International Journal of Fatigue 109 (2018) 1–9

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International Journal of Fatigue

journal homepage: www.elsevier.com/locate/ijfatigue

Grain size dependence of fatigue properties of friction stir processed T

ultrafine-grained Al-5024 alloy
⁎
Shivakant Shukla, Mageshwari Komarasamy, Rajiv S. Mishra
Center for Friction Stir Processing, Advanced Materials and Manufacturing Processes Institute, Department of Materials Science and Engineering, University of North Texas,
Denton, TX 76207, USA

A R T I C L E I N F O A B S T R A C T

Keywords: The main objective of the present study was to examine the effect of grain size on the fatigue properties of 5024
Ultrafine grain Al alloy. Two ultrafine-grained (UFG) and one fine-grain microstructures were produced via friction stir pro-
Fatigue properties cessing (FSP). Fatigue properties were investigated using a fully reversible bending fatigue testing machine.
Friction stir processing Microstructural evolution during fatigue was analyzed by carrying out interrupted fatigue testing with sub-
Basquin equation parameters
sequent orientation imaging microscopy. Emphasis was given to grain size on the evolution of deformed
structure, intergranular dislocation density, and overall S-N curve. A comparison with literature demonstrates
the importance of the processing route to obtain the UFG microstructure. This difference is highlighted through
an analysis of Basquin equation parameters. The results indicate that FSP can be utilized as an effective route to
obtain stable UFG microstructure. A fractographic study was done to understand the effect of microstructure on
fatigue crack initiation and propagation rates. Crack growth rates in stage-II has been compared for the three
different grain sizes.

1. Introduction aforementioned SPD processes have high fractions of non-equilibrium

Improvement in tensile properties, which has long been known to
enhance fatigue properties of material, has led to the development of a
number of strengthening mechanisms that rely on a combination of
solid solution, precipitates, and grain refinement [1,2]. Considerable
effort has been expended on grain refinement to improve material
strength. Severe plastic deformation (SPD) methods such as equal
channel angular pressing [3], high pressure torsion [3], accumulating
roll bonding [4], and multiaxial forging [5] are effective techniques to
obtain bulk ultra-fine grained (UFG) microstructures (grain size <
1 µm). A different approach is the ball-milling of powders, preferably at
cryogenic temperatures, to suppress recovery and subsequent re-
crystallization processes leading to UFG microstructure [6,7]. This ap-
proach is generally not suitable for bulk UFG materials; hence SPD
processes remain by far the most suitable method [8]. Another such
SPD method is friction stir processing (FSP), a derivative of friction stir
welding (FSW) developed by Mishra et al. [9], where the material is
severely deformed by a rotating pin with shoulder with a rise in
workpiece temperature high enough for recrystallization to occur. A
variation in dislocation density and grain boundary character dis-
tribution for each kind of SPD method affects both tensile and cyclic
loading properties of the material [3,10]. Microstructures produced via
grain boundaries and increased dislocation densities when compared
with FSP [11,12]; the result is microstructural instability, i.e., the for-
mation of shear bands (SBs) and grain/cell coarsening. While tensile
properties of UFG materials do increase by grain refinement using other
SPD methods, the above-mentioned microstructural instabilities bring
new challenges to fatigue properties. These microstructural instabilities
lead to cyclic softening, which detrimentally affects fatigue properties.
Many studies confirm that the need for annealing heat treatment to
improve fatigue properties in SPD-processed materials [13,14]. While
tensile properties are generally affected by the overall characteristics of
the microstructure, fatigue properties are influenced by local micro-
structural imperfections such as microstructural instability and grain/
cell coarsening. Thus, a direct relation between tensile and fatigue
properties of UFG materials is difficult to ascertain. In this regard, FSP
can be a viable technique to overcome these challenges, as dynamic
recrystallization involved in FSP engenders the formation of fine grains
with a high fraction of high angle grain boundaries (HAGB) and low
dislocation density. These characteristics are beneficial for fatigue
properties [15]. One long-established fact about cyclic loading is that
deformation in coarse grain (CG) materials occurs through nucleation
and multiplication of dislocations within the grain. Dislocation density
continues to increase, and deformation leads to the rearrangement and

⁎
Corresponding author.
E-mail address: rajiv.mishra@unt.edu (R.S. Mishra).

https://doi.org/10.1016/j.ijfatigue.2017.12.007
Received 19 September 2017; Received in revised form 17 November 2017; Accepted 9 December 2017
Available online 11 December 2017
0142-1123/ © 2017 Elsevier Ltd. All rights reserved.
S. Shukla et al.
formation of three-dimensional boundaries that, on further application
of stress, change into a two-dimensional (2-D) shape called sub-grain
boundaries [16]. Size and shapes of these sub-grain boundaries or cells
generally depend on the material and applied strain. For pure alu-
minum, this typical subgrain structure is ∼400 nm [17]. Given that
grain sizes in UFG Al alloys are comparable to or smaller than the ty-
pical dislocation substructure size, a question arises as to how the given
length scale affects the formation of sub-grain cells and the interaction
of dislocations with boundaries becomes important.
Because of their lightweight, aluminum alloys have been used ex-
tensively for the structural applications in the aerospace industries. The
addition of magnesium increases strength via solid solution strength-
ening without compromising the excellent strength-to-weight ratio.
Further micro-alloying addition of Sc (< 0.4%) improves strength sig-
nificantly due to the formation of coherent nanoscale Al3Sc precipitates
[18,19]. Al3Sc precipitates also hinder the mobility of grain boundaries
through Zener pinning and thus serves as a grain-refining agent during
high-temperature processing and application.
The aim of the present study was to understand how grain size
variation in UFG regime affects fatigue properties. Thus, two different
UFG microstructures were obtained with a very high fraction of HAGB.
The difference between the cyclic loading behavior of UFG and fine-
grained 5024 Al alloy was investigated in terms of S-N curve and
fractography.
2. Experimental
Al-Mg-Sc alloy of 7 mm thickness was obtained from Aleris with a
nominal composition of Al-4.0 wt% Mg-0.3 wt% Sc. FSP was done on
the plate to obtain UFG microstructure. Details of the tool used in this
processing were reported in [20,22]. Two different grain sizes obtained
by varying the FSP parameters will be referred to as UFG410 and UFG210
alloys as detailed in Table 1.
During UFG210 alloy processing, a copper backing plate was used to
accelerate heat flow so that a faster cooling rate could be obtained.
Apart from the two UFG 5024 Al materials, a fine grain microstructure
(average grain size > 1 µm) was produced by annealing the UFG410
alloy at 873 K for 1.5 h and hereinafter referred to as FG. FG alloy was
obtained to compare the fatigue properties of UFG materials with fine-
grain one. Tensile tests were carried out for all three conditions using a
computer-controlled mini-tensile testing machine at an initial strain
rate of 10−3 s−1. Gage length of the samples was ∼5 mm with width
∼1.2 mm, and thickness ∼1.1 mm. Mechanical polishing of all tensile
samples was carried out to 1 µm surface finish using diamond suspen-
sion on Kempad cloth. Three samples were tested for statistical vali-
dation. Bending fatigue testing was performed using a custom-made
tabletop mini-fatigue testing machine; complete details are in [23]. All
samples were tested at 20 Hz frequency and stress ratio (R) of −1. Since
fatigue properties are affected by surface condition, sample preparation
was done with extreme precaution. Samples were polished down to a
surface finish of 1 µm by diamond suspension followed by 0.05 µm,
then 0.02 µm surface finish using colloidal silica suspension to elim-
inate surface flaws. Grain size distribution (GSD) and misorientation
angle distribution information was obtained by orientation image mi-
croscopy (OIM) on FEI Nova NanoSEM 230, with a 15 kV accelerating
voltage. The EBSD analysis was done using SL Digiview III Electron
Backscatter Diffraction (EBSD) detector. Since the grains fall in the UFG
Table 1
Details of FSP parameters for processing AA2054 alloy.
Microstructure Rotational rate Traverse speed Tool tilt Cooling
(RPM) (IPM) (Degrees)
UFG410 325 8 -2.5 No cooling
UFG210 275 8 -2.5 Cu backing
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International Journal of Fatigue 109 (2018) 1–9
regime, a step size of 80 nm was used. Interrupted fatigue testing on
UFG410 with subsequent OIM analysis with the above-mentioned
parameter was performed to understand microstructural evolution
during fatigue testing. Fractography was done using FEI Quanta ESEM.
For fractographic studies, samples were preserved immediately, and
minimal cleaning was done.
3. Results and discussion
3.1. Initial microstructure characterization
Initial EBSD analysis of all the three samples was performed to
obtain grain size, grain size distribution, and grain boundary mis-
orientation angle distribution. The OIM micrographs of 5024 Al
UFG410, UFG210, and FG alloys with their corresponding GSD are shown
in Fig. 1. Inverse pole figure (IPF) in Fig. 1(g) shows crystallographic
orientation associated with different colors. Table 2 average value of
the grain size of UFG410, UFG210 and FG materials.
In UFG410 material, 98% of grains were < 1 µm, and 25% of grains
were below 500 nm; while in UFG210 material, 95% grains were < 1
µm, and 72% were < 500 nm. Of note is that step size was 80 nm. Even
though smaller step size would yield more information about the GSD,
it should not have any major effect on average grain size information.
On the other hand, average grain size for FG material was ∼4.61 µm,
with 93% grains below 10 µm and only 2% grains below 1 µm. Al3Sc
precipitates in 5024 Al provide excellent thermal stability to grain
growth [22]. Addition of Sc and Zr also suppresses abnormal grain
growth up to a temperature of 823 K [22].
3.2. Tensile properties
Typical stress – strain curve for all the three microstructural con-
ditions are shown in Fig. 2. Yield strength (YS) and ultimate tensile
stress (UTS) for UFG410 were 320 ± 3 MPa and 350 ± 5 MPa, re-
spectively with uniform elongation of ∼12% and total elongation of
20%. For UFG210 5024 Al alloy, YS and UTS values were 410 ± 5 MPa
and 415 ± 5 MPa, respectively, with ∼3% uniform elongation and 6%
failure elongation; while FG 5024 Al showed UTS of 290 ± 5 MPa and
YS of 175 ± 3 MPa, with uniform elongation of ∼14% and 16% total
elongation. As expected, the decrease in grain size has a significant
effect on tensile properties. YS of UFG alloy increased by almost
100 MPa when average grain size decreased from ∼ 410 nm
to ∼ 210 nm.
The significant impact of grain size on uniform elongation and work
hardening indicates that an increase in grain size improves work
hardening of 5024 Al alloy. This is related to the dislocation storage
when grain size reaches UFG domain [15]. Also, worth noting is the
variation in serration behavior observed in these alloys as a function of
grain size. As compared to FG alloy, serration amplitude (Δσ) in UFG410
alloy was higher and initiated at the beginning of plastic deformation.
Komarasamy and Mishra reported that the serreation amplitude and
frequency increased with decrease in grain size [20]. Such observations
have been attributed to decreasing grain size and resultant change in
the interaction between the dislocations and various microstructural
elements (solutes and grain boundaries). The above-mentioned values
of YS for all three microstructures followed a Hall-Petch relationship
[21], and the calculated grain size of 5024 Al UFG210 alloy by this
method is 198 nm, which was reasonably close to the value obtained via
OIM analysis (∼210 nm).
3.3. Fatigue behavior
To understand the overall fatigue behavior of 5024 Al UFG410,
UFG210, and FG alloys, S-N curves were generated for all three micro-
structural conditions at R of −1. Fig. 3(a) presents S-N data for all three
conditions. At a particular stress amplitude (e.g. at 220 MPa), UFG210
S. Shukla et al. International Journal of Fatigue 109 (2018) 1–9

Fig. 1. OIM micrographs of 5024 Al (a) UFG410, (b) UFG210, and (c) FG material and corresponding grain size distribution (d), (e), and (f) with (g) inverse pole figure.

alloy with the smallest grain size performed better as compared to

Table 2 UFG410 alloy, thereby confirming that finer grain size in the UFG re-
Average grain size values for UFG410, UFG210, and FG condition. gime does lead to longer fatigue life.
Although S-N curve for FG alloy was situated below both UFG410
Material UFG410 UFG210 FG and UFG210 material, its proximity with UFG410 S-N curve suggests that
Grain size 0.410 ± 0.280 µm 0.210 ± 0.110 µm 4.61 ± 3.45 µm fatigue properties of FG material are very close to UFG410 condition.
The fatigue curves of the FG and the UFG410 microstructures are very
close to each other, but the scatter in the FG data is comparatively

Fig. 2. (a) Engineering stress-strain curves and (b) true stress-strain curves for 5024 Al UFG410, UFG210, and FG alloys.

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S. Shukla et al.
Fig. 3. (a) S-N curves for 5024 Al UFG410, UFG210, and FG alloys and (b) normalized S-N curves for all three conditions.
large. Also, because of the lower yield strength of the FG micro-
structure, the stress range of testing is quite narrow. Since all the three
microstructures have different UTS values comparison of their fatigue
behavior on UTS normalized basis can provide additional insight
(Fig. 3(b)). Comparison of UFG410 with UFG210 reveals that at higher
normalized stress (> 0.5 UTS), UFG410 performs better than UFG210
condition; while at lower stresses (around 0.4 UTS), UFG210 performs
almost equal to UFG410 condition. Note also that 5024 Al FG material in
normalized stress plot performs better than both UFG410 and UFG210
microstructures. According to Landgraf [24] and Morrow [25], fatigue
properties can be categorized into low cycle fatigue (LCF) and high
cycle fatigue (HCF), and are determined by both ductility and strength.
LCF is governed by fatigue ductility, while HCF is controlled by fatigue
strength [16,24,25]. Since UFG210 alloy has higher tensile strength and
inferior ductility than UFG410 alloys, UFG210 alloy can be expected to
perform better in a high cyclic regime; while UFG410 alloy will be better
suited for lower cycle regime of HCF. A recent study by Liu et al. on Cu-
15 at% Al alloy also shows similar observations for high cycle region
[1].
3.4. Interrupted fatigue testing and subsequent OIM analysis
Grain coarsening has been a prime microstructural phenomenon in
UFG alloys during cyclic loading. Grain coarsening is generally believed
to occur by dynamic recrystallization, and may be the indication of
fatigue damage of the microstructure [16]. To study microstructural
changes during fatigue testing, 5024 Al UFG410 specimen was subjected
to interrupted fatigue test and subsequent OIM analysis.
1. OIM was done at a particular location in the gauge section before
fatigue. For certainty of the location, multiple images were taken at
various magnifications.
2. The specimen was subjected to a stress level of 265 MPa and was
interrupted at 15,000 cycles, the number of cycles required for crack
initiation. This stress and number of cycles were selected based on
the results from previous testing at the same stress amplitude.
3. After 15,000 cycles, OIM measurements were done at the same lo-
cation using the same scanning parameters; sample orientation was
also kept the same.
4. The sample was then loaded again at the same stress amplitude and
tested until specimen failure, which was around 25,000 cycles.
Fig. 4(a) and (b) shows OIM micrographs taken before fatigue and
after 15,000 cycles, respectively. The same grain was circled in both
images for comparison. From the above test data analyses was per-
formed regarding grain size variation, grain boundary character
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International Journal of Fatigue 109 (2018) 1–9
variation, and local misorientation change. Fig. 4(c) and (d) shows a
variation in grain size and misorientation angle before fatigue testing
and after 15,000 cycles. The average grain size changed from
410 ± 280 nm to around 430 ± 350 nm after 15,000 cycles. The
above observation confirms that only minimal grain variation, if any
occurred during fatigue testing. The local grain coarsening during fa-
tigue, which is a characteristic feature of SPD processed material [16],
was not observed. Fig. 4(d) presents the variation in misorientation
before fatigue testing and after 15,000 cycles; clearly, the fraction of
HAGB was also quite high indicating that the microstructure was fully
recrystallized and stable. Although there was a minor variation in
misorientation angle after 15,000 cycles, the fraction of HAGB re-
mained almost the same even after 15,000 cycles.
In the present study, kernel average misorientation (KAM) analysis
has been used to qualitatively compare the microstructure before and
after fatigue (15,000 cycles). This approach is similar to the reports by
Ulacia et al. [26], Yi et al. [27], and Calcagnotto et al. [28], where KAM
values have been related to dislocation density. The objective is to
understand change in local misorientation as KAM analysis can be a
useful tool in quantifying the average misorientation around a point
with respect to a specified set of nearest or nearest and next-nearest
neighbor points (here 2nd nearest neighbor to reduce the noise). Data
above the predefined threshold value (2° for present study) are ex-
cluded from the calculation, since misorientations in the range of 2–15°
are assigned to subgrain boundaries. Fig. 5(a) and (b) shows the change
in KAM before and after 15,000 cycles, respectively. All the other
parameters such as step size, frame, and nearest neighbors in KAM
analysis were kept same. To ensure a more accurate comparison, the
color assigned to each orientation of grains in both micrographs was
also kept same.
The total fraction above 0.8° misorientation (i.e., from 0.8° to 2°
misorientation) increased from 0.40 to 0.46; and the fraction above 1.2°
almost doubled after 15,000 cycles. This certainly points towards in-
tragranular dislocation storage, and is an indication of excellent cyclic
stability. Note that the grains in UFG410 are higher than the critical
grain size for the intragranular storage [17].
To better understand the reason for this fatigue behavior, the S-N
curve in Fig. 3 was fitted with Basquin equation, Δσ = σf′·(2Nf)b, where
σf′ is the fatigue strength coefficient, which is the intercept of the S-N
curve, and b is the slope of S-N curve. To enable a better analysis and
more objective comparison, three more datum points from the work of
Vinogradov et al. [29] were considered. Fig. 6 shows the relationship
among these parameters with respect to grain size. Fig. 6(a) and (b)
shows fatigue strength coefficient (σf′) and fatigue strength (σ−1) as a
function of grain size. It can be seen that for the present study, both
fatigue strength coefficient (σf′) and fatigue strength (σ−1) decrease
S. Shukla et al. International Journal of Fatigue 109 (2018) 1–9

Fig. 4. (a) and (b) OIM micrographs of same location before fatigue and after 15,000 cycles, (c) grain size variation and (d) misorientation angle variation.

continuously with an increase in grain size. Since tensile strength with an increase in grain size. No such correlation can be noted in the
generally governs fatigue strength coefficient (σf′) and decreasing grain work of Vinogradov et al. [29]. Fatigue strength exponent (b) in
size increases tensile strength, a decrease in both σf′ and σ−1 is expected Fig. 6(c), which indicates the damage mechanism [30], follows almost

Fig. 5. KAM analysis for dislocation storage on

UFG410 sample tested at a stress level of 265 MPa,
(a) before fatigue and (b) after 15,000 cycles.

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S. Shukla et al.
Fig. 6. Illustration of fatigue parameters as a function of grain size. (a) Fatigue strength exponent and grain size, (b) fatigue strength coefficient and grain size, (c) fatigue strength and
grain size, (d) fatigue ratio and grain size. Al–4.5 Mg–0.2Sc–0.2Zr, Al–3 Mg–0.2Sc–0.18Zr, and Al–1.5 Mg–0.2Sc–0.2Zr data points have been taken from Vinogradov et al. [29].
the same trend as does the (σ−1/σUTS) fatigue ratio (Fig. 6(d)) with
respect to the grain size. For the present study, it can be seen that with
an increase in grain size, fatigue strength exponent (b) increases
slightly, while the datum points from Vinogradov el al. [29] don’t
follow this trend. We propose that the reason behind such observations
is the difference between the inherent mechanisms of grain refinement
during FSP. In the present work, the UFG microstructure was obtained
via FSP while ECAP was used to produce UFG microstructure in the
work of Vinogradov et al. [29]. UFG alloys produced by FSP technique
contain a high fraction of equilibrium high angle boundaries because of
dynamic recrystallization during FSP. Further, due to the high thermal
energy involved, the intra-granular dislocation density is lower [11,12].
The UFG microstructure produced via ECAP and other SPD techniques
contain high dislocation density within the subgrains [12] as the grain
refinement mechanism involves fragmentation of grains by creation of
dislocation substructure and subsequent conversion to high angle grain
boundaries. Also, worth noting is the high value of the fatigue ratio (b)
for FG condition microstructure. This can be correlated to excellent
damage tolerance ability of the fine grain material leading to a high
fatigue strength ratio value.
3.5. Fractography
Fractography was done to observe the features of fatigue deforma-
tion. Samples from all three conditions were examined under SEM to
determine the difference in various modes of crack propagation and
their rates. To conduct a more comprehensive analysis, stress value
with respect to UTS (i.e., normalized stress) was kept close to ∼0.7.
Fig. 7(a) is a macroscopic view of the fractured surface of UFG410 alloy
that was tested at 265 MPa. The arrows indicate the origin points of
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International Journal of Fatigue 109 (2018) 1–9
cracks or crack nucleation points. The macroscopic view of the frac-
tured surface has three distinct regions. Region 1 (Fig. 7(a)) was gen-
erally smooth at low magnification and included crack initiation points
as well as stage I of crack growth [31]. Features such as river mark or
beach marks as well as the orientation of fatigue striation are important
in identifying the crack initiation [33]. Fig. 7(b) is a higher magnifi-
cation image of the same region consisting of ridges and plateaus. In
this region, the crack grew mainly along crystallographic directions.
Region 2 is stage II of crack propagation and often resulted in crack-
arrest marks, also known as fatigue striations, on the fracture surface.
Such crack-arrest marks are generally the indication of crack front
position during this stage of propagation.
Region 3 was the overload or final failure zone that occurred by
void nucleation, coalescence and growth; and consisted of a combi-
nation of coarse and fine dimples. Fig. 7(c) shows stage II and stage
III of fatigue failure; while 7(d) shows the typical striation marks
indicating stage II of crack growth regime. The average distance
between striation marks was ∼1.8 μm to 2 μm. Williams et al. [32]
conducted experiments on AA7075-T6 alloy and concluded that in
stage II crack growth regime, the association between striation spa-
cing and crack growth rate in that striation spacing is generally
equivalent to the crack growth rate (da/dN). Apart from this, Pelloux
et al. [33], with their experiment on AA2124–T351, demonstrated
that each cycle imposes one striation and width typically in corre-
spondence with cycle amplitude. Wanhill and Hattenberg [34] and
Wanhill and Molent [35] have used these markings to determine the
crack growth rate in aircraft component. A recent review article by
Lynch [36] mentions that fatigue crack growth for intermediate ΔK
values, where the striations are > 10.1–0.2 μm, corresponds with
macroscopic crack growth.
S. Shukla et al. International Journal of Fatigue 109 (2018) 1–9

Fig. 7. SEM image of failed surface of Al5024

UFG410 alloy tested at 265 MPa. (a) Macroscopic
view of the fractured surface where crack initia-
tion sites have been indicated by arrows, (b) re-
gion 1 at high magnification indicating stable
crack growth region, (c) final fracture region 3
and adjacent fatigue striation of different spacing,
and (d) magnified view of fatigue striation.

Fig. 8(a) is the macroscopic view of fatigue failed surface of 5024 Al compared to AA2054 UFG410 alloy in Fig. 7(a), which indicates that
UFG210 alloy tested at 295 MPa. Fig. 8(a) reveals that in region 1, crack 5024 Al UFG210 alloy has slower crack propagation rate than 5024 Al
initiation and stable crack growth rate occupied more area fraction as UFG410 alloy. Mughrabi et al. [16] and Mughrabi [17] mentioned that

Fig. 8. SEM image of failed surface of Al5024

UFG210 alloy tested at 295 MPa. (a) Macroscopic
view of the fractured surface where crack initia-
tion sites have been indicated by arrows, (b) re-
gion 1 at high magnification indication stable
crack growth region, (c) final fracture region and
adjacent fatigue striation of different spacing and
(d) magnified view of fatigue striation.

7
S. Shukla et al.
Table 3
Summary of fractographic observations and conclusion.
Conditions Summary
UFG410 • Various crack initiation points were observed
• Crack initiation time was higher, while crack propagation time is
lower than the FG alloy
UFG210 • Stage I of crack growth occupies more area compared to the
same in both UFG and FG
• Crack initiation time is higher than UFG and FG alloys
410
410
FG • No clear distinction between fractographic surface of Stage I
and Stage II of crack propagation is evident
• Stage
UFG
II of crack propagation occurs very early as compared to
210 and UFG 410
resistance to crack initiation increases with decrease in the grain size.
This will also lead to higher crack resistance in UFG210. A high mag-
nification image of this region as presented in 8(b) was very similar to
Fig. 7(b), and denotes bimodal structure with ridges and plateaus.
Fig. 8(c), the higher magnification view of regions 2 and 3 combined,
consists of striation marks and final failure dimples. Fatigue striations
in 5024 Al UFG210 alloys were less prominent than 5024 Al UFG410
alloy (Fig. 7(c) and (d)). If plastic blunting/re-sharpening model for
striation formation by Laird [37] is considered, in ductile face-centered
cubic materials, duplex slip is the main criterion for striation formation.
Since decrease in grain size portends an increased difficulty of dis-
location movement leading to a smaller planar slip, striation formation
becomes less difficult [38].
Average striation spacing in 5024 Al UFG210 alloy close to 1.7 μm
and almost the same as 5024 Al UFG410 alloy implies that the crack
propagation rate is approximately similar in both alloys. All the above
observation indicated that UFG210 has a higher crack resistance than
UFG410. Fig. 9(a) shows the low magnification image of 5024 Al FG
failed sample tested at 135 MPa. The magnified view of region 1 is very
close to crack initiation, and faint striation marks can be observed in
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International Journal of Fatigue 109 (2018) 1–9
Fig. 9. SEM image of failed surface of Al5024 FG
alloy tested at 130 MPa (a) Macroscopic view of
the fractured surface where crack initiation sites
are indicated by arrows, (b) region 1 in high
magnification showing faint fatigue striation, (c)
high magnification view of clearly visible fatigue
striation and final overload region and (d) mag-
nified view of fatigue striation.
this region (Fig. 9(b)). Average distance between striations was around
1 μm (Fig. 9(d)).
The two observations above validated two important conclusions:
(i) stage II of crack propagation starts very early in 5024 Al FG alloy as
compared to the other two UFG alloys. (ii) Crack propagation rate is
considerably less in 5024 Al FG alloy as compared to UFG alloys. Slow
crack propagation rate combined with excellent properties of fine grain
microstructure enable the 5024 Al FG alloy to exhibit excellent fatigue
properties when compared to normalized stress vs life graph in
Fig. 5(b). The above fractographic conclusions are summarized in
Table 3.
4. Conclusions
In this study, two UFG and one fine grain microstructure of 5024 Al
alloy were investigated to understand fatigue properties. EBSD analysis
of interrupted specimen verified that no major grain coarsening took
place in 5024 Al UFG alloy, and the microstructure obtained was stable.
An increase in intragranular dislocation density using KAM analysis
indicated excellent cyclic stability. S-N curves for UFG410 and UFG210
revealed that within the UFG regime, UFG210 condition with smaller
grains has better fatigue properties on the basis of absolute stress levels;
while in normalized stress, UFG210 shows improvement in high cycle
fatigue region and UFG410 in low cyclic region. Basquin equation
parameter analysis of all the three microstructure along with data
points from literature points to the microstructure stability of FSP
material. Fractography study confirmed that crack initiation and stable
crack propagation rate increased with reduction in grain size; while fine
grain microstructure had excellent crack propagation properties,
making it comparable in normalized stress vs life curve.
Acknowledgment
The authors gratefully acknowledge the support of National Science
Foundation (NSF) through grant no 1435810. Authors also thank the
S. Shukla et al. International Journal of Fatigue 109 (2018) 1–9

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