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"Eleven peer-reviewed papers, written by experts in their field, provide an understanding of residual stresses, fatigue crack growth, fatigue lifetime predictions, and their effect on structural integrity. Residual stresses can be present due to processing and manufacturing of materials and structures, so it is imperative to understand how and why they can influence the test data that we used in structural design methodologies. Residual stresses may also be intentionally engineered into structures in attempts to improve fatigue life, and it is equally important that designers understand how to account for these potential effects on fatigue life."--Publisher's website.
Experimental results on the effects of compressive and tensile residual stresses on Mode I fatigue crack growth are briefly reviewed. Prediction methods that attempt to account for the observed effects are compared. Current limitations of the methods and their relative advantages and drawbacks for use in design analysis are discussed. The possible role of residual stress re-equilibration on growth behavior, caused by crack extension itself, is also discussed.
Abstract: Residual stresses are a common and often undesired result of material processing, introduced through non-linear deformation and/or phase transformation of material under mechanical or thermo-mechanical loading. These macro stresses alter mechanical properties and the intrinsic fatigue crack growth characteristics of the material. Residual stress artifacts can introduce inconsistencies and significant errors when the true material behavior is needed for material development and optimization and for structural component design. The effects of quenching residual stresses on fatigue crack propagation behavior of various materials were investigated. In parallel, residual stresses similar in magnitude and distribution with the quenching residual stresses were generated using mechanical processes to decouple the effects of residual stresses from microstructural effects. Mechanical residual stress distributions predicted by 3D elastic-plastic finite element analysis showed good agreement with the stresses measured on fatigue crack growth testing specimens using fracture mechanics approaches. Crack propagation characteristics in fields with low and high residual stresses were studied using optical and scanning electron microscopy, and the effects of residual stress on crack path behavior were assessed. An original residual stress analytical correction to fatigue crack growth data was developed, compared to existing corrective methodologies, and validated using residual stress free data. Overall, the work provides tools to understand, control, and correct the effects of processing residual stresses on fatigue crack growth for accurate fatigue critical design and life predictions.
The effect of residual stress on the fatigue crack growth was investigated for cyclic tension. Three-point bend specimens were used with through thickness notches at the center line of the welded joint. The experiments were performed for different load amplitudes and load ratios under conditions of small-scale yielding. The influence of the residual stresses on fatigue crack growth was estimated by experimentally observed fatigue crack growth rate and measurement of residual stresses at the surface of specimen. This paper describes an approach taken in two models to estimate the residual stress effect on fatigue crack propagation and to predict remaining service life of a welded structure.