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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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Description

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.

Reference: VAL5-2024-001

Title: Fatigue Crack Growth in 7075-T6 Aluminum Alloy under Single-Spike Overloads and Aircraft Spectra
Author(s): K. F. Walker, J. C. Newman
DOI: 10.48447/VAL5-2024-001
Event: VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
Year of publication: 2024
Publication type: conference paper (PDF)
Language: English
Keywords: cracks,damage tolerance,plasticity,spike overloads,spectrum loading

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Editor(s): A. Esderts, S. Werdin, C. Bleicher

VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading

Publication type: conference proceedings (PDF)

English

€90.00

Online only

Author(s): E. Schäfer, V. Chmelko, M. Kučerková

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Loading spectra of the trailer chassis

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Author(s): M. Palmieri, A. Staffa, J. Slavic, F. Cianetti

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Author(s): A. Trapp, P. Wolfsteiner

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Author(s): J. Kraft, M. Vormwald

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Fatigue life estimation of notched components under multiaxial non-proportional loading with variable amplitudes.

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Author(s): A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner

A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment

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€25.00

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Author(s): P.M. Kyaw, M. Braun

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Author(s): T. Lecleve, S. Courtin, F. Szmytka, C. Mai

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