ALBERT

Notes: The changes in porosity and elastic moduli of YSZ-containing nickel-based anode materials for solid oxide fuel cells were studied as a function of the fraction of reduced NiO. Anode samples were reduced in a gas mixture of 4% hydrogen and 96% argon for different periods of time at 800°C and their Young's and shear moduli were determined afterward at room temperature using resonant ultrasound spectroscopy and impulse excitation. It was found that the magnitude of Young's and shear moduli decreased significantly with increasing fraction of reduced NiO and that the magnitude of the elastic moduli of a fully reduced Ni–YSZ anode was ∼45% lower than that of unreduced NiO–YSZ. Because the elastic moduli of NiO are close to those of Ni, the observed decrease in the magnitude of the elastic moduli was found to be caused mainly by the significant increase in the porosity of the sample as a result of NiO reduction. Expressions are presented for the amount of porosity and the magnitude of the elastic moduli as a function of the fraction of reduced NiO.

Notes: Two- and three-dimensional SiCr/SiC composites have been prepared starting from Tyranno SA(tm) fiber preforms. Preform densification has been performed by a modified preceramic polymer impregnation and pyrolysis (PIP) process consisting of filling the preform large interbundle voids with SiC powder before the PIP process. This step was accomplished by low-pressure infiltration of a SiC powder dilute slurry through the preform thickness. Specimens were further processed with polymer impregnation and pyrolysis to determine the effects on structural, thermal, and mechanical properties of the obtained composites. High-temperature pyrolysis treatment, which promoted polymer derived SiC matrix crystallization, markedly increased thermal diffusivity.

Notes: Carbon is commonly added to sulfate-fined silicate-glass batches to enhance the fining process. Reactions between carbon and Na2SO4 modify the SOx emissions from Na2SO4 decomposition. Fourier-transform infrared (FTIR) spectrometry is used to analyze the emission of air pollutants from the isothermal decomposition of Na2SO4 + C undertaken using thermogravimetric analysis (TGA). The FTIR spectrometer is calibrated using standard gas mixtures containing CO, CO2, SO2, NO, and NO2. The collected spectra are quantified using the classical least-squares (CLS) approximation. The TGA-FTIR system provides SOx, and COx, concentrations versus time data from the isothermal decomposition of Na2SO4, in the presence of a carbon black. Mass spectrometry (MS) complements FTIR by being able to detect SO(g).

Notes: Different ratios of the precursor phases of SrFeO3–x (SFO) and SrMoO4 (SMO) were used to prepare Sr2FeMoO6 (SFMO) by a solid-state reaction. X-ray diffraction was used to identify the phases. A residual SMO was observed to exist in the sample with an SFO/SMO ratio of 0.9:1. The sample with a residual SMO phase had higher resistivity, lower magnetization, but higher low-field magnetoresistance (LFMR). High-resolution transmission electron microscopy was used to identify the compositions and phases. Nanometer-sized amorphous-like clusters of SMO phase were located inside the grains rather than at grain boundaries; however, some boundaries were rich in the strontium ion. The possible mechanisms for the conduction and the increase of LFMR of SFMO are discussed.

Notes: Submicro- and nano-sized liquid-phase-sintered SiC ceramics were mechanically tested by nanoindentation in the peak load range 5–400 mN. The submicro-sized sample showed a marked indentation size effect which the nano-sized samples did not exhibit. The relevance of indentation depth with respect to the microstructural scale has been outlined. In the investigated grain-size range, the hardness dependence on the grain size could be described by a load-dependent inverse Hall–Petch relation. Young's modulus was less microstructure- and load-dependent. Because of the very fine microstructure, the nano-sized SiC materials gave lower elastic values than the submicro-sized SiC ceramic.

Notes: Samples of composition Ba1−xLaxTi1−x/4O3, x= 0, 0.003, 0.03, and 0.10, were prepared by an alkoxide sol–gel route with final firing of ceramics at 1100°C, 2 h in air. All samples showed bulk insulating behavior with no evidence of semiconductivity caused by either direct donor doping or oxygen loss.

Notes: We have studied the rheological property evolution and hydration behavior of white and ordinary portland cement (type I) pastes and concentrated cement–polyelectrolyte suspensions. Cement composition had a marked effect on the elastic property evolution (G′(t)) and hydration behavior of these suspensions in the presence of poly(acrylic acid)/poly(ethylene oxide) copolymer (PAA/PEO), even though their affinity to adsorb such species was nearly identical. Both white and ordinary portland cement pastes exhibited G′0 values of ∼104 Pa and fully reversible G′(t) behavior until the onset of the acceleratory period (t= 2 h), where the pastes stiffened irreversibly. In contrast, cement–PAA/PEO suspensions exhibited G′0 values of ∼1 Pa and G′(t) behavior comprised of both reversible and irreversible features. Interestingly, ordinary portland cement–PAA/PEO suspensions experienced a gel-to-fluid transition on high shear mixing at short hydration times (〈1 h), and the particle network did not rebuild until ∼24 h of hydration. In sharp contrast, white portland cement–PAA/PEO suspensions remained weakly gelled throughout the initial stage of hydration even after high shear mixing. At longer hydration times (〉1 h), both cement–PAA/PEO suspensions exhibited G′i(t) ∼ exp(t/τc) with τc values of 5.6 and 1.3 h for ordinary and white portland cement, respectively. Our observations suggest that hydration phenomena impact interparticle forces during early stage hydration and, ultimately, lead to initial setting through the formation of solid bridges at the contact points between particles within the gelled network.

Notes: A new ceramic freeze-casting technique capable of manufacturing near room temperature with a sublimable vehicle was accomplished. Fluid-concentrated slurries of Al2O3 powder in molten camphene (C10H16) were prepared at 55°C. These slurries were quickly solidified (frozen) at room temperature to yield rigid solid green bodies, followed by frozen camphene removal by sublimation (freeze-drying) with negligible shrinkage. Sintering without any special binder burnout process yielded sintered bodies with over 98% theoretical density. The proposed advantages include (1) elimination of extremely cold temperatures, (2) elimination of troublesome binder burnout process, and (3) fast manufacturing cycle due to quick solidification.

Notes: Dense composites in the Ti-B-N system have been produced by reactive hot pressing of titanium and BN powders. The effect of the addition of a small amount of nickel (1–3 wt%) on the reaction kinetics and densification of TiN–TiB2 (40 vol%) composite has been studied. Composites of ∼99% of theoretical density have been produced at 1600°C under 40 MPa for 30 min with 1% nickel. The hardness and fracture toughness of these composites are 24.5 ± 0.97 GPa and 6.53 ± 0.27 MPa·m1/2, respectively. The microstructural studies on samples produced at lower temperatures indicate the formation of a transient liquid phase, which enhances the kinetics of the reaction and densification of the composite.

Notes: This paper presents new findings on ultrasonic spray pyrolysis of zirconium hydroxyl acetate precursor drops whose sizes were precisely measured using laser light diffraction technique. Precursor concentration plays a predominant role in determination of product particle size. At 0.01 wt% precursor concentration, conventional spray pyrolysis at 750°C using precursor drops 5–8 μm in diameter, generated by an ultrasonic nebulizer at 2.66 MHz, yielded uniform spherical yttria-stabilized zirconia (YSZ) particles 73 nm in diameter measured by scanning electron microscopy. The YSZ particle diameters were much smaller than those predicted by the one-particle-per-drop mechanism. Under similar reaction conditions, the high-throughput ultrasound-modulated two-fluid (UMTF) spray pyrolysis of larger precursor drops (28-μm peak diameter) also yielded spherical dense particles; they were significantly smaller in size than those produced by the low-throughput conventional ultrasonic spray pyrolysis of smaller drops (6.8-μm peak diameter).

Notes: Thermoelectric elements consisting of the layered polycrystalline materials of Al-doped ZnO and NaCo2O4 were prepared using the pulse electric-current sintering (PECS) method at 900°C for 3 min. Direct contact between the polycrystalline Al-doped ZnO and the NaCo2O4 was obtained in a single-step process for the stacked powders. The electrical conductivities of the polycrystalline materials prepared by PECS were higher than those of materials prepared by conventional sintering, despite their porous structure. The thermoelectric voltage of the 1-mol%-Al-doped ZnO and NaCo2O4 polycrystalline element (measuring ∼6 mm × 3 mm × 15 mm) was 83 mV at dT= 500 K, when the junction of the elements was at 800°C.

Notes: Pb(Zr,Ti)O3–Pb(Mn1/3 Nb2/3)O3 (PZT–PMnN) system has been studied for high-power piezoelectric applications. This study investigates this system to find out the composition with high-power density piezoelectric characteristics and low tem-perature coefficient of resonance frequency (TCF). It was found that the composition 0.9PZT–0.1PMnN (Zr/Ti = 0.51/0.49) modified with 6 mol% Sr exhibits a TCF of −8 ppm/°C (−20 to +80°C). Further, the dielectric and piezoelectric properties of this composition are as follows: kp= 0.53; Qm= 800; d33= 274; ε33/ε0= 1290 and tan δ=1.1%, which shows the suitability of this composition for ultrasonic devices used under fluctuating thermal environment.

Notes: Beam bending is an excellent method for measuring low permeabilities (≤10−18 m2) in homogeneous materials, because it is fast, requires no high pressure, and provides a concurrent measurement of the modulus of the material. The method was previously analyzed and substantiated for cylindrical or square beams. Recently, the analysis was extended to include isotropic and transversely isotropic rectangular beams. In this paper, the analysis is applied to measurements performed on cement paste, and it is shown that the solution for isotropic rectangular beams accounts for changes in the hydrodynamic behavior caused by changing the aspect ratio of the sample. The permeability and elastic modulus results are verified through comparison to previous measurements on cylindrical beams.

Notes: The deformation behavior of boron- and carbon-doped β-silicon carbide (B,C-SiC) with an average grain size of 260 ± 18 nm containing 1 wt% boron was investigated by compression testing at elevated temperatures. Extensive grain growth during deformation was observed. The stress–strain curves were compensated for grain growth by assuming power-law type of dependence on grain size and strain rate. The stress exponent n was ∼1.3 and the grain size exponent p was ∼2.7 at temperatures ranging from 1593° to 1758°C. The apparent activation energy of deformation Qd was ∼760 kJ/mol, which was lower than the activation energy for lattice diffusion of silicon and carbon in SiC and higher than that for grain-boundary diffusion of carbon in SiC. These results suggest that the deformation mechanism of the fine-grained B,C-SiC is grain-boundary sliding accommodated by the grain-boundary diffusion.

Notes: Chromium-containing stainless steel (SS) is a prospective material for use as an interconnect in solid oxide fuel cells (SOFCs). However, during operations at high temperatures, the growth of oxide scales causes the performance of the interconnect and SOFC as a whole to deteriorate. The coating of SS 446 with a conducting perovskite is a potential method of slowing the growth of oxide scale and, therefore, improving overall SOFC performance. In the present research, the structural characterization of a pure LaCrO3 thin film on the SS 446 substrates has been performed as a model material that can be used as a barrier coating for the metallic interconnect. The deposition of an amorphous La-Cr-O thin film on SS 446 was performed using radio-frequency (rf) magnetron sputtering. The deposited amorphous film was annealed in air to form the desired perovskite phase. The film underwent an amorphous to LaCrO4 phase transition during annealing at 500°C with further transformation to LaCrO3 orthorhombic phase during annealing at 700°C. A self-organized dendritic structure was reported as a result of the perovskite-phase formation. Although formation of various oxides, such as Fe2O3 and Fe3O4, was observed during the annealing of uncoated SS 446 in air, the coating of SS 446 surface with LaCrO3 film prevented formation of various oxide phases at the interconnect surface. The structural characterization of the films and SS 446 surfaces was accomplished using scanning electron microscopy with energy-dispersive X-ray analysis, X-ray diffractometry, micro-Raman spectroscopy, and nanoindentation.

Notes: The density, surface tension, and viscosity of the melts from the PbO-B2O3-SiO2 system have been measured at temperatures in the range 1073–1473 K. The effect of composition on these properties was also investigated. The density of the melt was found to increase linearly with increasing PbO content. Molar volume was derived from the density data, and its deviation from the additivity of partial molar volumes was calculated. These deviations in molar volume from those obtained from additivity rules have been used along with the ratio of various coordination numbers of boron (as reported by Bray) to discuss the structure of the melts. The surface tension was found to decrease with decreasing SiO2/B2O3 ratio, and to increase in the range of the PbO content between 30 and 60 mol%, showing a maximum at ∼60 mol% PbO, and then decreased with further additions. This result suggested that the surface tension would be affected primarily by the B2O3 content in the range of the PbO content between 30–60 mol%, and mainly by the PbO content in the range of the PbO content 〉60 mol%, respectively. The viscosity of the melt was found to decrease linearly with increasing PbO content. The results obtained indicate that the increase in viscosity with B2O3 was half that of SiO2 (on a molar basis), and an empirical equation has been proposed for the viscosity as a function of mole fraction.

Notes: Core/shell structures have been prepared via a mechanofusion system by employing several kinds of spherical polymers as a core material and Al2O3 powder or a mixture of Al2O3 and SiO2 powders as a shell material. The effect of the kind of core polymers on the quality of the resulting hollow alumina microspheres has been discussed on the basis of the thermal decomposition behavior of spherical polymers used as a core material. A large fraction of hollow alumina microspheres reflecting the shape and the particle size distribution of the core polymer could be fabricated after sintering at 1600°3C for 3 h, when highly cross-linked poly(methyl methacrylate) (PMMA) microspheres with a gel fraction of 99.03% were used as a core polymer, and abrupt firing at temperatures higher than 500°3C was adopted to remove the PMMA microspheres. The addition of 5 mass% SiO2 to the Al2O3 shell layer was found to be useful for maintaining the spherical shell structure during the firing process and for fabricating a large fraction of hollow alumina microspheres after the sintering.

Notes: Well-defined and stoichiometric spherical particles of BaTiO3 of narrow size distribution were produced at 82° and 92°3C by precipitation from chloride solutions in a strong alkaline environment. The size of the particles can be tailored in the range from ≅103 to 70–80 nm by increasing the barium concentration from ≅0.07 to 0.7 mol/L. The particles are composed of tight aggregates resulting from the assembly of several nanocrystals. The size of the nanocrystals decreases from 200–300 to 30–40 nm by increasing reactant concentration. At low barium concentration (≤0.07 mol/L at 82°3C, ≤0.06 mol/L at 92°3C), formation of BaTiO3 is strongly slowed down and nonstoichiometric, Ti-rich powders are produced. Under these conditions, the particles have the tendency to develop a dendritic-like morphology.

Notes: Crystals of δ-Y2Si2O7 (space group P121/c1) were examined using high-temperature powder X-ray diffractometry to determine their unit-cell dimensions from 296 to 1473 K. The lattice deformation induced by thermal expansion was investigated using matrix algebra analysis to determine the directions and magnitudes of the principal distortions (Λi, i= 1,2, and 3). The directions of Λ1 and Λ3 were defined by the acute angle Λ1c, which linearly decreased from 5(2)° to —5.5(3)° with increased temperature from 504 to 1473 K. The Λ2-axis invariably coincided with the crystallographic b-axis. The magnitudes of Λ1 and Λ2 steadily increased to, respectively, 1.0061(1) and 1.0068(1) during heating to 1473 K, while Λ3 remained almost constant for the entire temperature range. The mean principal distortion, Λm (= (Λ1+Λ2+Λ3)/3), steadily increased to 1.0044(1) with increased temperature to 1473 K. The coefficient of mean linear thermal expansion (α) was derived from the mean principal strain (Λm - 1) as α= (Λm - 1)/ΔT. The temperature dependence was determined to be α= 2.03 times 103+ 1.36(T - 296) (10-9 K-1). Provided that the rule-of-mixtures holds for the Y2Si2O7/Y2SiO5 composites as protective coating on SiC substrates, the volume fractions of 0.72-0.77 (70–75 mass%) would be necessary for the Y2Si2O7 component to match the α-values of both materials.

Notes: Microcellular silicon oxycarbide open cell ceramic foams were fabricated from a silicone resin. Microcellular foams, with a cell size ranging from ∼1–80 μm, were fabricated using poly(methyl methacrylate) microbeads as sacrificial templates. The compression strength of the foams decreased with increasing cell size.

Notes: Electroconductive zirconia-toughened mullite (TiN/ZTM) intragranular nanocomposite was fabricated by hot-pressing a powder mixture of nano-sized TiN, ZrO2(2Y), and mullite gel. The material showed a good sinterability and could be highly densified at a low temperature of 1300°3C. Sintering temperature strongly influenced the microstructure and electrical resistivity of the material. The electrical resistivity increased monotonously from 20 Ω-cm to 1.5 times 106°3Cm, as the sintering temperature was increased from 1300° to 1500°3C. TEM results indicated that such a phenomenon could be ascribed to the changes in the microstructure of the material, which led to a decrease in the connectivity of the TiN network in the sample as the sintering temperature was increased.

Notes: Effects of fluids on material removal rate, chipping damage, and surface roughness in the simulated clinical-dental machining of a dental-type glass ceramic were investigated. Significant differences in removal rate were obtained among the fluids investigated, but only a 4 wt% boric acid solution gave a higher removal rate than conventionally used water. Chipping damage was substantially lower for the boric acid and an oil-emulsion coolant compared with other fluids tested. Surface roughness was independent of the fluids used. The results indicate that improvement can be achieved in both material removal rate and machining damage by the appropriate selection of coolant chemistry.

Notes: This paper reviews the structures and properties of 10 binary, ternary, and quaternary crystals within the equilibrium phase diagram of the SiO2–Y2O3–Si3N4 system. They are binary compounds SiO2, Y2O3, Si3N4; ternary compounds Si2N2O, Y2Si2O7, and YSi2O5; and quaternary crystals Y2Si3N4O3 (M-melilite), Y4Si2O7N2, (N-YAM), YSiO2N (wallastonite), and Y10(SiO4)6N2 (N-apatite, N-APT). Although the binary compounds are well-known and extensively studied, the ternary and the quaternary crystals are not. Most of the ternary and the quaternary crystals simply have been referenced as secondary phases in the processing of nitrogen ceramics. Their crystal structures are complex and not precisely determined. In the quaternary crystals, there exists O/N disorder in that the exact atomic positions of the anions cannot be uniquely determined. It is envisioned that a variety of cation–anion bonding configurations exist in these complex crystals. The electronic structure and bonding in these crystals are, therefore, of great interest and are indispensable for a fundamental understanding of structural ceramics. We have used ab initio methods to study the structure and bonding properties of these 10 crystals. For crystals with unknown or incomplete structural information, we use an accurate total energy relaxation scheme to obtain the most likely atomic positions. Based on the theoretically modeled structures, the electronic structure and bonding in these crystals are investigated and related to various local cation–anion bonding configurations. These results are presented in the form of atom-resolved partial density of states, Mulliken effective charges, and bond order values. It is shown that Y–O and Y–N bonding are not negligible and should be a part of the discussion of the overall bonding schemes in these crystals. Spectroscopic properties in the form of complex, frequency-dependent dielectric functions, X-ray absorption near-edge structure (XANES), and the electron energy-loss near-edge structure (ELNES) spectra in these crystals also are calculated and compared. These results are discussed in the context of specific bonding configurations between cations (silicon and yttrium) and anions (oxygen and nitrogen) and their implications on intergranular thin films in polycrystalline Si3N4 containing rare-earth elements.

Notes: Simultaneous synthesis and sintering of hexagonal α-Ti1−x-Alx(N) (0 ≤x≤ 0.08) solid solutions, which contain a small amount of nitrogen, have been performed by a self-propagating high-temperature combustion method under a nitrogen pressure of 4 MPa. Dense materials (∼99% of theoretical) prepared directly from a mixture of elemental (Ti and Al) powders reveal homogeneous microstructure composed of fine grains (12–16 μm). α-Ti1−xAlx(N) (x= 0.02; Ti0.98Al0.02N0.26) exhibits a three-point bending strength σb of 390 MPa, a Vickers hardness Hv of 9.24 GPa, and a fracture toughness KIC of 4.89 MPa·m1/2; their mechanical properties are much improved by doping Al into α-Ti(N), in comparison with those (σb= 245 MPa, Hv= 9.02 GPa, and KIC= 3.77 MPa·m1/2) of α-Ti(N) fabricated under the same conditions.

Notes: Electrophoretic deposition has been used to synthesize nickel–alumina, functionally graded materials from NiO and alumina suspensions in ethanol. Suspension stability and the kinetics of deposition were studied to determine optimum conditions. Deposition starts with an alumina suspension into which a stream of NiO suspension is injected at various flow rates to obtain the desired profiles. The latter were controlled by varying the deposition current density and component flow rate. The green bodies obtained were sintered in Ar/H2 atmosphere to reduce the NiO to nickel. Various gradation profiles were obtained illustrating the facility of EPD to synthesize continuously graded materials. NiO was used as the precursor for nickel to alleviate settling and rough columnar deposit problems.

Notes: Abstract— Hysteresis loops of a low carbon steel measured at various temperatures and plastic strain amplitudes are analysed using the statistical theory of the hysteresis loop. It is shown that the parameters of the statistical theory characterizing the saturated hysteresis loop, i.e. the probability density function and effective saturated stress, can be obtained from experiments. The probability density function is influenced mainly by strain amplitude; the effective saturated stress mainly by temperature.

Notes: Abstract— Room temperature fatigue crack propagation in a sintered tungsten alloy was studied. The fatigue crack growth rates were found to be identical for the material in the sintered and forged and as sintered conditions. The propagation rates are slower when compared with other metals due to the relatively high Young's modulus of tungsten. The value of the exponent m in Paris' power law equation was found to be 12 which is higher than for most metals. This was ascribed to the activity of a cleavage mechanism through some of the tungsten grains along with the ductile decohesion fatigue mechanism.

Notes: Abstract— The present work emphasizes the need to understand the processes involved in fatigue–creep interactions before reliable life predictions may be sensibly made. In particular, the simultaneous interaction involving a strain controlled cycle with a dwell period at maximum tensile strain is analysed and the accumulation of fatigue–creep damage computed in terms of strain range, extent of dwell and microstructure. Dominant failure modes are thus identified and the findings are used to explain the apparently different failure mechanisms previously reported for a 1Cr–Mo–V alloy steel and a Type 316 stainless steel. Due to lack of data overall mapping of regimes of dominance is not possible, but in cases where a single mechanism prevails throughout the duration of dwell accurate lifetime prediction may be achieved.

Notes: Stress intensity factors are determined for internally and externally cracked, pressurized thick cylinders with partial autofrettage (less than 100% overstrain). The solutions are based on a superposition of existing solutions which does not involve any loss of accuracy. Implications of the stress intensity factor results for the safe-life design of pressure vessels subjected to fatigue are discussed.

Notes: Fatigue crack propagation tests were conducted under conditions of equibiaxial, uniaxial and shear loading by using a cruciform specimen in a servo hydraulic testing machine. The effect of non-singular stress cycling on the fatigue crack propagation rate was examined based on the observation of crack opening behavior. The crack propagation rate was significantly influenced by the non-singular stress parallel to the crack when it was correlated to the stress intensity range. The crack closure behavior was greatly affected by the non-singular stress. The crack propagation rate was uniquely correlated to the effective range of the stress intensity factor except for the case of completely reversed shear loading where significant plasticity was detected. The crack opening displacement range was concluded to be a parameter controlling the crack propagation rate for all the stress conditions examined in the present experiments. Some discussion is made on the effect of material anisotropy on fatigue crack propagation in a biaxial stress field.

Notes: The paper presents a comprehensive review, supplemented by original data, of the engineering fatigue behaviour of copper. Variations in manufacturing route and softening treatments are shown to have little effect on the fatigue of annealed copper but the high cycle fatigue strength is increased by cold work. The high strain fatigue behaviour is defined in terms of the plastic strain range and the cyclic stress-strain characteristics are documented. Fatigue behaviour in bending and torsion is defined by data and related to that in tension by simple design rules.Notches are found to reduce the laboratory measured fatigue strength of copper by ∼ 30% and the effect of surface finish, surface distortion and surface residual stress is defined in the literature. Fatigue crack growth is defined in terms of stress intensity factor range ΔK by an upperbound law and, together with the conditions for non-growth (ΔK0), shown to relate to the equivalent conditions for steels via the ratio of the respective elastic moduli.The effect of environment on the fatigue of copper has received scant attention in the literature, such results as exist suggesting little if any reduction in strength to be brought about by gaseous or aqueous environments. The most dramatic change is the improvement of about an order of magnitude which results when tests in vacuum are compared with equivalent tests in air. Results of fatigue tests on copper in ammoniacal environments are conspicuously absent from the literature.As the test temperature is reduced below room temperature there is a predictable increase in high cycle fatigue strength, a reduction in fatigue strength occurring above room temperature. High strain fatigue test results presented in terms of plastic strain range appear insensitive to temperature although at very low strain rates and high temperatures a reduction in fatigue strength occurs. A linear life fraction cumulative damage creep-fatigue law appears sometimes to be non-conservative but much more testing is needed to evaluate fatigue damage summation laws generally for copper.Numerical data are given in support of all the aspects of the engineering fatigue behaviour reviewed in the paper.

Notes: The birth and growth of short cracks is analysed from an elastic-plastic fracture mechanics viewpoint. Low to high cumulative damage tests from the low stress to high strain regime indicate that there is no crack initiation period in the metallurgical sense and that cracks grow from the first cycle, but at a slow rate. The initiation phase terminates when one crack starts to dominate and accelerates to failure, its initial size being given by 〈displayedItem type="mathematics" xml:id="mu1" numbered="no"〉〈mediaResource alt="image" href="urn:x-wiley:8756758X:FFE263:FFE_263_mu1"/〉 for the medium carbon steel tested here, of grain size 56 μm.

Notes: Fractographic analyses have been used to explain the cyclic crack growth behaviour of A533-B, Ducol W30, a C-Mn steel and type 304 stainless steel in simulated light water reactor environments at ambient temperature. Fractographic observations have offered an explanation for anomalous crack growth behaviour and have also indicated where micro structural or environmental variables dominate in producing certain fracture modes and crack growth rates. An understanding of the operative corrosion fatigue mechanisms has been formulated through these fractographic analyses. Environmental crack growth in the ferritic steels has been described by a model involving both anodic dissolution and hydrogen embrittlement. Conditions where only one of these mechanisms would dominate have been identified and limits to their effect postulated. A crystallographic mode of failure observed in the austenitic type 304 stainless steel has also been explained by a selective dissolution process.

Notes: Abstract— Impact fatigue tests were carried out using a rotating-disk type impact fatigue testing machine. The influence of prior austenite grain size, ductile-brittle transition temperature and test temperature on impact fatigue crack growth rate was investigated by means of fracture mechanics and fractography in quenched and tempered Cr-Mo alloy steel in which the prior austenite grain size was varied from 8–3 to 25-4 μm. The results in impact fatigue tests were compared to those under non-impact conditions. The crack growth rates associated with striation formation were insensitive to the change in prior austenite grain size, ductile-brittle transition temperature and test temperature regardless of impact and non-impact fatigue. When the material was in the brittle condition, impact fatigue gave rise to a transition from striation formation to intergranular and cleavage cracking. Such a transition will result in the acceleration of crack growth rate. The Paris Law exponent values in impact fatigue were reasonably expressed by the ratio of test temperature to ductile-brittle transition temperature.

Notes: Abstract—The detection and measurement of surface microcracks in unnotched specimens are becoming more important, both from the point of view of description of crack growth by linear elastic fracture mechanics and from the classical endurance limit approach. Theoretical analyses of the current distribution in a cylindrical test specimen show promise that the a.c. potential drop method will become more sensitive for surface microcracks when higher current frequencies are applied. This effect was experimentally affirmed during fatigue tests on unnotched cylindrical specimens. With a 40 kHz current frequency semicircular surface microcracks with an area of 0.0066 mm2 (0.05% of the specimen cross-section) were detected. For accurate and reproducible crack growth measurements, a 5 kHz current frequency is preferable.

Notes: Abstract—A fully age hardened Al-4%Cu-1%Mg alloy has been subjected to plain-fatigue and fretting-fatigue and the resulting fracture surfaces compared. Crack initiation in the plain-fatigue sample occurred at cracked inter-metallic inclusions and subsequent crack growth was at 90° to the surface. Crack initiation in the fretting-fatigue sample occurred at the edge of wear scar and subsequent crack growth was at 45° to the surface. Measurement of fatigue striation spacing on the fracture surfaces showed that, for the same applied stress, the initial crack propagation rate was an order of magnitude higher in the fretting-fatigue sample. This accelerated crack propagation rate was maintained until the crack reached a depth of 0.5–1.0 mm; thereafter the growth rate was the same as that in the plain-fatigue sample.

Notes: Abstract—Ultrasonic bulk measurement technique was used to measure crack closure and a clip-on gage surface measurement technique was used to measure residual displacement at the crack tip of a propagating fatigue crack in 2219 and 7075 aluminum alloys. Experiments were carried out in vacuum, humid air, dry O2 gas, N2 gas, and deuteriated water vapor environments to evaluate effects of environments on residual strain and crack closure loads. It was observed that the closure load detected by ultrasonics decreased with introduction of humidity while the residual strain parameter dincreased with the humidity. The results are modeled as a build-up of oxide layer in addition to strengthening of asperities on the fracture surface. In the light of these observations, the effectiveness of surface and bulk measurements is evaluated. The results demonstrate that surface measurements are not always representative of the bulk behavior and use of such measurements in predictive analysis for fatigue can be misleading.

Notes: Abstract —Low-cycle fatigue properties were investigated on four carbon steels and five low alloy steels specified in JIS (Japanese Industrial Standard) for machine structural use, which are the most commonly used in Japan. Several different heats from each of several representative manufacturers were sampled so as to represent the average fatigue characteristics of current materials. The cyclic deformation behaviour of material was denned by comparing the monotonie yield stress on the extrapolated tensile work hardening curve with the cyclic yield stress in the cyclic stress-strain curve determined by incremental step test. The normalized ferrite-pearlitic steels cyclically hardened, while the quench-tempered martensitic were cyclically stable or softened. The S–N relations derived from the strain-controlled low-cycle tests were compared with the results obtained by load-controlled high-cycle tests. The extrapolated S–N curves based on the cyclic stress-strain curve predicted the fatigue strength in the high-cycle range to be stronger for cyclic-hardening steels, but weaker for cyclic-softening steels. The predicted S–N curves for stable steels coincided with the high cycle test data. The fatigue limit had a proportional relationship with cyclic yield stress, slightly depending on the cyclic deformation behaviour. On the other hand, the cyclic yield stress was found to exhibit a very good linear correlation with the monotonie tensile strength, independent of cyclic deformation behaviour. This explains the empirical law that the fatigue limit is approximately proportional to the tensile strength.

Notes: Abstract— Optical and scanning electron microscopy have revealed the existence of grain boundary cavities in a series of specimens which had been cyclically deformed in the strain range ±0.25% with hold times ranging from 0 to 1000 min. The way in which these defects increase in size and number has been measured and found to correlate with the creep strain accumulated during the hold periods.A further observation is that a critical amount of deformation is required before either fatigue or creep type damage is nucleated. These observations lead to an alternative method to the currently accepted linear damage summation rule for estimating a lower bound of the creep-fatigue endurance.

Notes: This paper puts forward a new method for analysing the behaviour of very short fatigue cracks. A probability function is introduced into the definition of the growth threshold, which rationalises the scatter in experimental data produced using an aluminium bronze alloy. This probability function can be visualised in terms of the microstructure of the material.It is shown that, in this material as in mild steels, fatigue crack initiation is not the critical stage. Initiation occurs relatively easily, but the cracks so formed may grow to only a few grain diameters in length before being arrested; thus it is the behaviour of cracks of this length which is critical in determining the fatigue strength of the material.These observations, when combined with the probability functions, allow estimation of the probability of failure of a component or structure in service with greater confidence than the methods used at present.

Notes: The high temperature low cycle fatigue properties of modified 9Cr-1Mo ferritic steel in a hot forged and a hot rolled condition have been evaluated. The hot forged material exhibited inferior fatigue properties as compared to the finer grained hot rolled material. Analysis of the data indicates that a larger grain size adversely affects the initiation stage but has little effect on the propagation stage. A steeper slope on the Coffin-Manson plot results when the number of cycles to initiation is reduced.

Notes: The overload induced fatigue crack propagation behavior of several aluminum and steel alloys was examined as a function of the baseline stress intensity factor range (δKb). In order to gain a clearer understanding of the parameters which influence the cyclic delay phenomenon, under both plane strain and plane stress conditions, tests were conducted at δKb values ranging from the near threshold regime to high δK levels approaching fast fracture. Large amounts of overload induced cyclic delay (˜100,000 cycles) were observed at both high and low δK levels (provided the plastic zone size/thickness ratio and plastic zone size/grain size ratio approached unity, respectively) with significantly less delay occurring at intermediate δK values. All alloys examined exhibited this type of delay behavior which can be described by a “U-shaped” plot. The delay phenomenon at high δKb levels under plane stress conditions was attributed to increased crack closure associated with large tensile displacements in the wake of the advancing crack. At low δKb levels increasing cyclic delay was attributed to an increased effective overload ratio as δK approached δKth.

Notes: Changes in the crack growth behavior of 7075-T651 aluminum specimens which had been exposed to temperatures between 121 and 179°C were evaluated. Specimens were fatigue tested at room temperature under flight-by-flight loading conditions. Results from these tests were then compared with data from the as-received material. Exposure to 141°C or more produced a definite increase in specimen life, apparently due to a decrease in crack growth rate. In contrast, preliminary experiments using constant amplitude loading did not show noticeable effects of these thermal treatments on fatigue lifetime. The thermal treatments were found to cause overaging of the metastable precipitate microstructure, which was thought to be responsible for the changes in fatigue response.

Notes: The initiation stage and short crack behaviour in torsional fatigue of a 0.4% C steel was investigated by a replication technique.The fatigue cracks initiated and propagated in the ferrite phase which is located at the prior austenite grain boundaries in the form of long allotriomorphs. At this stage of crack development it is proposed that crack growth rate depends on the extent and intensity of plasticity at the tip of the crack. Crack growth per cycle is correspondingly proportional to the strength of the slip band. The ferrite-pearlite boundaries are strong barriers to crack propagation, which is manifested by a deceleration of growth and possible arrest. On raising the stress level the previously non-propagating cracks may continue to grow by branching or joining with other cracks in the ferrite phase. This process is repeated until the stress fields of one or more dominant cracks attain a critical value to sustain continued growth that leads to failure.

Notes: CT type specimens containing two layers of 309L and 308L cladding stainless steels welded to A508 carbon steel and 316 stainless steel were specially devised to test the influence of R ratio and environment on the crack propagation rate behaviour of cladding materials at 300°C. Large effects are shown. The crack growth rate under vacuum can be smaller by more than one order of magnitude as compared to air. Large differences are also shown on the fracture surfaces, where it is observed than vacuum promotes the formation of large crystallographic {111} facets. The effect of environment is briefly discussed on the basis of existing gas adsorption models.

Notes: The monitoring of fatigue crack initiation mechanisms and short fatigue crack growth usually involves interrupting otherwise continuous load cycling for examination of the test-piece. This permits attainment of high resolution over a large area of surface where the fatigue cracks could initiate. However, breaks in the fatigue cycling can affect the fatigue endurance of the test-piece and in the present study of Ti-6A1-4V this has been shown to depend on the duration of the rests, the number of cycles between rests, the type of examination employed and the hydrogen content of the material. The results of the work are discussed in terms of the possible influence of the monitoring technique on the fatigue process.

Notes: Abstract— Fatigue crack tip opening displacements and strains in the material very close to the crack tip have been determined from measured displacements for cracks grown in both vacuum and humid air environments. The environment alters both the relations between crack tip opening displacement and crack tip strain, and the effect of cyclic stress intensity on these factors. Results of dynamic observation of intermittent crack growth are correlated with fractographic evidence. The relationships between crack tip parameters are used in a previously developed mathematical model. The effect of wet air on fatigue crack growth is found to be a reduction in crack tip plasticity.

Notes: Abstract— Unexpected arrest of long fatigue cracks was observed in mild steel single edge notch three-point bend specimens tested under constant amplitude loading. Arrest was associated with a low, but still positive, slope of the crack length against stress intensity factor curve, and can be explained using the R -curve concept for fatigue-crack growth. At a stress ratio of 0.1, the fatigue threshold was 6.6, 7.3 or 8.0 MN/m3/2 depending on the definition of threshold used. This has obvious implications for both the development of a standard test method for the fatigue threshold and the application of data to practical problems.

Notes: Abstract— The influence of age-hardening on the middle and low crack growth rates of a 7075 Al alloy is studied in vacuum. A transition in fracture surfaces morphology and crack growth curves is observed with the T 651 and T 7351 treatments in the near-threshold regime. Measurements of crack closure show its dependance on surfaces roughness and explain the lack of dependance of ΔKth with load ratio, except for the T 7351 alloy. An equation of crack growth rate to the fourth power of ΔKeff is in good agreement only with the crack propagation curves obtained for microstructure with an homogeneous deformation mode.

Notes: Abstract— Fatigue crack growth measurements are usually made on standard specimens containing long cracks (∼10 mm) although in most practical situations, a large part of the fatigue life is spent with much shorter dimensions. The purpose of the present study is a comparison of crack growth behaviour for long cracks (∼13–16 mm) in CT specimens and smaller ones (∼0.3–0.5 mm) in four point bend specimens. Large effects are noticed indicating that, at a given stress intensity factor amplitude, the crack growth rate is significantly higher in specimens with short cracks. Mouth displacement measurements for both specimen configurations show that the crack closure phenomenon accounts for the observed effect. Crack closure is likely to be associated with fracture surface roughness as shown by partly machining the material left behind the crack tip in CT specimens.

Notes: Abstract— The fatigue crack closure response was investigated for a surface crack in BS4360 50B structural steel, subjected to (1) constant amplitude loading and (2) constant amplitude loading interrupted by a single peak overload. A variety of compliance techniques was employed to determine closure behaviour. The crack mouth gauge measured the bulk, plane strain closure load, while the near tip strain gauge indicated the surface, plane stress closure response. For constant amplitude loading it was found that the surface regions of a surface crack are closed for a greater portion of the load cycle than the maximum depth point. A single peak overload caused different closure and growth rate transients at the surface of the thumbnail crack and at the maximum depth point. For growth rates above 10-6 mm/cycle, such behaviour agrees with the response of a through crack when subjected to constant amplitude loading, and a single peak overload.

Notes: Abstract— Fatigue cracking of complex structure often involves several interacting cracks developing in a sequence of crack growth, arrest and reinitiation. A “combined” method of damage tolerance analysis is presented which employs fracture mechanics concepts to calculate crack growth and fatigue data from notched coupons with the appropriate notch radius for the crack initiation phase. The notched coupon data, plotted as peak elastic notch stress vs cycles to crack initiation, are shown to be applicable even when limited yielding occurs at the notch root. For several practical reasons it is recommended to select the initial crack size, ai, for the crack growth phase to be as large as possible, but in accord with two selection criteria. First, ai, must be within a notch-root region wherein the elastic stress distributions near a variety of notches are virtually identical. Secondly, ai must be small enough not to significantly influence the stress distributions for other cracks. The Combined Method is illustrated by means of an example involving fatigue crack growth along a widthwise row of holes in 305 mm wide test panels.

Notes: Abstract— Crack shape evolution has been studied in high strength, rolled thread, bolts. It has been found that, using the Crack Microgauge, it is possible to detect and size fatigue cracks, located at the thread root, from depths of less than 0.1 mm up to fracture. This work required a special probe system to be developed and also a theoretical solution for the a.c. field distribution in a thread. Some of the work and results are briefly described in this technical note.

Notes: Abstract— The paper shows the practical significance of theoretical studies of fatigue crack propagation in real structures, and a comparison of the results of fracture mechanics theory with the actual failure mode of structures. It follows from these conclusions that neither the influence of the magnitude and complexity of structure, nor that of the random character of loading can be overlooked. Therefore, when applying laboratory test data the character of the structure under consideration and the loading conditions should be thoroughly appreciated.

Notes: Abstract— The problem associated with short crack growth, defined as situations in which the intensity of the crack tip field is underestimated by linear elastic fracture mechanics analyses, is briefly reviewed.Two cases are identified, cracks growing in plastically strained materials, such as occurs in high strain fatigue studies and at notch roots, and small cracks growing in single grains as occurs close to the fatigue limit in plain specimens.Important mechanical and metallurgical features of short cracks are discussed with particular reference to the upper and lower bound definition of a short crack.

Notes: Abstract— Stress and strain distributions and crack opening displacement characteristics of short cracks have been studied in single edge notch bend and centre cracked panel specimens using elastic–plastic finite element analyses incorporating both a non strain hardening and a power law hardening behaviour. J contour integral solutions to describe stress strain conditions at crack tips for short cracks differ from those for long cracks. The analyses show that (i) short cracks can propagate at stress levels lower than those required for long cracks and (ii) a two-parameter description of crack tip fields is necessary for crack propagation.

Notes: Abstract—The application of dimensional analysis and similarity methods to the study of the speed of fatigue crack growth is considered. It is shown that the Paris range of the crack propagation diagram is an intermediate-asymptotic stage of the crack growth process. Over this stage the influence of the initial conditions on the process of fatigue crack growth has disappeared but the influence of the instability has not yet intruded. So-called incomplete self-similarity prevails at this stage with respect to a basic similarity parameter, equal to the ratio of the stress intensity factor amplitude to the fracture toughness. It is shown that for a certain material under fixed external loading conditions the exponent in the Paris power law is a universal function of the ratio of specimen thickness to the ultimate size of the cyclic plastic zone. Processing of available experimental data confirmed the results obtained by this approach.

Notes: Abstract— Fracture surfaces of both service and laboratory fatigue fractures frequently show dark tongue-shaped marks. In fatigue tests on 7075–T6 specimens such tongues were produced by high peak loads. Measurements indicated that a tongue is not formed during a single burst of crack extension but is the result of a number of successive pop-ins requiring an increasing load. Therefore tongue formation is a quasi-stable phenomenon. The tunnelling fracture in the centre of plate thickness is accompanied by unfailed ligaments at the plate surfaces which reduce the stress intensity at the crack tip. The effect of different material conditions and loading direction on tongue forming was studied. A new model was developed to describe the growth of a tongue. The model was in good agreement with the various test results. The analysis of the problem has some relevance to validity requirements for K1c. A formula pertaining to tongues proposed by Forsyth was slightly modified and found to be approximately correct for the present results.

Notes: Abstract— A theoretical development based on a simple physical model is proposed to help the designer predict high strain multi-axial fatigue behaviour. This approach hypothesises that the maximum shear strain γ*, on planes driving the crack through the thickness, controls the fatigue crack propagation rate and hence the life. The direct strain δ*n acting normal to the plane of γ* can exert a secondary modifying influence. Experimental results from several research laboratories have been analysed in this manner with some success.

Notes: Abstract— Strain controlled continuous cycling fatigue tests are reported on three casts of Type 316 steel; the results obtained are shown to be consistent with published data.Strain controlled creep/fatigue tests are reported involving a hold period per cycle of between 0·2 and 168 h on one batch of Type 316 steel. An empirical extrapolation of the data and one involving a linear damage summation suggest that the existing Code Case N47 creep/fatigue design curve and rules are over-conservative. A stress relaxation/fatigue endurance correlation shows some promise for predictive purposes. Although many of the mechanical test and metallurgical features observed are consistent with a fundamental crack growth extrapolation approach, further consideration of detailed aspects are necessary before it can be used with confidence. It is concluded that there are no entirely reliable methods of extrapolation currently available for Type 316 steel and longer term tests are therefore essential to reduce the extrapolation uncertainties.

Notes: Abstract— Fatigue crack propagation tests were carried out in different environments on 7075–T6 and 2024–T3 centre-cracked sheet specimens. Observations were made on the macroscopic transition from tensile mode to shear mode. The transition is suppressed by an aggressive environment, whereas it is promoted by an inert environment. As a consequence there is no unique correlation between the state of stress and the mode of cracking. Both the state of stress and the environment have a significant effect on the mode of cracking. A simple model for the effect of environment on fatigue crack growth is presented. The implications for crack growth under corrosion fatigue conditions are discussed.

Notes: This paper presents the results of fatigue crack growth and fatigue fracture toughness studies of a high-pressure vessel steel with particular emphasis on the influence of heat treatment, low temperatures, plastic prestraining, the stress ratio and specimen dimensions.It has been shown that steels in an embrittled state, caused primarily by thermal treatment and low-temperatures, exhibit unstable fatigue crack growth which is characterized by alternate crack jumps (cleavage zones) and zones of fatigue crack growth. The fatigue fracture toughness, which corresponds to the first crack jump, and final fracture can be appreciably lower (i.e. up to 50%) than the static fracture toughness under plane strain conditions at the corresponding temperature.An analysis has been performed of unstable and stable fatigue crack growth and a model of unstable crack propagation is proposed which accounts for the observed experimental behaviour.

Notes: Abstract— Elastic-plastic finite element analysis is used to study fatigue crack closure at three different crack length to width ratios for three plane stress specimen geometries: center-cracked plate, single-edge-cracked plate (tension), and single-edge-cracked plate (bend). The maximum stress to flow stress ratio, Smax/σO, which successfully describes closure results in many center-cracked plate configurations, does not correlate the effect of different geometries on the normalized opening stress, Sopen/Smax. Crack opening stresses for different geometries and crack lengths are successfully correlated by a normalized stress intensity parameter, Kmax/K0, where K0=σ0φa. The quality of the correlation is very high at small Kmax/K0, and gradually deteriorates as Kmax/K0 increases beyond the small-scale yielding regime.

Notes: Abstract— Fatigue crack propagation threshold values have been determined with two experimental methods, it., the constant R method and the constant Kmax method. Three materials, namely A17075-T7351 and Ti6A14V STA in the LT- and TL-orientations, and a Ti-turbine disk material (IMI 685) in the CR-orientation, were investigated.The paper is divided into 3 parts. In the first part the test conditions, the experimental results and the conclusions drawn from the experimental results are presented, namely that the three different functional dependencies of ΔKth on R cannot be reconciled with present continuum mechanics concepts. In the second part, some facts used in conjunction with the da/dN–ΔKeff methodology are applied to the non-propagation condition ΔKth. Parameters such as KOp, the threshold ΔKT, and a parameter “KLL” are investigated by numerical modelling of their individual influence on the ΔKth versus R curves. This modelling work shows that the individual ΔKth versus R curves are primarily dependent on the Kop behavior of the respective material. Further, it is shown that the threshold ΔKT is a constant value, independent of any particular cyclic loading condition. In the third part of the paper, the ΔKeff concept is applied to the experimental results obtained in the first part. Using either experimentally or semi-empirically determined Kop functions and the measured ΔKT values, the ΔKth versus R curves of the three materials investigated were accurately reconstructed. It follows that the ΔKth versus R curves of the individual materials are the natural consequence of the driving force for fatigue crack propagation, namely ΔKeff

Notes: Abstract— Anderson and Dodds have recently introduced a test specimen size requirement in the transition regime which they suggest must be satisfied for the cleavage fracture resistance to be size independent. This paper assesses the implications of imposing the size requirement in fracture toughness testing standards. It is shown that imposing the size requirement can lead to a size dependence in fracture toughness data. This observation raises the general question of whether even existing size requirements for the lower shelf and upper shelf regimes are capable of giving size independent data.

Notes: Abstract— A new method of analysis is proposed for an infinite solid containing an embedded plane crack of arbitrary shape. The analysis is fundamentally based on the body force method, but proper expressions of the body force densities are introduced and the stress conditions of the crack surface are replaced by the resultant force conditions in order to improve the accuracy and validity of the method. Numerical results for typical crack problems, based on coarse mesh patterns, are shown to be in remarkable agreement with known solutions. The method is also applied to the bending of circular and rectangular cracks generated from compressive surface contacts for which reliable solutions have not yet been proposed by any other methods. The results are found to be very different from conventional free-surface solutions.

Notes: Abstract— The cyclic stress-strain response of two heats of austenitic stainless steel 3 16L was experimentally studied under a wide range of cyclic plastic strain amplitudes. Three domains on the cyclic stress- strain curve were found. In the middle domain the plateau behaviour corresponds to fatigue softening. The domain at low plastic strain amplitudes is characterized by stabilized behaviour and the domain of the highest plastic strain amplitudes by continuous hardening. Individual domains were correlated with observed dislocation structures. The existence of the plateau can be related to the localization of the cyclic strain into persistent slip bands. A Manson-Coffin plot of the material over a wide cyclic amplitude range is curved and can be approximated by a double logarithmic dependence.

Notes: Abstract— Near crack tip stress and displacement fields are obtained for anisotropic bimaterial interface cracks. A contact zone model is used in order to get rid of the unphysical oscillatory interpenetration between the edges of the crack. Semi-infinite and the finite crack problems have been studied. Using the near crack tip results of this model crack branching angles can be predicted. These results are illustrated by numerical results for various materials.

Notes: Abstract— In order to investigate the fatigue strength and fracture mechanism of ceramic-sprayed steel, rotary bending fatigue tests were conducted at room temperature in air and 3% NaCl solution using specimens of a medium carbon steel (S45C) with sprayed coating layers of Ni-5% A1 (under-coating) and chromia (top-coating). The results obtained are discussed based on observations of fatigue cracks and experimental data on specimens subjected to individual treatments during the ceramic spraying process. It was found that at a very early stage of fatigue life, cracks were initiated at the interface between under- and top-coating layers, and grew rapidly into the ceramic-sprayed layer. However, these cracks did not propagate continuously into the substrate, and the final failure was led by the growth of a crack newly initiated at the surface of the substrate steel. Thus, the fatigue strength of the ceramic-sprayed steel in air could be evaluated due to the property of the substrate. The corrosion fatigue strength of ceramic- sprayed steel was improved when compared to that of the substrate steel. However, the coating layer contained many pores, through which NaCl solution was supplied from the specimen surface to the substrate. Corrosion pits were formed at the interface between the under-coating and the substrate. Subsequently, cracks initiated from the pits and grew into the substrate. Tests were also conducted on specimens whose pores were closed by a shielding treatment. In this case, NaCl solution was supplied to the substrate by cracks initiated in the top-coating layer. The shielding treatment was effective at low stress levels where fatigue life was more than 107 cycles, while it had little effect on improving corrosion fatigue strength at higher stress levels because of the many cracks initiated in the top-coating layer.

Notes: Abstract— The development of an elastic-plastic fracture mechanics model for predicting fatigue crack growth rates in notched specimens is presented in this paper. The model is based on experimental short and long crack growth results from un-notched specimens and the distribution of strain ahead of the notch root. This approach may be applied to the assessment of the lifetime of many high technology engineering components.

Notes: Abstract— By conducting creep tests and creep-fatigue tests at temperatures of 800°C, 900°C, and 1000°C, on centrifugal cast HK40 alloy (which is used for example for the steam reformer tubes of fuel cell plants) and varying the strain rate during the loading and unloading process, the influence of strain history on the life of the material has been clarified. Furthermore, the data obtained from these tests were subjected to analyses by means of life evaluation methods utilizing the life fraction rule, strain range partitioning method, and damage rate approach, and comparative studies were conducted on each life evaluation method. As a result, problematic points concerning the application of the life fraction rule, strain range partitioning method, and damage rate approach have been clarified and data which would be useful in establishing design guidelines for structures to be used under conditions such as involves the interaction of creep and fatigue have been obtained.

Notes: Abstract— By adopting a suggestion made by Thomason, a new failure criterion for the Gurson-Tvergaard model has been recently introduced by the authors. In this study, a method based on the Gurson-Tvergaard constitutive model and the new failure criterion is applied to the analysis of ductile fracture. The main features of the method are that the material failure is a natural process of the development of Thomason's dual dilational constitutive responses, and the void volume fraction corresponding to the failure by void coalescence is not necessarily a material constant and is not needed to be fitted beforehand. Furthermore, void nucleation parameter(s) can be numerically fitted from experimental tension results. This method has been implemented into the ABAQUS finite element program via a user material subroutine and is applied to the prediction of tension problems conducted by the authors. In the analyses, two strain-controlled void nucleation models have been studied and compared. The void nucleation parameters corresponding to the two models have been calibrated. The crack initiation of both smooth and notched axisymmetric tensile specimens are well predicted by the method. Finally, several critical issues in the analysis of ductile fracture are discussed.

Notes: Abstract— A computer program that creates time histories for use in fatigue tests in servo-hydraulic machines is presented. The time histories can be tailored from certain user specifications, namely the irregularity factor and the level-crossing spectrum. The program is based on the theory of stochastic time series, and the formulae needed for the program are derived in the paper. Problems of optimality are treated both with respect to fulfilment of the specifications and with respect to machine performance. Examples from two fatigue-testing projects, where the program has been applied, are presented.

Notes: Abstract— The interaction between fatigue damage (i.e., fatigue crack propagation) and internal grain boundary damage (i.e., cavity formation at grain boundaries) has been studied for the Alloy 800H at 750°C for constant plastic strain ranges but different experimental conditions. Most experiments were performed at constant ranges of alternating tensile/compression stresses. Symmetrical as well as asymmetrical tests (with larger compression stresses) were performed. In comparison to the former tests, asymmetrical tests led to shorter cyclic lifetimes mainly due to cavity formation which was not observed for symmetrical tests. It could be shown that a fast compressive and a slow tensile half cycle (at large compressive and low tensile stresses) are ideal conditions for the nucleation and growth of cavities. Based on quantitative measurements of the cavity density from interrupted fatigue tests, a physical model is presented which can predict the number of cycles to failure. This cycle number is determined only by fatigue crack growth which is controlled by (a) athermal plastic deformation, (b) creep deformation and (c) rate enhancement by cavitation.

Notes: Abstract— The fatigue behaviour of a Ni-Cr-base powder flame-spray coating on a 0.4% C steel is investigated. Fatigue tests were carried out using mild hour-glass profile specimens. Cracks were detected and measured using plastic replicas and an image analysis system. Coated specimens showed a slightly lower fatigue endurance than plain specimens under torsion loading, while the opposite was observed for push-pull loading. Microcracks in coated specimens invariably form at pores.Contrary to the usual case of stage I shear growth for a plain 0.4% C steel in tension or torsion loading, the coated specimens show initial crack growth from pores along directions perpendicular to the maximum tensile stress. The crucial behaviour of short cracks, and their growth rates, relative to the thickness of the coating, are discussed in some detail.

Notes: Abstract— The effect of stress state on the time and strain to failure has been considered in terms of currently accepted models of cavity growth. It is shown that the increasing contributions of compressive stress cause changes in cavity growth mechanisms which lead to increases in ductility. A tensile component of stress is necessary to provide the driving force for cavity growth by diffusion of vacancies and hence only strains in the presence of a tensile stress can lead to creep-dominated failure in creep-fatigue.Equivalent stress functions for isochronous stress rupture have been derived in terms of the cavity growth models and their corresponding relationships for calculating damage in terms of strain fractions developed. It is shown that it is difficult to discriminate between the various models on the basis of available experimental data. However, the analysis allows data to be assessed within the framework of physically based mechanisms and suggests methods which lead to conservative lower bound estimates of endurance.It is concluded that the shape of the isochronous creep rupture locus depends on the controlling process of cavity growth and that a detailed analysis of uniaxial creep ductility is necessary to obtain a complete description of the multiaxial behaviour. In many instances such an analysis will prove more valuable than simply performing creep tests over a limited range of stress states. Increasing contribution of principal stress to the failure process leads to a greater value for the equivalent stress in the presence of a compressive component compared with the von Mises equivalent value. However, the equivalent stress is reduced in the tensile quadrant of bi-axial stress. Hence the degree of conservatism arising from using the von Mises equivalent stress will vary with stress and may become slightly non-conservative. The relationship between equivalent stress functions for application in a time fraction assessment of creep and the calculation of creep damage by a strain fraction method has been demonstrated. Finally, guidance is given on how a limited data base of uniaxial rupture properties can be used to obtain a conservative estimate of behaviour under multiaxial loading.

Notes: Abstract— Different aspects of fatigue design problems are indicated and uncertainties are listed. Scatter as observed in many laboratory studies is analyzed. It is argued that scatter of crack initiation and crack growth are different issues. Various sources of scatter are discussed and illustrative examples are presented. Comments are given on statistical distribution functions, scatter under Variable-Amplitude loading, and scatter in service. The discussion touches upon the experience and meaning of scatter of laboratory test series related to practical problems.

Notes: Abstract— The notched strengths of four woven laminates (two orthotropic, one quasi-isotropic and one square symmetrical) under monotonic uniaxial loading, predicted with the point and average stress criteria, the two parameter criterion, the progressive degradation model, and the initial and improved point and minimal strength models, have been respectively compared with the experimental data. The damage mechanisms for the laminates were tentatively studied. The results show that, for minimal experimental information, the notched strengths predicted by the improved minimal strength models are the most precise and the progressive degradation model can numerically illustrate the damage mechanisms in detail. The damage mechanisms of the woven laminates were found to be very different from those of non-woven laminates.

Notes: Abstract— The dislocation substructures of ferrite in plain carbon, ferrite plus martensite, dual-phase steels in different stages of fatigue crack propagation were examined by transmission electron microscopy. The experimental results show that the dislocations are in random arrays in the ferrite before cyclic loading. At stages of low ΔK (near threshold) values, parallel clusters of dislocations and prolonged dislocation lines can be observed. At stages of intermediate ΔK values, the dislocations are rearranged into networks and loops while at stages of high ΔK (prior to failure) values, they are changed into dislocation cells or patches. It was also found that the volume fraction and carbon content of martensite have significant effects on the dislocation substructures of ferrite after cyclic deformation.

Notes: Abstract— Thermo-mechanical fatigue stress-strain data on ferritic/austenitic steels and superalloys from a variety of sources are analysed with regard to hysteresis loop stress asymmetry. This arises from a decoupling of the thermal and mechanical strain signals in the test technique so that many tension-compression load combinations are possible. Data from simplified isothermal and bithermal tests are also examined. Taking a typical example of an “out-of-phase” thermo-mechanical loop on a 1/2 CrMoV steel cycled between 200 and 550°C, isothermal stress-strain data were generated at 50°C intervals on material from the same cast and, used in conjunction with the elastic characteristics of the apparatus, an attempt was made to re-create this loop. The methods employed were (i) a graphical construction between appropriate isothermal yield contours (ii) a tangent modulus calculation (iii) a secant modulus calculation. Method (i) appeared to give the closest agreement in the present case.

Notes: Abstract— The plastic deformation of thin-walled cylinders has been experimentally examined for the loading conditions of ±1% axial strain with hoop stresses of approximately 0, 1/4, 1/2 and 3/4 of the initial uniaxial yield stress.Two materials similar to those used in the pipework of PWR nuclear plant in the U.K. have been tested, namely 304S11 stainless steel and En6 low-carbon steel. The results of the tests were to be compared with the allowable stresses and deformations specified in the ASME Boiler and Pressure Vessel Code, Section III. The code specifies that a prescribed combination of primary stresses must not exceed 1.5Sm, where Sm is a stress value defined for each material.The results indicate that the limit of 1.5Sm is excessively low for both materials and that in particular, the stainless steel could tolerate 5Sm. Although the En6 steel is more prone to ratchetting than the stainless steel, the results suggest that it too could tolerate a higher primary stress than the code allows. Both materials are shown to satisfy the proposed ASME ratchet strain limit of 5% hoop strain after 10 cycles of ±1% axial strain range, for any value of internal pressure.

Notes: Abstract— The susceptibility of an X65 line pipe steel to hydrogen-induced stress corrosion cracking (SCC) is investigated. SCC tests on the steel are carried out in three environments of different aggressivity based on a NACE TM-01-77 solution with dissolved gaseous H2S. The threshold stress intensity factor is calculated for each environment using the multiple specimen technique. The steel is tested in the as-received condition and after homogenisation. Permeation tests are carried out on specimens of the same steel in the same environment. The relationship between threshold stress intensity factor and hydrogen concentration is obtained. The results from these studies are used to generate the parameters in the micro-mechanic model of Akhurst and Baker. The validity and physical significance of the model is assessed.

Notes: Abstract— Measurements of the effect of stress ratio on the constant amplitude fatigue crack growth rates in four quenched and tempered steels in the Paris regime are reported. This data and published data for other alloys (including lower strength steels and non-ferrous alloys) are evaluated, and a correlation function suitable for practical fatigue life calculations is derived. In addition to stress intensity factor range and stress ratio, other significant parameters are the yield stress of the material and its thickness. For the four steels on which new measurements were made, the degree of dependence of the crack growth rate on stress ratio may be related to sensitivity to environmental conditions.

Notes: Abstract— A model based upon linear elastic bridging and fiber crack tip shielding is proposed for predicting fatigue crack growth in a SCS-6/Ti-6–4 composite. The model is characterized by the fiber/matrix debond length rather than the fiber/matrix interfacial frictional shear strength used in most current fatigue models. Finite elements combined with fracture mechanics are applied for computing the local stress intensity. The local stress intensity in the matrix is then utilized to predict crack growth in the composite via comparison to monolithic fatigue crack propagation data for a similar Ti-6–4 matrix material.

Notes: Abstract— The Modified Crack Closure Integral (MCCI) technique based on Irwin's crack closure integral concept is very effective for estimation of strain energy release rates G in individual as well as mixed-mode configurations in linear elastic fracture mechanics problems. In a finite element approach, MCCI can be evaluated in the post-processing stage in terms of nodal forces and displacements near the crack tip. The MCCI expressions are however, element dependent and require a systematic derivation using stress and displacement distributions in the crack tip elements.Earlier a general procedure was proposed by the present authors for the derivation of MCCI expressions for 3-dimensional (3-d) crack problems modelled with 8-noded brick elements. A concept of sub-area integration was proposed to estimate strain energy release rates at a large number of points along the crack front. In the present paper a similar procedure is adopted for the derivation of MCCI expressions for 3-d cracks modelled with 20-noded brick elements. Numerical results are presented for center crack tension and edge crack shear specimens in thick slabs, showing a comparison between present results and those available in the literature.

Notes: Abstract— Experiments have been performed on specimens subjected to strain cycles similar to those experienced by sub-surface elements of material in rolling/sliding contact. It has been observed that if the strain cycle is closed then failure takes place by low cycle fatigue and the Coffin-Manson relationship may be used to predict the number of cycles to failure. If however, the strain cycle is open, so that the material accumulates unidirectional plastic strain (the situation known as “ratchetting”) a different type of failure, which is termed ratchetting failure may occur. It occurs when the total accumulated plastic strain reaches a critical value which is comparable with the strain to failure in a monotonic tension test. The number of cycles to failure under these circumstances may be estimated by dividing this critical strain by the ratchetting strain per cycle. It is suggested that low cycle fatigue and ratchetting are independent and competitive mechanisms so that failure occurs by whichever of them corresponds to a shorter life. The results of both uniaxial and biaxial tests reported in the literature have been re-evaluated and these, together with new data on biaxial tests on copper, found to be consistent with this hypothesis.

Notes: Abstract— A hypothesis on the statistical relation between the local microscopic directions of fatigue crack growth and the macroscopic crack front shape is postulated. The method of fractographic reconstitution of the fatigue crack front shape from local microscopic directions of crack growth is proposed and tested in two different applications.

Notes: Abstract— Large scale, structurally representative, double tension crack arrest tests have been undertaken at temperatures between −99°C and −87°C. Applied stresses and the length of the embrittled crack starter sections were varied to give different applied stress intensity factors in the tests. The results indicate that crack arrest in structures is not governed solely by a so-called crack arrest temperature but that static linear elastic fracture mechanics can be used to describe it. The measured crack arrest toughness temperature curve of the 1.5%Ni TMCP steel investigated lies at the lower bound of published data.

Notes: Abstract— The criteria for determining whether ferritic material exhibits fully ductile behaviour are generally based on the fracture toughness vs temperature relationship determined from standard laboratory test pieces (e.g. Charpy V Impact tests or fracture toughness specimens). This relationship defines a ductile-brittle transition region. When fully ductile, microvoid coalescence behaviour is experienced, and fracture toughness is described as being on the “upper shelf”. At “off the shelf” temperatures brittle, cleavage fracture is experienced. On the lower shelf the material is entirely brittle, exhibiting 100% crystallinity on the fracture face. As the temperature increases, initiation of tearing by microvoid coalescence occurs and some stable tearing can occur prior to the cleavage event. Material toughness increases with temperature until the upper shelf condition is achieved.The characteristics of fracture toughness tests in terms of the toughness level exhibited and the extent of ductile tearing experienced have been used as a guide to whether the structural application (e.g. a pressure vessel) will behave in a brittle or a ductile manner. This paper reports on a feasibility study where various worked examples have been performed to examine the concept of using a “cut off” on the failure assessment diagram, determined from the conditions required to cause plastic collapse of a pressure vessel, as a criterion for defining effective “ductile” operation. Fracture assessment procedures (R6 revisions 2 and 3 and PD6493 levels 2 and 3) have been utilised to determine the influence on pressure vessel performance of the behaviour of fracture toughness test specimens.The procedure of plotting a structural collapse “cut off” on a failure assessment diagram enables the assessment of whether a particular flaw geometry would result in gross deformation of the structure at failure. The use of this procedure provides an unambiguous demarcation between “fracture dominated” and “collapse controlled” conditions. This procedure facilitates judgements on the level of toughness necessary to ensure ductile operation and whether a “tearing plus toughness” requirement is necessary.It is recommended that consideration be given to including structural collapse into fracture assessment procedures carried out using R6 revision 3 or PD 6493:1991 procedures in order to determine the conditions when enhanced toughness no longer influences structural performance (i.e. when effective “upper shelf” conditions are attained).

Notes: Abstract— The use of a previously presented general criterion of failure for high cycle multiaxial fatigue, τa/tA,B+σn.max/2σT= 1, is extended to cases where the shear and normal stress on the critical plane are non-proportional and also to give life predictions in the range of 104 to 106 cycles. The criterion takes account of whether case A cracks, growing along the surface, or case B cracks, growing in from the surface, occur.

Notes: Abstract— The successful implementation of a fracture mechanics approach to the in-service structural integrity assessment of welded and machined components requires an accurate and reliable NDT method for detecting and sizing surface breaking cracks. This paper discusses and compares the crack depth sizing abilities of two theoretically-based NDT techniques: alternating current potential difference (ACPD) and alternating current field measurement (ACFM). Surface fatigue cracks of high and low aspect ratio are used in the investigation. It is demonstrated that ACPD is capable of accurately sizing long shallow cracks and that ACFM provides accurate crack depth predictions for small deep cracks.