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Acta Metall Sin  2018, Vol. 54 Issue (11): 1693-1704    DOI: 10.11900/0412.1961.2018.00331
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Exploration on the Unified Model for Fatigue Properties Prediction of Metallic Materials
Zhefeng ZHANG(), Rui LIU, Zhenjun ZHANG, Yanzhong TIAN, Peng ZHANG
Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
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Abstract  

The fatigue of metallic materials can be divided into high-cycle fatigue (HCF) and low-cycle fatigue (LCF); the damage of these two types of fatigue is commonly evaluated through stress amplitude and strain amplitude of cyclic loading, respectively. The mismatch of the evaluation standards between HCF and LCF leads to difficulties in the design and selection of anti-fatigue materials. Under this condition, systematic researches on fatigue properties and microscopic damage mechanisms of HCF, LCF and extra-low-cycle fatigue (ELCF) for pure Cu and Cu-Al alloys were summarized in this work. On the bases of the experimental results, a three-dimensional fatigue model is proposed, which is simultaneously applicable to both the HCF and LCF properties. The model is built up in a three-dimensional coordinate system of stress amplitude-strain amplitude-fatigue life; it could be associated with the cyclic stress-strain (CSS) curve, S-N curve and E-N curve through the projection method, or be transformed into the Basquin equation, Coffin-Manson equation and hysteretic energy model under specific conditions. In this way, this generally applicable fatigue model helps provide a new viewpoint for the evaluation and optimization of fatigue properties based on the classical fatigue theories.

Key words:  metallic material      high-cycle fatigue      low-cycle fatigue      fatigue damage parameter      fatigue property prediction     
Received:  18 July 2018     
ZTFLH:  TG111.8  
Fund: Supported by National Natural Science Foundation of China (Nos.51331007, 51501198 and 51771208) and the Strategic Priority Research Program of Chinese Academy of Sciences (No.XDB22020202)

Cite this article: 

Zhefeng ZHANG, Rui LIU, Zhenjun ZHANG, Yanzhong TIAN, Peng ZHANG. Exploration on the Unified Model for Fatigue Properties Prediction of Metallic Materials. Acta Metall Sin, 2018, 54(11): 1693-1704.

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2018.00331     OR     https://www.ams.org.cn/EN/Y2018/V54/I11/1693

Fig.1  S-N curves of high-cycle fatigue (HCF) of coarse-grain (CG) materials (a), fine-grain (FG) materials (b), ultra-fine-grain (UFG) materials (c) and nano-grain (NG) materials (d) in pure Cu and Cu-Al alloys (ECAP—equal-channel angular pressing, HPT—high-pressure torsion, CR—cold-rolling, FSP—friction stir processing, Δσ/2—stress amplitude, Nf—cycles to failure)[12]
Fig.2  Low-cycle fatigue (LCF) properties of E-N curves (a) and S-N curves (b) for pure Cu and Cu-Al alloys (Δε/2—strain amplitude)[12]
Fig.3  Extra-low-cycle fatigue (ELCF) properties of pure Cu and Cu-Al alloys including stabilized cyclic stress-strain (CSS) hysteresis loops with Δε/2=6.0% (a), stabilized CSS hysteresis loops of Cu-8%Al alloy with various strain amplitudes (b), CSS curves (c), E-N curves (d), S-N curves (e) and W-N curves (f) (Wa—hysteresis energy)[12]
Fig.4  Microstructure evolution of pure Cu and Cu-Al alloys during fatigue tests[12]
(a1~a3) original states of CG, UFG and NG materials, respectively
(b1~b3) microstructures of Cu-5%Al, Cu-11%Al and Cu-15%Al after HCF tests, respectively
(c1~c3) microstructures of pure Cu, Cu-5%Al and Cu-11%Al after LCF tests, respectively
(d1~d3) microstructures of Cu-5%Al, Cu-8%Al and Cu-11%Al after ELCF tests, respectively
Fig.5  Construction and projection of the three-dimensional fatigue model including hysteresis loop planes, space curve and projected CSS curve (a), space curve and projected S-N curve (b), space curve and projected E-N curve (c) and space plane of the three-dimensional fatigue model, as well as the definition of energy-based evaluation criterion Wf (d)
Microstructure Material lg(σ0 / MPa) lg(ε0 / 106) lgNf0 lg(Wf / (MJm-3))
CG Cu 10.56 4.56 25.96 35.09
5Al 9.80 4.21 46.26 54.26
11Al 10.20 4.52 41.88 50.61
15Al 10.40 4.63 39.91 48.95
FG 5Al 9.94 4.69 44.70 53.33
11Al 9.89 4.85 57.12 65.87
15Al 10.61 5.02 56.96 66.60
UFG Cu 10.30 4.93 37.08 46.30
5Al 9.16 5.08 41.63 49.86
11Al 10.16 5.31 39.72 49.19
15Al 11.23 5.37 42.59 53.19
NG-CR 5Al-CR 11.43 5.48 32.64 43.54
NG-ECAP Cu-ECAP 11.94 5.60 22.31 33.86
5Al-ECAP 11.79 5.66 25.59 37.04
11Al-ECAP 11.69 5.81 27.15 38.65
NG-HPT Cu-HPT 12.27 5.76 20.76 32.79
5Al-HPT 12.48 5.97 22.82 35.26
15Al-HPT 12.28 6.08 23.86 36.22
Table 1  Typical values of parameters in the three-dimensional fatigue model for pure Cu and Cu-Al alloys
Fig.6  Validation and plane fitting of the three-dimensional fatigue model for pure Cu (a1, a2), Cu-5%Al (b1, b2) and Cu-11%Al (c1, c2) produced by ECAP from overall view (a1~c1) and partial view (a2~c2) (Data points in black for HCF properties, and data points in red for LCF properties)
Fig.7  Evaluation of fatigue properties based on the three-dimensional fatigue model including plots of Wf against Al contents (a), plots of Wf against grain sizes (b), plots of Wf against Al contents, with materials under different processes (c) and three-dimensional plots of Wf against Al contents and grain sizes (d)
Fig.8  Optimization of fatigue properties based on the three-dimensional fatigue model
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