In materials science, fatigue is the initiation and propagation of cracks in a material due to cyclic loading. Once a fatigue crack has initiated, it grows a small amount with each loading cycle, typically producing striations on some parts of the fracture surface. The crack will continue to grow until it reaches a critical size, which occurs when the stress intensity factor of the crack exceeds the fracture toughness of the material, producing rapid propagation and typically complete fracture of the structure. Fatigue has traditionally been associated with the failure of metal components which led to the term metal fatigue. In the nineteenth century, the sudden failing of metal railway axles was thought to be caused by the metal crystallising because of the brittle appearance of the fracture surface, but this has since been disproved. Most materials, such as composites, plastics and ceramics, seem to experience some sort of fatigue-related failure. To aid in predicting the fatigue life of a component, fatigue tests are carried out using coupons to measure the rate of crack growth by applying constant amplitude cyclic loading and averaging the measured growth of a crack over thousands of cycles. There are also special cases that need to be considered where the rate of crack growth is significantly different compared to that obtained from constant amplitude testing, such as the reduced rate of growth that occurs for small loads near the threshold or after the application of an overload, and the increased rate of crack growth associated with short cracks or after the application of an underload. If the loads are above a certain threshold, microscopic cracks will begin to initiate at stress concentrations such as holes, persistent slip bands (PSBs), composite interfaces or grain boundaries in metals. The stress values that cause fatigue damage are typically much less than the yield strength of the material.
Stages of fatigue
Historically, fatigue has been separated into regions of high cycle fatigue that require more than 104 cycles to failure where stress is low and primarily elastic and low cycle fatigue where there is significant plasticity. Experiments have shown that low cycle fatigue is also crack growth. Fatigue failures, both for high and low cycles, all follow the same basic steps: crack initiation, crack growth stages I and II, and finally ultimate failure. To begin the process, cracks must nucleate within a material. This process can occur either at stress risers in metallic samples or at areas with a high void density in polymer samples. These cracks propagate slowly at first during stage I crack growth along crystallographic planes, where shear stresses are highest. Once the cracks reach a critical size they propagate quickly during stage II crack growth in a direction perpendicular to the applied force. These cracks can eventually lead to the ultimate failure of the material, often in a brittle catastrophic fashion.
Crack initiation The formation of initial cracks preceding fatigue failure is a separate process consisting of four discrete steps in metallic samples. The material will develop cell structures and harden in response to the applied load. This causes the amplitude of the applied stress to increase given the new restraints on strain. These newly formed cell structures will eventually break down with the formation of persistent slip bands (PSBs). Slip in the material is localized at these PSBs, and the exaggerated slip can now serve as a stress concentrator for a crack to form. Nucleation and growth of a crack to a detectable size accounts for most of the cracking process. It is for this reason that cyclic fatigue failures seem to occur so suddenly where the bulk of the changes in the material are not visible without destructive testing. Even in normally ductile materials, fatigue failures will resemble sudden brittle failures. PSB-induced slip planes result in intrusions and extrusions along the surface of a material, often occurring in pairs. This slip is not a microstructural change within the material, but rather a propagation of dislocations within the material. Instead of a smooth interface, the intrusions and extrusions will cause the surface of the material to resemble the edge of a deck of cards, where not all cards are perfectly aligned. Slip-induced intrusions and extrusions create extremely fine surface structures on the material. With surface structure size inversely related to stress concentration factors, PSB-induced surface slip can cause fractures to initiate. These steps can also be bypassed entirely if the cracks form at a pre-existing stress concentrator such as from an inclusion in the material or from a geometric stress concentrator caused by a sharp internal corner or fillet.
Crack growth
Most of the fatigue life is generally consumed in the crack growth phase. The rate of growth is primarily driven by the range of cyclic loading although additional factors such as mean stress, environment, overloads and underloads can also affect the rate of growth. Crack growth may stop if the loads are small enough to fall below a critical threshold. Fatigue cracks can grow from material or manufacturing defects from as small as 10 μm. When the rate of growth becomes large enough, fatigue striations can be seen on the fracture surface. Striations mark the position of the crack tip and the width of each striation represents the growth from one loading cycle. Striations are a result of plasticity at the crack tip. When the stress intensity exceeds a critical value known as the fracture toughness, unsustainable fast fracture will occur, usually by a process of microvoid coalescence. Prior to final fracture, the fracture surface may contain a mixture of areas of fatigue and fast fracture.
Acceleration and retardation The following effects change the rate of growth:
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