ENVIRONMENTAL EFFECT

FATIGUE FAILURE CREEP FAILURE FRACTURE BEARING MATERIAL

FATIGUE FAILURE OF METALS

FATIGUE FAILURE OF METALS

What is metal fatigue?

Metal fatigue is a failure which occur under repeated

cycling of load/stress. A progressive localized damage due to fluctuating stresses and strains on the material. This repetitive stresses which is much lower stress than the part can withstand under the application of single static stress.

FATIGUE FAILURE OF METALS

Fatigue fracture surface

The process of fatigue consists of three stages: Initial crack initiation Progressive crack growth across the part Final sudden fracture of the remaining cross section

FATIGUE FAILURE OF METALS

Preventing Fatigue Failure

The most effective method of improving fatigue performance is improvements in design: Eliminate or reduce stress raisers by streamlining the part Avoid sharp surface tears resulting from punching, stamping, shearing, or other processes Prevent the development of surface discontinuities during processing. Reduce or eliminate tensile residual stresses caused by manufacturing. Improve the details of fabrication and fastening procedures

Fatigue cyclic stresses

STRESS VS NUMBER OF CYCLE (SN ) CURVE

FATIGUE LIMIT

Fatigue limit (endurance limit) occurs for some

materials (some Fe and Ti allows). In this case, the SN curve becomes horizontal at large N. The fatigue limit is a maximum stress amplitude below which the material never fails, no matter how large the number of cycles is.

CREEP FAILURE
WHAT IS CREEP FAILURE ? Creep is a time-dependent and permanent deformation
of materials when subjected to a constant load at a high temperature (> 0.4 Tm). Examples: turbine blades, steam generators.

Stages of creep at the creep curve

1. Instantaneous deformation mainly elastic. 2. Primary/transient creep - Slope of strain vs. time decreases with time: work-hardening 3. Secondary/steady-state creep -Rate of straining is constant: balance of work-hardening and recovery. 4. Tertiary - Rapidly accelerating strain rate up to failure: formation of internal cracks, voids, grain boundary separation, necking, etc.

Creep failure

Creep is generally minimized in materials with: High melting temperature High elastic modulus Large grain sizes (inhibits grain boundary sliding)