Investigation of subsurface fatigue crack growth behavior of D2 tool steel (JIS SKD11) based on a novel measurement method

•Two-step stress amplitude test can measure subsurface crack growth behaviors.•Fatigue life can be estimated by using a FCG law based on the subsurface behaviors.•Superposition of nominal and residual stress is effective for the FCG life estimation. In our preliminary study of the fatigue properties...

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Bibliographic Details
Published in:International journal of fatigue 2020-04, Vol.133, p.105395, Article 105395
Main Authors: Masuda, K., Oguma, N., Ishihara, S., McEvily, A.J.
Format: Article
Language:English
Subjects:
Compressive properties
Crack growth
Crack propagation
Fatigue
Fatigue cracks
Fatigue failure
Fracture mechanics
Materials fatigue
Nondestructive testing
Residual stress
Specimen preparation
Stress intensity factors
Subsurface crack
Surface layers
Tool steel
Tool steels
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Summary:•Two-step stress amplitude test can measure subsurface crack growth behaviors.•Fatigue life can be estimated by using a FCG law based on the subsurface behaviors.•Superposition of nominal and residual stress is effective for the FCG life estimation. In our preliminary study of the fatigue properties of D2 tool steel (JIS SKD11), it was found that owing to grinding in the specimen preparation process, high compressive residual stresses were introduced in the surface layers of the fatigue specimens, and as a result, the fatigue crack growth of the specimen was entirely subsurface. As relatively little is known about the subsurface growth of fatigue cracks, this finding gave us the opportunity to learn more about the subsurface fatigue crack growth process. An S–N curve covering fatigue lifetimes from 103 to 108 cycles was established for R = −1 loading condition. The velocity of fatigue crack growth as a function of the maximum stress intensity factor Kmax was determined to be in the range of 10−11–10−7 m/cycle. The Murakami √area method and a new experimental procedure were used to estimate the stress intensity factor and crack growth velocity under the specimen surface, respectively. An analytical equation for the velocity of crack growth as a function of the maximum stress intensity factor Kmax was developed, which agrees with the experimental results. The integration of this equation led to estimates of the fatigue lifetime for given stress ranges. These estimates were also in agreement with the experimental results.
ISSN:0142-1123
1879-3452
DOI:10.1016/j.ijfatigue.2019.105395