A weight function based modified strip-yield model is adapted to include the mode I effects of roughness induced crack closure. The weight function methodology is verified for arbitrary mixed mode loading conditions under load levels experienced in fatigue crack growth. A rough crack geometry is simulated as a sine wave fitted to a sawtooth defined by an asperity angle and period. Additional mode I crack closure due to mode II sliding of crack faces is calculated and incorporated into the strip-yield model by lengthening and shortening the crack face elements. Simulations of fatigue crack growth using the newly developed model are examined via a design and analysis of computer experiments. The effects of model parameters are identified. Combined roughness and plasticity induced crack closure for long cracks is studied.

Fatigue damage of aluminium alloys is one of the key concerns in transport industries, particularly in the aerospace industry. The purpose of the project is to develop new knowledge and techniques against fatigue failure for these industries through a systematic investigation of fatigue resistance and crack growth behaviours of aluminium alloys. Fatigue and fracture mechanics have been investigated analytically, numerically and experimentally in this project. Overload transient effect on fatigue crack growth has been examined by considering various parameters including crack closure, overload ratio (OLR), load ratio (R ratio), baseline stress intensity factor range, (∆K)_BL and geometry. It was found that crack closure can be correlated qualitatively and quantitatively to all other parameters associated with overload transient behaviour. It is proposed that the effect of crack tip plasticity on the non-linearity of the compliance curve can be separated to obtain reliable crack closure measurement. In this project, different methods are used to better understand the transient retardation process so that the damage tolerance design (DTD) of the components made of aluminium alloys can be enhanced. Another important parameter for fatigue and damage tolerance design (DTD) of engineering components is the threshold stress intensity factor range for fatigue crack growth, ∆K_th. A small variation in identification of ∆K_th can lead to a big change in overall estimation of fatigue life. In this project, an analytical model has been developed for aluminium alloys by fitting an analytical curve with raw crack growth data in order to identify the ∆K_th. This model has the capacity to identify ∆K_th for different aluminium alloys at various R ratios. There is a great demand for enhanced fatigue life of aluminium alloys in the transport industry. This project has carried out a detailed investigation of electromagnetic treatment (ET) in the form of electropulsing treatment to develop an efficient technique for fatigue resistance enhancement. ET parameters including the treatment intensity, treatment time and the number of applications have been optimised. It is suggested that the duration of ET treatment can be used as the main parameter among all these to control the fatigue resistance of the aluminium alloy. The improvement in fatigue resistance has been explained by the change in microhardness and conductivity of aluminium alloy due to ET. Additionally, the fracture morphology was analysed using scanning electron microscopy (SEM). The precipitates and dislocation characteristics were also studied using transmission electron microscopy (TEM). The outcomes of this investigation will help improve structural integrity by enhancing fatigue resistance of aluminium alloys.

[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.

One of prominent issues related to failures in nuclear power components is attributed to material degradation due the aggressive environment conditions, and mechanical stresses. For instance, reactor core support components, such as fuel claddings, are under prolonged exposure to an intense neutron field from the fission of fuel and operate at elevated temperature under fatigue loadings caused by start up, shut down, and unscheduled emergency shut down. Additionally, exposure to highluence neutron radiation can lead to microscopic defects that result in material hardening and embrittlement, which significantly affects the physical and mechanical properties of the materials, resulting in further reduction in fatigue life of reactor structural components. The effects of fatigue damage on material deterioration can be further exacerbated by the presence of thermal loading, hold-time, and high-temperature water coolant environments. In this study, uniaxial fatigue models were used to predict fatigue behavior based only on simple monotonic properties including ultimate tensile strength and Brinell hardness. Two existing models, the Bäumel Seeger uniform material law and the Roessle Fatemi hardness method, were employed and extended to include the effects of test temperature, neutron irradiation fluence, irradiation induced helium and irradiation induced swellings on fatigue life of austenitic stainless steels. Furthermore, a methodology to estimate fatigue crack length using a strip-yield based model is presented. This methodology is also extended to address the effect of creep deformation in a presence of hold- times, and expanded to include the effects of irradiation and water environment. Reasonable fatigue life predictions and crack growth estimations are obtained for irradiated austenitic stainless steels types 304, 304L, and 316, when compared to the experimental data available in the literature. Lastly, a failure analysis methodology of a mixer unit shaft made of AISI 304 stainless steel is also presented using a conventional 14-step failure analysis approach. The primary mode of failure is identified to be intergranular stress cracking at the heat affected zones. A means of circumventing this type of failure in the future is presented.