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IJSI
3,4 Fatigue life prediction of scratch
damaged shot peened components
R.A. Cláudio
396 Department of Mechanical Engineering, Instituto Politécnico de Setúbal,
Setúbal, Portugal and
ICEMS, Instituto Superior Técnico, UTL, Lisboa, Portugal
J.M. Silva
AeroG/LAETA – Aeronautics and Astronautics Research Center,
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Abstract
Purpose – This paper aims to present a methodology, based on traditional approaches, to predict the
fatigue life and non-propagating cracks of shot peened components and the damaging effect of a
scratch created over the treated surface.
Design/methodology/approach – The finite element method is used to determine the actual strain
at surface and fracture mechanics parameters calculated from cracks at the surface. The model
considers residual stress (in order to introduce the effect of shot peening) and the scratch geometry.
The total fatigue life is obtained by adding initiation life, to early and long crack propagation life using
appropriate criteria.
Findings – Numerical predictions were compared with previous experimental tests, showing that
this method is quite reliable for predicting both fatigue life and non-propagating cracks of shot peened
components, including the effect of damage due to a scratch.
Research limitations/implications – The proposed method provides good results and a clear
understanding of the fatigue process, however it requires a considerable amount of both material and
shot peening parameters.
Practical implications – The methodology presented in this paper allows the determination of
fatigue life and the prediction of non-propagating cracks for components, including the effects of shot
peening and scratch damage. These results can be used to quantify the scratch damage limits of
components improved by shot peening.
Originality/value – This paper provides a useful tool for prediction of the effects of shot peening
and scratch damage on fatigue life, using traditional approaches.
Keywords Shot peening, Scratch, Finite element method, Fracture mechanics, Strain-life,
Non-propagating cracks, Finite element analysis, Fracture, Strain measurement
Paper type Research paper
hundreds of microns depth, but enough to be quite effective. Both McClung (2007) and
Ivetic (2011) present an interesting work comparing different improvement techniques
evidencing some benefits of SP and typical residual stress profiles.
Some concern arises if the treated surface is damaged in some way, for example by a
scratch. Recent experimental work demonstrated that if a scratch is created over the
treated surface the benefit may be reduced or vanish completely (Cláudio et al., 2007).
Little work has been published about the simulation of a scratch in a compressive
residual stress field like that induced by SP. Benedetti et al. (2010) recently proposed an
approach based on the stress field state and on the characterization of the fatigue
properties of the material in different metallurgical states. However, this method
provides only an estimate of the fatigue life and does not give information about crack
propagation. Guagliano and Vergani (2004), proposed an approach to predict fatigue
strength of SP components by computing DKeff considering the residual stress profile
but it does not take into account neither the notch nor the scratch effect. The value of
DKeff, calculated using the finite element method, is compared with the actual fatigue
threshold value of the material to determine the improvement induced by SP. Cláudio et al.
(2010) presented another method, based on traditional approaches, i.e. fracture
mechanics and strain-life, which allows calculating the fatigue life of SP components.
In this case the strain at surface and DKeff are used in strain-life and fracture mechanics
models, respectively, to obtain crack initiation, early crack propagation and long crack
propagation lives. Apart from providing very good fatigue life predictions, this model
also allows determining crack arresting thus contributing to the understanding of the
fatigue process in SP components. In this paper, the model proposed by Cláudio et al.
(2010) to assess fatigue life of SP components is going to be adapted and applied to
scratch damaged surfaces in order to demonstrate that it still provides accurate fatigue
life predictions by comparing the numerical results with experimental observations.
398
(regimes II and III) is calculated by integrating the Paris law between a crack size as
defined by the El Haddad et al. (1979) constant a0 up to the critical limit of the material,
usually Kc. a0 is a material parameter which relates to a fracture mechanics parameter
according to:
DK th 2 1
a0 ¼ · ð1Þ
Y :Ds0 p
where DK th is the stress intensity factor threshold, Ds0 the plain specimen fatigue
strength range and Y a geometric parameter.
For cracks emerged in the residual stress field and influenced by the scratch
(regime II) J integral solutions are calculated close to the scratch root using a non-linear
finite element method accounting for the effect of the residual stress induced by the SP
and crack closure. In order to use the Paris law, J integral solutions are converted to
stress intensity (K) solutions assuming plain strain. In regime III, K solutions are used
without the effect of SP or scratch. As proposed by Dowling (1999) the transition crack
length, between regimes II and III, is determined when both K solutions are equal.
w P Figure 2.
Scratch Specimen details
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90° 90°
0.1
05
05
0.05
R0.
R0.
Notes: (a) 50mm depth, (b) 100mm depth, (c) 50mm depth 3D measurement; in (a) and Figure 3.
Scratch details
(b) the dimensions are in mm
the 50 mm scratch depth and Kt ¼ 5.03 for the 100 mm scratch depth (calculated by the
finite element method). The specimens were fatigue tested in a servo-hydraulic testing
machine, in load control, with a trapezoidal waveform 1-1-1-1s and load ratio of R ¼ 0.1
(this loading cycle is representative of a compressor disc operating under severe
conditions). Loads were selected so that failure could occur in the range of 1,000 to
100,000 cycles, which corresponds to a maximum nominal stress (MNS) over the critical
cross-section in the range of 700 up to 1,100 MPa. The experimental observations
indicated in the last column of Table II were calculated for several load levels by
interpolating (power fit) the experimental results that are published in Cláudio et al.
(2010).
Figure 4.
(a) 2D FE element model
with boundary conditions;
(b) mesh in the critical
y y section with scratches
x x
created to assess strain
Y and stress; (c) crack with
X
50 mm depth in the root of
a scratch with 50 mm
depth
(a) (b) (c)
2,000
1,500
1,000
Stress σxx [MPa]
500
0 Figure 5.
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Stress profile after the first
–500 t = 0 - Before Loading loading cycle with a MNS
t = 0.2, 0.4, 0.6 & 0.8 - Loading curves of 900 MPa in a scratched
–1000 t = 1.0...2.0 - Maximun Load surface treated with SP
t = 2.2, 2.4, 2.6 & 2.8 - Unloading Curves (trapezoidal waveform
t = 3.0…4.0 - Minimun Load 1-1-1-1s and load ratio of
–1500 R ¼ 0.1)
Depth [mm]
IJSI level and scratch size, the effect of residual stresses is still present. As it can be seen
3,4 in Figure 6, the effect of SP is only noticed in the mean stress, being the strain range
coincident for both SP and as machined conditions (AM). However, at the surface
(scratch root) the stress level (and strain) is almost the same with and without SP (notice
that strain life model only considers strain at surface).
The second model includes a very small crack in the root of the scratch with crack tip
402 elements collapsed with midside nodes moved to 1/4 position. The value of the J integral
solution converges after the third contour, and the fourth contour is selected to be
representative of the J integral. A master-slave surface was defined in the crack faces to
prevent overlapping when the crack closes, assuming a friction coefficient of 0.5. Figure 7
shows the DKeff solutions for a MNS of 900 MPa, the El Haddad et al. (1979) material
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3 1,500
Strain Range Stress AM NoSc
Stress SP NoSc Stress AM Sc50
2.5 Stress SP Sc50 Stress AM Sc100
Stress SP Sc100 1,000
σm [MPa]
∆ε [%]
500
Figure 6. 1.5
Strain range and mean
stress finite element
0
results for the geometry 1 Strain Range
without scratch, 50 mm Strain Range SP &AM Sc100µm
Strain Range
and 100 mm scratch depth SP & AM Sc50µm
SP & AM NoSc
for a maximum nominal 0.5 –500
stress of 900 MPa after 0 0.05 0.1 0.15 0.2
cyclic stabilization
Depth [mm]
50
a0 + 100 µm
AM NoSc SP NoSc
a0 + 50 µm
a0
AM Sc50 SP Sc50
40 AM Sc100 SP Sc100
∆Keff [MPa.m0.5]
30
20
10 ∆kth
Figure 7.
2D J integral solutions for
900 MPa MNS plotted 0
against crack size for the 0 0.05 0.1 0.15 0.2
surface AM and SP
Crack size a [mm]
constant is estimated as a0 ¼ 17.1pmm, based on an estimate of the stress intensity factor Fatigue life
threshold range DKth ¼ 6.6 MPa m, for similar materials. prediction
From Figure 7, for the SP surface, it is possible to note a strong closure
effect for crack sizes smaller than 0.07 mm. The SP effect becomes smaller for
larger crack sizes (outside the influence of the residual stresses due to SP). For the
geometries with scratch the curve follows exactly the values obtained for those
without damage, there being noticed only a very small (almost negligible) influence 403
of the scratch root. Only for a 100 mm scratch size, without SP, it is possible to observe
a small difference. In order to use crack propagation results obtained in terms of DK
for long cracks, J integral values were converted to K, considering plain strain
conditions.
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The third model is necessary for long crack propagation. As the influence of the
scratch and SP is almost negligible in fatigue life for large crack sizes, the model does
not include these effects. The geometry is 3D (Figure 2), representing 1/2 of the
specimen studied, meshed with hexahedral (brick) elements with 20 nodes (C3D20 in
ABAQUS code). As it can be observed in Figure 8, the elements were collapsed and
midside nodes moved to 1/4 position. The material model is linear elastic.
Equation (4) presents the K solutions for any crack size, aspect ratio and angular
position (under certain limits). The geometric parameter Y (equation (5)) was calculated
by the least squares method from the finite element results. The maximum
interpolation error is 2.8 per cent:
pffiffiffiffiffiffiffiffiffi
K ¼ Y ða=c; a=w; uÞ · s · p · a ð4Þ
where a is the crack depth, c half of the crack size at surface, w the distance from the
surface where the crack starts to the back face and Y the geometric factor which for the
washer specimen is given by:
Figure 8.
Crack region of the
3D finite element model
(1/2 geometry)
IJSI Y ða=c; a=w; uÞ ¼ 1:997 2 3:326 · a=c þ 5:609 · a=c 2
3,4 þ u · ð1:886 · 1023 2 4:859 · 1023 · a=c þ 2:914 · 1023 · a=c 2 Þ
þ u 2 · ð21:524 · 1024 þ 2:585 · 1024 · a=c 2 9:663 · 1025 · a=c 2 Þ
þ a=w · ð23:392 þ 3:292 · a=c 2 1:376 · a=c 2 Þ
404 þ u · ð5:150 · 1023 2 1:207 · 1022 · a=c 2 6:217 · 1023 · a=c 2 Þ
þ u 2 · ð2:956 · 1024 2 4:131 · 1024 · a=c þ 1:792 · 1024 · a=c 2 Þ ð5Þ
2 2
þ a=w · ð8:245 2 8:582 · a=c þ 3:925 · a=c Þ
þ u · ð7:112 · 1023 2 2:679 · 1022 · a=c þ 1:906 · 1022 · a=c 2 Þ
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Domain of validity:
0:25 # a=c # 1:0
0:25 # a=w # 0:6
0 # u # 908 for negative u values use absðuÞ
7. Discussion
Figure 9 and Table II show a very good correlation between the numerical results and
the experimental observations. Even for SP, predicted life is fairly accurate. The
maximum deviation is for the geometry with 50 mm scratch, where the expected
fatigue life ranges from one half to the double of that experimentally obtained.
According to the results of Table II, this deviation in fatigue life calculation seems to be
in regime II. The definition of a0 has an important influence in this region; however it is
not enough to justify this difference. The principal reason may be associated with some
Fatigue life
Scratch Total Experimental
Surface depth MNS Regime II Regime III predicted observations prediction
conditions (mm) (MPa) Regime I (cycles) (cycles) (cycles) (cycles) (cycles)
Figure 9.
Numerical predictions
against experimental
results
assumptions that were made to obtain the J integral (modelling such a small crack
and notch, conversions to K solutions and not including stress relaxation and residual
stresses due to the scratch creation). Apart from these assumptions, the results
obtained are quite good for fatigue life predictions, even for the 50 mm scratch size.
Analysing the results of Table II, and according to this model, the SP effect is quite
notable in short crack propagation (having almost one order of magnitude increase in
IJSI fatigue life) and has almost no influence on crack initiation and long crack propagation.
3,4 In fact, cyclic relaxation almost eliminates the SP effect at the surface as it can be seen
in the strain range and mean stress results of Figure 6. This is in agreement with the
conclusions of other authors, such as Song and Wen (1999) and Guagliano et al. (2004),
who argue that the superior fatigue resistance of SP components is due to the ability of
the residual stress in stopping microcrack propagation and less in preventing fatigue
406 crack initiation.
As published by Cláudio et al. (2009) many shot peened specimens that were fatigue
tested did not fail after a large number of cycles, and multi-cracks were found that started
at the scratch root and stopped after some tens of microns. These non-propagating
cracks can be successfully predicted by determining the load at which DKeff # DKth at
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the El Haddad et al. (1979) a0 length from results of Figure 7. As can be seen in
Cláudio et al. (2009) the predictions are very good, showing that the same finite element
results can be used for fatigue life and crack arrest predictions.
8. Conclusions
A fatigue life prediction model, based on traditional approaches (strain-life method and
fracture mechanics), was provided in order to predict fatigue life of scratch damaged
shot peened components. According to this method, fatigue life prediction is made in
three different regimes: crack initiation, early crack propagation and long crack
propagation. Three finite element models were built, one for each regime, in order to
provide the parameters necessary for the fatigue life prediction model.
Based on the outcomes of this work, the following conclusions were formed:
.
As a contribution to safe life prediction in design, fatigue life was successfully
predicted for the specimens studied, both SP and scratched, using properties
taken from plain specimens including: material parameters, LCF results, crack
propagation data and information about the residual stress profile due to SP.
.
By summing the fatigue life in crack initiation with early crack propagation and
long crack propagation, the model proposed provides a detailed understanding
of the fatigue crack growth in SP components.
.
According to numerical results and other published research, SP seems to have a
limited effect on crack initiation, especially for scratched geometries.
. Compressive residual stress seems to play the most important role in extending
fatigue life, since accurate life predictions were numerically obtained using only
the compressive residual stress field.
.
Non-propagating cracks, which are usually found in shot peened components
that do not fail after a large number of cycles, can be predicted for scratch
damaged SP components by determining the load at which DKeff # DKth at the
El Haddad et al. (1979) a0 length.
References
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peened high-strength aluminium alloys: Experiments and predictions using a critical
distance method”, International Journal of Fatigue, Vol. 32, pp. 1600-11.
Buchanan, D.J., Shepard, M.J. and John, R. (2011), “Retained residual stress profiles in a laser Fatigue life
shock-peened and shot-peened nickel base superalloy subject to thermal exposure”,
International Journal of Structural Integrity, Vol. 2 No. 1, pp. 34-41.
prediction
Cameron, A.D. and Smith, R.A. (1982), “Fatigue life prediction for notched members”,
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Cláudio, R.A., Branco, C.M. and Byrne, J. (2007), “Fatigue behaviour of scratch damaged shot
peened specimens at elevated temperature”, Proceedings of the International Conference on 407
Experimental Mechanics 13, Alexandoupolis, Greece.
Cláudio, R.A., Burgess, A., Branco, C.M. and Byrne, J. (2009), “Failure analysis of scratch
damaged shot peened simulated components”, Engineering Failure Analysis, Vol. 16,
pp. 1208-20.
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Cláudio, R.A., Silva, J.M., Branco, C.M. and Byrne, J. (2010), “The ability of current models for
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Deformation, Fracture, and Fatigue, 2nd ed., Prentice-Hall, Upper Saddle River, NJ.
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Silva, J.M., Cláudio, R.A., Sousa e Brito, A., Branco, C.M. and Byrne, J. (2006),
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generation Ni-base superalloy for aeroengine usage”, Procedia Engineering, Vol. 2,
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Fatigue, Vol. 26, pp. 829-37.
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PhD thesis, University of Portsmouth.
IJSI Further reading
3,4 Sherratt, F. (1993), “The rational basis of the peening process”, in Marsh, K.J. (Ed.), Shot Peening:
Techniques and Applications, EMAS, London.
Zhao, L.G., Tong, J., Vermeulen, B. and Byrne, J. (2001), “On the uniaxial mechanical behaviour of
an advanced nickel base superalloy at high temperature”, Mechanics of Materials, Vol. 33,
pp. 593-600.
408
Corresponding author
R.A. Cláudio can be contacted at: ricardo.claudio@estsetubal.ips.pt
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