Effect of mean stress on fretting fatigue of Ti-6Al-4V on Ti-6Al-4V

Fretting fatigue tests of Ti-6Al-4V on Ti-6Al-4V have been conducted to determine the influence of stress amplitude and mean stress on life. The stress ratio was varied from R = -1 to 0.8. Both flat and cylindrical contacts were studied using a bridge-type fretting fatigue test apparatus operating either in the partial slip or mixed fretting regimes. The fretting fatigue lives were correlated to a Walker equivalent stress relation. The influence of mean stress on fretting fatigue crack initiation, characterized by the value of the Walker exponent, is smaller compared with plain fatigue. The fretting fatigue knockdown factor based on the Walker equivalent stress is 4. Formation of fretting cracks is primarily associated with the tangential force amplitude at the contact interface. A simple fretting fatigue crack initiation metric that is based on the strength of the singular stress field at the edge of contact is evaluated. The metric has the advantage in that it is neither dependent on the coefficient of friction nor the location of the stick/slip boundary, both of which are often difficult to define with certainty a priori.

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