journal article·2014-02Open access

Microstructure-sensitive weighted probability approach for modeling surface to bulk transition of high cycle fatigue failures dominated by primary inclusions

Nima Salajegheh, David L. McDowell

Abstract

Abstract A simulation-based probabilistic strategy is developed to characterize the surface to bulk transition of high cycle fatigue failures dominated by primary inclusions. The probability of fatigue crack initiation in the surface region is calculated by computing the expected number of critical fatigue hot spots in this region. This is done by considering the probability of inclusion-matrix debonding and the fatigue crack initiation potency of partially-debonded inclusions for a given load ratio and stress amplitude. A case study is presented whereby the surface initiation probability is studied in uniaxial strain-controlled cyclic loading simulations of round smooth specimens of the fine grained powder metallurgy (PM) processed Ni-base superalloy IN100. The fatigue crack initiation potency of partially-debonded nonmetallic inclusions is assessed by calculating the Fatemi–Socie (FS) critical plane parameter from generalized plain strain crystal plasticity finite element simulations. Idealized spherical ceramic inclusions with homogeneous linear elastic isotropic material properties are considered to isolate the FS parameter sensitivity to inclusions’ size, stress amplitude, and polycrystalline microstructure realization around the inclusion.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Fatigue and fracture mechanics · High Temperature Alloys and Creep · High-Velocity Impact and Material Behavior

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (62)

Show source-provided references
1. A non local theory applied to high cycle multiaxial fatigue10.1046/j.1460-2695.2002.00527.x ↗
2. Invariant formulation of a gradient dependent multiaxial high-cycle fatigue criterion10.1016/S0013-7944(96)00047-1 ↗
3. The size effect in fatigue of plain and notched steel specimens loaded under reversed direct stress10.1243/PIME_PROC_1951_165_014_02 ↗
4. Inclusion-controlled fatigue properties of 1800MPa-class spring steels10.1007/s11661-004-0279-1 ↗
5. Experimental study of the influence of inclusions on the fatigue properties of steel10.1016/0013-7944(74)90073-3 ↗
6. Recent evaluation procedures of nonmetallic inclusions in bearing steels. Statistics of extreme value method and development of higher frequency ultrasonic testing method
7. Fatigue life prediction from inclusion initiated cracks10.1016/S0142-1123(97)00136-9 ↗
8. On the life-controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime10.1046/j.1460-2695.1999.00186.x ↗
9. Mughrabi H. Fatigue crack initiation mechanisms and fatigue life in high-cycle and in ultrahigh-cycle fatigue, in: Fatigue: a David L. Davidson symposium as held at the 2002 TMS annual meeting, Minerals, Metals and Materials Society, Seattle, WA, United States; 2002. p. 3–15.
10. Fatigue fracture behavior of high-strength steel in super long life range10.1299/jsmea.45.517 ↗
11. Stepwise S–N curve and fish-eye failure in gigacycle fatigue10.1046/j.1460-2695.1999.00206.x ↗
12. Divergence of mechanisms and the effect on the fatigue life variability of rene’ 88 DT10.7449/2004/Superalloys_2004_305_312 ↗
13. A new paradigm of fatigue variability behavior and implications for life prediction10.1016/j.msea.2006.10.171 ↗
14. Mean vs. life-limiting fatigue behavior of a nickel-based superalloy
15. Towards a physics-based description of fatigue variability behavior in probabilistic life-prediction10.1016/j.engfracmech.2008.10.013 ↗
16. Dual fatigue failure modes in Ti–6Al–2Sn–4Zr–6Mo and consequences on probabilistic life prediction10.1016/S1359-6462(03)00132-5 ↗
17. S–N curve characteristics and subsurface crack initiation behaviour in ultra-long life fatigue of a high carbon–chromium bearing steel10.1046/j.1460-2695.2001.00459.x ↗
18. Competing failure modes and complex S–N curves in fatigue of structural materials10.1016/j.ijfatigue.2009.08.004 ↗
19. A review of competing modes fatigue behavior10.1016/j.ijfatigue.2009.04.018 ↗
20. Caton MJ, Rosenberger AH. Fatigue crack growth variability in waspaloy under representative loading conditions. In: Larsen JM, editor, Materials damage prognosis – proceedings of a symposium of the materials science and technology 2004 conference, Minerals, Metals and Materials Society, New Orleans, LA, United States; 2004. p. 113–9.
21. Random heterogeneity scales and probabilistic description of the long-lifetime regime of fatigue
22. Mean vs. life-limiting fatigue behavior of a nickel-based superalloy
23. Fatigue crack propagation of nickel-base superalloys at 650°C
24. Fatigue crack initiation and propagation in several nickel-base superalloys at 650°C10.1016/0142-1123(83)90026-9 ↗
25. Cashman GT. A model for competing failures modes in elevated temperature strain cycle fatigue. PhD thesis, Department of Mechanical Engineering, The University of Dayton, Dayton, Ohio; 2000.
26. A mathematical model for competing failure modes in strain cycle fatigue10.1115/1.2712468 ↗
27. Microstructural conditions contributing to fatigue variability in p/m nickel-base superalloys
28. Bernstein H. Materials issues for users of gas turbines. In: Proceedings of the 27th Texas A&M Turbomachinery, Symposium; 1998. p. 197.
29. Ashbaugh · 2000
30. Bonacuse P, Kantzos P, Barrie R, Telesman J, Ghosn L, Gabb T. Distribution of inclusion-initiated fatigue cracking in powder metallurgy Udimet 720 characterized, NASA Technical Report Server; 2004.
31. A comparison of high temperature fatigue crack propagation in various subsolvus heat treated turbine disc alloys10.1179/174328407X213189 ↗
32. A statistical methodology for the preparation of a competing modes fatigue design curve10.1115/1.2401619 ↗
33. Gumbel · 2004
34. Schaffer J. A probabilistic approach to modeling microstructural variability and fatigue behavior in ASTM F562 medical grade wire. In: Gilbert J, editor, Medical device materials IV: proceedings of the materials & processes for medical devices conference, ASM International, Palm Desert, California, USA; 2007.
35. Freedman · 1997
36. The effect of defects on the fatigue crack initiation process in two P/M superalloys. I. Fatigue origins10.1007/BF02642413 ↗
37. The effect of defects on the fatigue crack initiation process in two P/M superalloys. II. Surface-subsurface transition10.1007/BF02642414 ↗
38. Microstructure-sensitive extreme value probabilities for high cycle fatigue of Ni-base superalloy IN10010.1016/j.ijplas.2009.08.001 ↗
39. An investigation of fatigue origins in superalloy powder compacts10.1007/BF02647181 ↗
40. Prediction of the competition between surface and internal fatigue crack initiation in PM alloys10.1111/j.1460-2695.1994.tb00219.x ↗
41. A probabilistic model for prediction of LCF surface crack initiation in PM alloys10.1111/j.1460-2695.1993.tb00125.x ↗
42. The influence of Inclusions on low cycle fatigue life in a P/M nickel-base disk superalloy
43. Xie X, Zhang L, Zhang M, Dong J, Bain K. Micro-mechanical behavior study of non-metallic inclusions in P/M disk superalloy Rene’95. In: Green KA, Pollock TM, Harada H, Howson TE, Reed RC, Schirra JJ, et al., editors, Superalloys 2004: proceedings of the tenth international symposium on superalloys, Minerals, Metals and Materials Society, Champion, PA, United States; 2004. p. 451–8.10.7449/2004/Superalloys_2004_451_458 ↗
44. Wusatowska-Sarnek · 2007 · 2960
45. ABAQUS 6.7. Simulia, Providence, RI; 2006.
46. A grain level model for the study of failure initiation and evolution in polycrystalline brittle materials. Part I: Theory and numerical implementation10.1016/S0167-6636(02)00285-5 ↗
47. Simulation of material microstructure using a 3D Voronoi tesselation: calculation of effective thermal expansion coefficient of polycrystalline materials10.1016/0956-7151(94)90170-8 ↗
48. Crystal plasticity: micro-shear banding in polycrystals using Voronoi tessellation10.1016/S0749-6419(98)00022-9 ↗
49. Constructing microstructures of poly-and nanocrystalline materials for numerical modeling and simulation10.1063/1.1432448 ↗
50. Estimating fatigue sensitivity to polycrystalline Ni-base superalloy microstructures using a computational approach10.1111/j.1460-2695.2007.01159.x ↗
51. Simulation of microplasticity-induced deformation in uniaxially strained ceramics by 3-D Voronoi polycrystal modeling10.1016/j.ijplas.2004.05.010 ↗
52. Microstructure-sensitive modeling of polycrystalline IN 10010.1016/j.ijplas.2008.01.001 ↗
53. Multiaxial fatigue life predictions under the influence of mean-stresses10.1115/1.3226066 ↗
54. Critical plane approach to multiaxial fatigue damage including out-of-phase loading10.1111/j.1460-2695.1988.tb01169.x ↗
55. Bulk deformation fatigue damage models10.1016/0025-5416(88)90546-0 ↗
56. Findley K. Physically-based model for elevated temperature low cycle fatigue crack initiation and growth in Rene88DT. PhD thesis, Department of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia; 2005.
57. Cyclic plasticity at pores and inclusions in cast Al–Si alloys10.1016/S0013-7944(02)00097-8 ↗
58. Finite element analysis of the stress distributions near damaged Si particle clusters in cast Al–Si alloys10.1016/S0167-6636(00)00003-X ↗
59. Modeling effects of compliant coatings on HCF resistance of primary inclusions in high strength steels10.1115/1.3030943 ↗
60. 3D modeling of subsurface fatigue crack nucleation potency of primary inclusions in heat treated and shot peened martensitic gear steels10.1016/j.ijfatigue.2008.12.001 ↗
61. A ΔJ-based approach to biaxial fatigue10.1111/j.1460-2695.1992.tb00053.x ↗
62. Assessment of small fatigue crack growth driving forces in single crystals with and without slip bands