Predicting crack growth in specimens with overloads and cold-worked holes with residual stresses

Abstract The FASTRAN life-prediction code was used to predict crack growth in specimens with compressive residual stresses on two aluminum alloys. All test data were obtained from the literature on middle-crack-tension or on specimens with a single through crack at an open hole. Specimens tested by Liu induced residual stresses by remote overloads, whereas the specimens tested by LaRue induced residual stresses by cold-expansion of the hole. Some modifications were made to FASTRAN to improve the residual-stress distribution and to simulate reaming of cold-worked holes. Overloads of specific magnitudes were applied to the FASTRAN strip-yield model to generate residual stresses that simulate those calculated from finite-element analyses from the literature. FASTRAN was then used to make fatigue-crack-growth predictions under residual-stress fields that compared fairly well with test results from the two aluminum alloys.

[1]  S. R. Daniewicz,et al.  Predicting the effect of residual stress on fatigue crack growth , 2007 .

[2]  James C. Newman,et al.  The growth of short cracks in 4340 steel and aluminum-lithium 2090 , 1990 .

[3]  Martin R. Wolf,et al.  K3 User Guide , 2000 .

[4]  J. Newman,et al.  THE EFFECTS OF A MACHINING-LIKE SCRATCH ON THE FATIGUE LIFE OF 4340 STEEL , 2002 .

[5]  Edward P. Phillips.  The Influence of Crack Closure on Fatigue Crack Growth Thresholds in 2024-T3 Aluminum Alloy , 1988 .

[6]  Herbert F. Hardrath,et al.  EFFECTS OF CHANGING STRESS AMPLITUDE ON THE RATE OF FATIGUE-CRACK PROPAGATION IN TWO ALUMINUM ALLOYS , 1961 .

[7]  D. S. Dugdale.  Yielding of steel sheets containing slits , 1960 .

[8]  Y. Lam,et al.  The effect of residual stress and its redistribution of fatigue crack growth , 1989 .

[9]  Hiroshi Tada,et al.  The stress analysis of cracks handbook , 2000 .

[10]  G. R. Yoder,et al.  On microstructural control of near-threshold fatigue crack growth in 7000-series aluminum alloys , 1982 .

[11]  A. A. Bahashwan.  Effect of stress ratio on fatigue crack growth , 2014 .

[12]  Clifford Goodman,et al.  American Society of Mechanical Engineers , 1988 .

[13]  J. Newman,et al.  Fatigue-life prediction methodology using small-crack theory , 1999 .

[14]  Cgc Poussard,et al.  A finite element simulation of the cold working process for fastener holes , 1997 .

[15]  James C. Newman,et al.  A nonlinear fracture mechanics approach to the growth of small cracks , 1983 .

[16]  J. C. Newman,et al.  Small-Crack Effects in High-Strength Aluminum Alloys A NASA/CAE Cooperative Program , 1994 .

[17]  R. Forman,et al.  Green's function for a crack emanating from a circular hole in an infinite sheet , 1980 .

[18]  James C. Newman,et al.  Prediction of Fatigue Crack Growth under Variable-Amplitude and Spectrum Loading Using a Closure Model , 1982 .

[19]  J. Newman.  A crack opening stress equation for fatigue crack growth , 1984 .

[20]  R. C. McClung,et al.  FINITE ELEMENT ANALYSIS OF SPECIMEN GEOMETRY EFFECTS ON FATIGUE CRACK CLOSURE , 1994 .

[21]  W. Elber.  The Significance of Fatigue Crack Closure , 1971 .

[22]  Robert S. Piascik,et al.  Environmental fatigue of an Al-Li-Cu alloy: Part II. Microscopic hydrogen cracking processes , 1993, Metallurgical and Materials Transactions A.

[23]  M. Mear,et al.  A boundary element method for two dimensional linear elastic fracture analysis , 1996 .

[24]  Lf Impellizzeri,et al.  Fatigue Analysis of Cold-Worked and Interference Fit Fastener Holes , 1977 .

[25]  C. M. Hudson.  Effect of stress ratio on fatigue-crack growth in 7075-T6 and 2024-T3 aluminum-alloy specimens , 1969 .

[26]  M. Isida.  Stress-Intensity Factors for the Tension of an Eccentrically Cracked Strip , 1966 .

[27]  J. Newman.  A crack-closure model for predicting fatigue crack growth under aircraft spectrum loading , 1981 .