform layer. Finite element results were used to verify the analytical solutions for crack-tip stress intensity factor and crack face displacements. These results indicate that closure for rough cracks can occur at two locations: (1) at the crack-tip, and (2) at the asperity nearest the crack-tip. Both tip contact and asperity contact must be considered for rough cracks. Tip contact is more likely for high Kmax levels, thick oxide layers, and shallow asperity angles, a. Model results indicate that closure mechanisms combine in a synergistic manner. That is, when multiple closure mechanisms are active, the total closure level is greater than the sum of individual mechanisms acting alone. To better understand fatigue crack closure where multiple closure mechanisms are active (i.e. FCG threshold), these interactions must be considered. Model results are well supported by experimental data over a wide range of DK, including FCG threshold. Closure-free load ratio effects were studied for aluminum alloys 2024, 7050, and 8009. Alloys 7050 and 8009 were selected because load ratio effects at FCG threshold are not entirely explained by fatigue crack closure. It is believed that closure-free load ratio mechanisms occur in these alloys. Aluminum alloy 2024 was selected for study because it is relatively well behaved, meandering most load ratio effects are explained by fatigue crack closure. A series of constant Kmax threshold tests on aluminum alloys were conducted to eliminate fatigue crack closure at threshold. Even in the absence of fatigue crack closure load ratio (Kmax) effects persist, and are correlated with increased crack-tip damage (i.e. voids) seen on the fatigue crack surfaces. Accelerated FCG was observed during constant Kmax threshold testing of 8009 aluminum. A distinct transition is seen the FCG data and is correlated with a dramatic increase in void production seen along the crack faces. Void production in 8009 aluminum is limited to the specimen interior (plane-strain conditions), promoting crack tunneling. At higher values of Kmax (+_ 22.0 MPaà m), where plane-stress conditions dominate, a transition to slant cracking occurs at threshold. The transition to slant cracking produces an apparent increase in FCG rate with decreasing DK. This unstable threshold behavior is related to constraint conditions. Finally, a model is developed to predict the accelerated FCG rates, at higher Kmax levels, in terms of crack-tip damage. The effect of humidity (in laboratory air) on threshold FCG was studied to ensure that environmental effects at threshold were separated from load ratio effects. Although changes in humidity were shown to strongly affect threshold FCG rates, this influence was small for ambient humidity levels (relative humidity between 30% and 70%). Transient FCG behavior, following an abrupt change in humidity level, indicated environmental damage accumulated in the crack-tip monotonic plastic zone. Previous research implies that hydrogen (a component of water vapor) is the likely cause of this environmental damage. Analysis suggests that bulk diffusion is not a likely hydrogen transport mechanism in the crack-tip monotonic plastic zone. Rather, dislocation-assisted diffusion is presented as the likely hydrogen transport mechanism. Finally, the (extrinsic) fatigue crack closure model and the (intrinsic) crack-tip damage model are put in the context of a comprehensive threshold model. The ultimate goal of the comprehensive threshold model is to predict fatigue lives of cyclically loaded engineering components from (small) crack nucleation, through FCG, and including failure. The models developed in this dissertation provide a basis for a more complete evaluation of threshold FCG and fatigue life prediction. The research described in this dissertation was performed at NASA-Langley Research Center in Hampton, Virginia. Funding was provided through the NASA GSRP program (Graduate Student Researcher Program, grant number NGT-1-52174). / Ph. D.

The ability to predict fatigue crack growth rates is essential in safety critical systems. The discovery of fatigue crack closure in 1970 caused a flourish of research in attempts to simulate this behaviour, which crucially affects crack growth rates. Historically, crack tip plasticity models have been based on one-dimensional rays of plasticity emanating from the crack tip, either co-linear with the crack (for the case of plane stress), or at a chosen angle in the plane of analysis (for plane strain). In this thesis, one such model for plane stress, developed to predict fatigue crack closure, has been refined. It is applied to a study of the relationship between the apparent stress intensity range (easily calculated using linear elastic fracture mechanics), and the true stress intensity range, which includes the effects of plasticity induced fatigue crack closure. Results are presented for all load cases for a finite crack in an infinite plane, and a method is demonstrated which allows the calculation of the true stress intensity range for a growing crack, based only on the apparent stress intensity range for a static crack. Although the yield criterion is satisfied along the plastic ray, these one-dimensional plasticity models violate the yield criterion in the area immediately surrounding the plasticity ray. An area plasticity model is therefore required in order to model the plasticity more accurately. This thesis develops such a model by distributing dislocations over an area. Use of the model reveals that current methods for incremental plasticity algorithms using distributed dislocations produce an over-constrained system, due to misleading assumptions concerning the normality condition. A method is presented which allows the system an extra degree of freedom; this requires the introduction of a parameter, derived using the Prandtl-Reuss flow rule, which relates the magnitude of slip on complementary shear planes. The method is applied to two problems, confirming its validity.