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Titanium (Ti) alloys have been commonly used in the aerospace industry, not only because they have a high strength-to-weight ratio (comparing to the steels) but also their satisfactory corrosion resistance. Furthermore, they can be assembled with the carbon fibre composite parts. However, conventional manufacturing methods cause high material scrap rate and require lots of machining to obtain the final shape and size, which increases both the manufacturing time and cost. In order to improve the efficiency and reduce the cost of Ti parts, Additive Manufacturing (AM) has been developed. Rolled Wire and Arc Additive Manufacturing (rolled WAAM) is one of the AM processes. The main characteristics of this technology is the reduced β grain size to refine the alloy's microstructure. Both the ultimate tensile strength and yield strength of Ti alloy made by rolled WAAM are at least 10% higher than traditional wrought Ti. This project is to investigate the fatigue crack growth rates of the Ti-6Al-4V built by rolled WAAM process in both the longitudinal and transverse orientations to study the effect of rolling on fatigue crack growth rate of WAAM processed Ti. The project was carried out by testing the fatigue crack growth rates for 4 compact tension specimens. The test results of different orientations were compared with each other, and scatters in fatigue life and fatigue crack growth rate were found. Fatigue crack growth rate is lower in the longitudinal specimens. The results are also compared with those of the unrolled WAAM specimens tested in a previous project. It was found that rolling can significantly improve the fatigue crack growth behaviour in WAAM processed Ti, and can reduce the difference between the two orientations, i.e. achieving better isotropic material properties. Recorded scatters may be caused by the process induced residual stresses, error in measurement, and the test machine load range being much higher than the applied loads. More specimens can be tested to validate above observations further.

<p>Many engineering components reach a finite fatigue life well above 10⁹load cycles. Some examples of such components are found in airplanes, automobiles or high speed trains. For some materials the fatigue failures have lately been found to occur well after 10⁷ load cycles, namely in the Very High Cycle Fatigue (VHCF) range. This finding contradicted the established concept of fatigue limit for these materials, which postulates that having sustained 10⁷ load cycles the material is capable of enduring an infinite number of cycles provided that the service conditions are unchanged. With the development of modern ultrasonic fatigue testing equipment it became possible to experimentally establish VHCF behaviour of various materials. For most of them the existence of the fatigue limit at 10⁷ load cycles has been proved wrong and their fatigue strength continues to decrease with increasing number of load cycles.</p><p> </p><p>One important group of materials used for the production of high performance components subjected to the VHCF is tool steels. This study explores the VHCF phenomenon using experimental data of ultrasonic fatigue testing of some tool steel grades. The causes and mechanisms of VHCF failures are investigated by means of high resolution scanning electron microscopy, and in relation to the existing theories of fatigue crack initiation and growth. The main type of VHCF origins in steels are slag inclusions.</p><p>However, other microstructural defects may also initiate fatigue failure. A particular attention is paid to the fatigue crack initiation, as it has been shown that in the VHCF range crack formation consumes the majority of the total fatigue life. Understanding the driving forces for the fatigue crack initiation is a key to improve properties of components used for very long service lives. Finite element modelling of VHCF testing was added as an additional perspective to the study by enabling calculation of local stresses at the fatigue initiating defects.</p><p> </p><p> </p>

Many engineering components reach a finite fatigue life well above 109 load cycles. Some examples of such components are found in airplanes, automobiles or high speed trains. For some materials the fatigue failures have lately been found to occur well after 107 load cycles, namely in the Very High Cycle Fatigue (VHCF) range. This finding contradicted the established concept of fatigue limit for these materials, which postulates that having sustained 107 load cycles the material is capable of enduring an infinite number of cycles provided that the service conditions are unchanged. With the development of modern ultrasonic fatigue testing equipment it became possible to experimentally establish VHCF behaviour of various materials. For most of them the existence of the fatigue limit at 107 load cycles has been proved wrong and their fatigue strength continues to decrease with increasing number of load cycles.   One important group of materials used for the production of high performance components subjected to the VHCF is tool steels. This study explores the VHCF phenomenon using experimental data of ultrasonic fatigue testing of some tool steel grades. The causes and mechanisms of VHCF failures are investigated by means of high resolution scanning electron microscopy, and in relation to the existing theories of fatigue crack initiation and growth. The main type of VHCF origins in steels are slag inclusions. However, other microstructural defects may also initiate fatigue failure. A particular attention is paid to the fatigue crack initiation, as it has been shown that in the VHCF range crack formation consumes the majority of the total fatigue life. Understanding the driving forces for the fatigue crack initiation is a key to improve properties of components used for very long service lives. Finite element modelling of VHCF testing was added as an additional perspective to the study by enabling calculation of local stresses at the fatigue initiating defects.

In aerospace industry and other major mechanical industry systems, engineering components that are subjected to cyclic loads often lead to progressive crack growth that eventually results in struc-tural fracture. The damage tolerance design which is based on the assumption of pre-existed flaws in a structure is an important approach in aircraft industry since it is impossible to have flaw-free manufactured components.In this thesis work, an evaluation of crack propagation models was carried out. Fatigue crack growth threshold and fatigue crack growth rate models were evaluated. A method to present ex-perimental data available was developed to evaluate uncertainties in fatigue life models for more accurate predictions. Currently, a software that is used for predicting crack propagation life is NASGRO. The study has been made for two types of materials: a nickel-iron-based alloy (Inconel 718 forging) and titanium alloys (Ti 6-4 both forging and casting).A threshold model is in the normal case developed for each temperature. A method to model fatigue threshold (ΔKth) has been suggested by assuming temperature independence of ΔKth. In this method, a new threshold model was created by making use of an A/P (Actual/Predicted) plot so that all measured threshold values are on the conservative side of the minimum model. With this method, an understanding of fatigue threshold model was improved over the other method due to the possibilities to model ΔKth with average and minimum threshold values for each load ratio (ΔKth, R).Moreover, a method to investigate which set of parameters that best represent the crack growth behaviour has been suggested. In this method the best set of parameters were chosen to be the set of parameters giving the best fit to the available (da/dN, ΔK) points. The comparison between this method and the method with the set of parameters that give minimum scatter in the A/P values was done.Crack growth rate da/dN log curves were plotted as function of stress intensity range ΔK for R-ratio values ranging from -2 to 0.9 for the two different methods. A distinctive difference between the two methods was observed in Paris region at high temperatures (5500C-6500C) which becomes more obvious at lower R-ratios. Predicting crack propagation rate model with set of parameters giving minimum standard deviation in da/dN points was shown to be less conservative than that of parameter sets giving lowest scatter in A/P. Using both evaluation methods, da/dN versus ΔK plots of Inconel718forging were compared to da/dN (ΔK) plots for the pre-existing data at 5500C for R-ratios ranging from 0 to 0.8. An overall R-ratio influence was observed throughout for both ΔKth and da/dN.

The effect of the element length is examined in modelling crack growth in fatigue loading of an adhesive joint. This is done for a cohesive element using an expression for the damage evolution developed at the University of Skövde which is implemented using the UMAT subroutine in the FE-solver Abaqus. These analyses are done for pure mode I loading by analysing a DCB-specimen loaded by a pure moment. An expression is developed in which the critical element length is dependent on the geometry of the specimen (in the form of the wave number of the adhesive joint), the element length, the material properties of the adhesive (in form of the material parameters , , ), the load applied (in form of the stress in the crack tip), the time step used in the analysis and the crack growth rate. It is shown that the results converge by decreasing the element length and the time step used. Therefore an expression for the crack growth rate as a function of the remaining parameters can be determined. Another expression is thereafter developed for the element length needed in order to get a crack growth rate within a certain range of the critical element length. The results show a regular pattern but are not monotone. Therefor two different definitions of the critical element length are tested, either by defining the critical element length as the point where the error is greater than an arbitrary boundary of 1 % of a converged result or where a least square approximation of the error is within 1 % of the converged results. The first method shows a highly irregular result which makes it difficult to develop an expression out of these results. The second method on the other hand gives results that are predictable enough to develop a function out of them. This is done using a regression analysis with all parameters of a third order expression in order to get an expression.

Les surfaces de rupture par fatigue peuvent représenter les aspects complexes en fonction de: type de matériau, le mécanisme de condition de sollicitations mécaniques, environnement ambiant etc.Dans le cadre des chargements complexes ou variables les surfaces de rupture sont encore plus difficiles à analyser, car de telles sollicitations peuvent engendrer les changements de mécanismes dans certains matériaux.Dans le cadre de changements variables, l'une des questions importantes est la connaissance de la vitesse de croissance des fissures.Des techniques actuelles de mesures de vitesse font appel aux mesures optiques ou aux mesures indirectes de mesures de la cinétique de croissance de fissures.Une méthode élégante consiste à faire des cycles marqueurs qui permettent de laisser une marque sur la surface de rupture que l'on ensuite identifier par analyse au microscope à balayage.A cette fin on peut utiliser : - les petites surcharges, les sous charges, les cycles en dessous du seuil de non propagation, un changement de température etc.Le but de travail de thèse serait de développer les cycles marqueurs sur trois matériaux:un alliage d'aluminium, un acier et un caoutchouc synthétique.L'idée étant de développer des cycles de marquage sans modifier le cinétique de propagation.Les essais comparatifs de fissuration seront menés avec ou sans cycles de marquage pour vérifier cette hypothèse.Le travail expérimental sera effectué au LMR (machine de fatigue) ainsi que l'analyse MEB. / The fracture surfaces of fatigue can represent complex aspects according to:type of material, provided mechanism of mechanical stresses, ambient environment, etc.Under complex loadings or variable ones, fracture surfaces are more difficult to analyze because such changes can cause change in mechanisms in certain materials.Under variable amplitudes, one of the important issues is the knowledge of the crack growth rate.Current techniques involve optical measurements or indirect ones that measures the kinetics of crack growth.An elegant method is to generate marker bands that can leave a mark on the fracture surface which is then identified by scanning electron microscope analysis.For this purpose one can use: - small overload, under load, cycles below the threshold, a change of temperature, etc.The aim of this thesis is to develop the technique of marker bands on three materials:an aluminum alloy, steel and synthetic rubber.The idea is to develop this technique without changing the propagation kinetics.The experiments will be conducted by fatigue cracking with or without marking marker bands to test this hypothesis.The experimental work has been carried out in LMR laboratory.

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This thesis investigates fatigue crack growth rate behavior in the threshold and near-threshold regimes for a Ti-6Al-4V (STOA) alloy using two proposed ASTM procedures- (1) load-shedding (LS) using a larger load-shed rate than the current ASTM Standard E647 load-reduction (LR) test procedure, and (2) compression pre-cracking constant-amplitude (CPCA) or load-increasing (CPLI) and load-shedding (CPLS). Tests were conducted at a low stress ratio (R = 0.1) on compact C(T) specimens of two different widths (W = 51 and 76 mm) and threshold fatigue crack growth rates were generated. These test data were compared to previous test data produced from the same batch of material using the current LR and the CPCA test procedure. While no test procedure provided an exact representation of the threshold value (?Kth), the compression pre-cracking (CP) procedures were the most promising. The LR, LS, and CPLS test procedures were influenced by prior loading-history and various crack-closure mechanisms, leading to higher ?Kth values and slower crack growths in the threshold regime. The LS tests (at shed-rates of -0.08,-0.32, and -0.95 mm-1) generated ?Kth values that were 15% to 32% higher than the estimated threshold stress-intensity factor range (?*Kth)R=0.1. The CP test procedures are a more accurate alternative for developing near-threshold and threshold fatigue crack growth rates. The CPLS test procedure produced a ?Kth value that was 10% higher than (?*Kth)R=0.1. LR and LS tests produced different ?Kth values as a function of the specimen width for the given load ratio. The CP test procedures produced consistent crack growth rates over the same range of ?K values examined, independent of the specimen width. Further research is required for developing test procedure(s) capable of providing a more definitive representation of the ?Kth value and closureree fatigue crack growth rates in the threshold regime.

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