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Fatigue Failures
Metal Fatigue Failures
Metallurgical Consultants
Home Failure Analysis Root Cause Analysis Welding Metallurgy Process Control Expert Witness Experience Customer Cases Fees Links
Failure Mechanisms
Fatigue
Creep & stress rupture
Corrosion
Stress corrosion cracking
Ductile and
brittle fractures
Wear
Hydrogen
embrittlement
Liquid
metal embrittlement
Welding
MIG
TIG
Stick
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Corrosion
Corrosion failures
Stress corrosion cracking
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Pitting
corrosion
Crevice corrosion
Marine corrosion
Topics
Explosions
Castings
Boilers
Heat Exchangers
Pressure Vessels
Pipelines
Lifting Equipment
Fasteners
Gears
Bearings
Shafts
Residual Stresses
Chemical Processing
Pulp and Paper
Food Processing
Automotive
Ships
Alloys
Steel
Stainless Steel
Aluminum
Copper
Titanium
Fatigue Failures
Metal fatigue is caused by repeated cycling of of the
load. It is a progressive localized damage due to fluctuating stresses and
strains on the material. Metal fatigue cracks initiate and propagate in regions
where the strain is most severe. The process of fatigue consists of three stages:
Initial crack initiation
Progressive crack growth across the part
Final sudden fracture of the remaining cross
section
Schematic of S-N Curve, showing
increase in fatigue life with decreasing stresses.
Stress Ratio
The most commonly used stress
ratio is R, the ratio of the minimum stress to the maximum stress (Smin/Smax).
If the stresses are
fully reversed, then R = -1.
If the stresses are
partially reversed, R = a negative number less than 1.
If the stress is
cycled between a maximum stress and no load, R = zero.
If the stress is
cycled between two tensile stresses, R = a positive number less than 1.
Variations in the
stress ratios can significantly affect fatigue life. The
presence of a mean stress component has a substantial effect on fatigue
failure. When a tensile mean stress is added to the alternating stresses, a
component will fail at lower alternating stress than it does under a fully
reversed stress.
Preventing Fatigue Failure
The most effective method of improving
fatigue performance is improvements in design:
Eliminate or reduce stress raisers by
streamlining the part
Avoid sharp surface tears resulting from
punching, stamping, shearing, or other processes
Prevent the development of surface
discontinuities during processing.
Reduce or eliminate tensile residual
stresses caused by manufacturing.
Improve the details of fabrication and
fastening procedures
Fatigue Failure Analysis
Metal fatigue is a significant problem because it can
occur due to repeated loads below the static yield strength. This can
result in an unexpected and catastrophic failure in use.
Because most engineering materials contain
discontinuities most metal fatigue cracks initiate from discontinuities in highly
stressed regions of the component. The failure may be due the
discontinuity, design, improper maintenance or other causes. A failure
analysis can determine the cause of the failure.
Contact Information
Telephone
407-880-4945 ----------- Consulting assistance is only available for customers
FAX
425-962-2959
Postal address
AMC
931 N. State Road 434
Suite 1201 - #189
Altamonte Springs, FL 32714
Electronic mail
General Information:
Consulting@MaterialsEngineer.com
Customer Support:
Support@MaterialsEngineer.com
Webmaster:
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Copyright © 1999 Metallurgical Consultants
Last modified:
September 11, 2007
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