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Fatigue Crack Growth in 7075-T6 Aluminum Alloy under Single-Spike Overloads and Aircraft Spectra

In the mid-1960’s, the phenomenon of flat-to slant crack growth was studied by many in the aircraft industry. At low stress-intensity factors, a fatigue-crack surface is flat (tensile mode) and the crack-front region is under plane-strain conditions (high constraint). As the crack grows with higher stress-intensity factors, a 45-degree shear lip starts to develop at the intersection of the crack front and free surfaces. With further crack extension, a complete shear failure occurs through the thickness of the sheet or plate. This behavior is the shear mode, which is under low constraint or plane-stress conditions. In 1966, Schijve found that the transition from flat-to-slant crack growth on a 2024-T3 aluminum alloy over a wide range in stress ratios (R) occurred at a constant…

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In the mid-1960’s, the phenomenon of flat-to slant crack growth was studied by many in the aircraft industry. At low stress-intensity factors, a fatigue-crack surface is flat (tensile mode) and the crack-front region is under plane-strain conditions (high constraint). As the crack grows with higher stress-intensity factors, a 45-degree shear lip starts to develop at the intersection of the crack front and free surfaces. With further crack extension, a complete shear failure occurs through the thickness of the sheet or plate. This behavior is the shear mode, which is under low constraint or plane-stress conditions. In 1966, Schijve found that the transition from flat-to-slant crack growth on a 2024-T3 aluminum alloy over a wide range in stress ratios (R) occurred at a constant crack-growth rate. Newman and Hudson showed the same behavior on 7075-T6 and Ti-8Al-1Mo-1V alloys, validating Schijve’s observation that the crack-growth rate was the key parameter for flat-to-slant crack-growth behavior.

The material considered herein is 7075-T6 aluminum alloy sheet material. Crack growth during single-spike overload-underload behavior and simulated aircraft spectrum loading are presented. The FASTRAN crack-closure based life-prediction code was used to correlate the constant-amplitude crack-growth-rate data over a wide range in stress ratios (R) and rates from threshold to near fracture, and to calculate or predict the crack-growth behavior on the single-spike overload-underload tests. Crack-closure behavior is strongly dependent upon the level of constraint. The main objective was to see if the constraint-loss region (flat-to-slant crack growth) is the primary reason for crack-growth delays after single-spike overloads. Tests were also conducted under the Mini-TWIST (standard European) transport wing spectrum. Crack-growth analyses using crack-closure theory without constraint loss were unable to predict crack growth under spike overloads or simulated aircraft spectra. However, predicted crack length against cycles with constraint-loss behavior compared reasonably well on all tests.

Artikelnummer
VAL5-2024-001

Titel
Fatigue Crack Growth in 7075-T6 Aluminum Alloy under Single-Spike Overloads and Aircraft Spectra
Autor(en)
K. F. Walker, J. C. Newman
DOI
10.48447/VAL5-2024-001
Veranstaltung
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
Jahr der Veröffentlichung
2024
Publikationsart
Tagungsmanuskript (PDF)
Sprache
Englisch
Stichwörter
cracks,damage tolerance,plasticity,spike overloads,spectrum loading

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1
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
B. Möller, M. Scurria, T. Korschinsky
10.48447/VAL5-2024-030
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve 
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1
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
B. Möller, M. Scurria, T. Korschinsky
10.48447/VAL5-2024-030
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve
Preis 25,00 €
Nur online erhältlich
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Autor(en): B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
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1
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading
Preis 25,00 €
Nur online erhältlich
Service strength assessment of macroscopic imperfections in cast steel alloys
Autor(en): M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Local fatigue assessment,Total strain energy density,Cast steel,Macroscopic shrinkage defects,Service strength 
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1
Service strength assessment of macroscopic imperfections in cast steel alloys
Service strength assessment of macroscopic imperfections in cast steel alloys
M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Service strength assessment of macroscopic imperfections in cast steel alloys
M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Local fatigue assessment,Total strain energy density,Cast steel,Macroscopic shrinkage defects,Service strength
Preis 25,00 €
Nur online erhältlich
Simulation-based lifetime prediction for cables
Autor(en): F. Schneider-Jung, M. Speckert, K. Dreßler
10.48447/VAL5-2024-023
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Cable Simulation,Lifetime Prediction,SN Curves 
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1
Simulation-based lifetime prediction for cables
Simulation-based lifetime prediction for cables
F. Schneider-Jung, M. Speckert, K. Dreßler
10.48447/VAL5-2024-023
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Cable Simulation,Lifetime Prediction,SN Curves 
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Simulation-based lifetime prediction for cables
F. Schneider-Jung, M. Speckert, K. Dreßler
10.48447/VAL5-2024-023
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Cable Simulation,Lifetime Prediction,SN Curves
Preis 25,00 €
Nur online erhältlich
Loading spectra of the trailer chassis
Autor(en): E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra 
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Loading spectra of the trailer chassis
Loading spectra of the trailer chassis
E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra 
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Loading spectra of the trailer chassis
E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra
Preis 25,00 €
Nur online erhältlich
Experimental research on fatigue self-awareness of single-process 3d-printed structures
Autor(en): M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors 
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Experimental research on fatigue self-awareness of single-process 3d-printed structures
Experimental research on fatigue self-awareness of single-process 3d-printed structures
M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors 
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Experimental research on fatigue self-awareness of single-process 3d-printed structures
M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors
Preis 25,00 €
Nur online erhältlich
An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
Autor(en): D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random loading,critical plane,maximum variance 
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An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
random loading,critical plane,maximum variance 
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An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random loading,critical plane,maximum variance
Preis 25,00 €
Nur online erhältlich
Data-driven load spectrum estimator for non-stationary random vibration loading
Autor(en): D. Fräulin, A. Trapp, M. Hinz, P. Wolfsteiner
10.48447/VAL5-2024-024
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
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Data-driven load spectrum estimator for non-stationary random vibration loading
Data-driven load spectrum estimator for non-stationary random vibration loading
D. Fräulin, A. Trapp, M. Hinz, P. Wolfsteiner
10.48447/VAL5-2024-024
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
random vibration loading,non-stationary loading,load spectrum estimator,spectral methods,machine learning 
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1
Data-driven load spectrum estimator for non-stationary random vibration loading
D. Fräulin, A. Trapp, M. Hinz, P. Wolfsteiner
10.48447/VAL5-2024-024
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random vibration loading,non-stationary loading,load spectrum estimator,spectral methods,machine learning
Preis 25,00 €
Nur online erhältlich
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Autor(en): P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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1
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum
Preis 25,00 €
Nur online erhältlich
A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
Autor(en): A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
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A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatemi-Socie criterion,frequency domain,vibration fatigue,multiaxial fatigue
Preis 25,00 €
Nur online erhältlich
VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
10.48447/VAL5-2024-BB
978-3-9820591-3-6
Herausgeber: A. Esderts, S. Werdin, C. Bleicher
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Berichtsband (PDF)
Englisch
Variable Amplitude Loading, VAL, VAL5 
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VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
10.48447/VAL5-2024-BB
978-3-9820591-3-6
A. Esderts, S. Werdin, C. Bleicher
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Berichtsband (PDF)
Englisch
Variable Amplitude Loading, VAL, VAL5 
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VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
10.48447/VAL5-2024-BB
978-3-9820591-3-6
A. Esderts, S. Werdin, C. Bleicher
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Berichtsband (PDF)
Englisch
Variable Amplitude Loading, VAL, VAL5
Preis 90,00 €
Nur online erhältlich
A demonstrator example for virtual sensing approaches in predictive maintenance applications
Autor(en): L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning 
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A demonstrator example for virtual sensing approaches in predictive maintenance applications
A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning 
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A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning
Preis 25,00 €
Nur online erhältlich