Directions of high cycle fatigue cracks emanating from circular notches studied by optical profilometry

Abstract

Current models for predicting the fatigue endurance of notched solids use the stresses along a straight line, beginning at the notch root, as a simplification of the real crack propagation path. In this work, the experimental crack paths for hollow notched samples were analysed through different microscopy techniques, with the objective of establishing high cycle fatigue crack growth directions in a mild steel. Fully reversed tension–compression fatigue tests of thin-walled tube specimens with a passing-through hole were carried out. The crack paths observed in the outer cylindrical surface were studied in each case, with special attention to the crack initiation point and the crack direction along the first grains. Moreover, the analysis of the fracture surfaces allowed the same analysis to be performed to determine the internal crack paths. It was observed that the crack initiation point was close to the maximum principal stress point at the hole contour as obtained from linear elastic finite element analysis, and the crack direction in its initiation was generally close to Mode I direction, contrary to the conventionally accepted 45 crack growth direction.