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Cyclic Slip Irreversibilities and the Evolution of Fatigue Damage

  • 2008 Edward DeMille Campbell Memorial Lecture ASM International
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Abstract

In this article, the physical origin of fatigue crack initiation in ductile metals is discussed from a historical perspective. The main focus is to assess those cyclic slip irreversibilities in a microstructural sense that occur not only at the surface but also in the bulk at the dislocation scale and to show how they contribute to surface fatigue damage. The evolution of early fatigue damage, as evidenced experimentally in the last decades, is reviewed. The phenomenon of cyclic strain localization in persistent slip bands (PSBs) and models of the formation of extrusions, intrusions, and microcracks are discussed in detail. The predictions of these models are compared with experimental evidence obtained on mono- and polycrystalline face-centered-cubic (fcc) metals. In addition, examples of the evolution of fatigue damage in selected fcc solid solution alloys and precipitation-hardened alloys and in body-centered-cubic (bcc) metals are analyzed. Where possible, the cyclic slip irreversibilities p, defined as the fraction of plastic shear strain that is microstructurally irreversible, have been estimated quantitatively. Broadly speaking, p has been found to vary over orders of magnitude (0 < p < 1), being almost negligible at low loading amplitudes (high fatigue lives) and substantial at larger loading amplitudes (low fatigue lives).

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Acknowledgments

The author is grateful to his colleagues and the doctoral students who contributed over the years to the work reported here. In particular, he thanks his former colleagues, Klaus Differt and Uwe Essmann, Max-Planck-Institut für Metallforschung (Stuttgart), sincerely for many heated and fruitful discussions. The author has also benefited greatly from the very motivating and spirited discussions concerning PSBs with many of his colleagues, most notably with Mick Brown, Campbell Laird, Peter Neumann, Petr Lukáš, and Jaroslav Polák, and he wishes to express his gratitude and respect to these colleagues, friends and rivals of the past.

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  1. Department Werkstoffwissenschaften, Allgemeine Werkstoffeigenschaften, Universität Erlangen Nürnberg, 91058, Erlangen, Germany

    Hael Mughrabi (Professor Emeritus)

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  1. Hael Mughrabi
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Correspondence to Hael Mughrabi.

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Hael Mughrabi obtained his primary school education in Germany and subsequently attended different British schools in Jerusalem, Palestine, and in Cairo, Egypt, where he graduated from secondary school at The English School in 1955. He is a German citizen. After a three-year apprenticeship as a mechanic and toolmaker at Bosch GmbH Company in Stuttgart, he entered the Engineering University of Stuttgart to study physics. During his studies, in his doctoral thesis work and in his subsequent occupation as a senior researcher at the Max-Planck-Institute of Metal Research in Stuttgart (1966–1983), he specialized in metal physics and performed mainly research in the fields of crystal defects, mechanical properties, and microstructural characterization. He held a Visiting Professorship at Cornell University in 1978–1979. After receiving offers from three universities, he joined the University of Erlangen–Nürnberg in 1984 as a Professor of Materials Science and Engineering and Head of an Institute of General Materials Properties. In subsequent years, he held positions as Department Head and Dean of the School of Engineering. Since 2002, Hael Mughrabi has been formally retired but is still active in various forms in research and in committee work.

Hael Mughrabi has published almost 300 papers and book chapters and has been editor or co-editor of several books and conference proceedings, mainly in the fields of crystal plasticity, materials characterization, metal fatigue, high-temperature mechanical properties of nickel-base superalloys, and modeling of mechanical behavior. He has been active in the organization and chairing of many international conferences and has frequently been invited as a plenary or keynote speaker. Hael Mughrabi has been a member of TMS for 25 years and of a number of other professional societies, including the German Materials Society (Deutsche Gesellschaft für Materialkunde (DGM)). He has been a member of the Board of Directors of DGM and Chairman of the DGM Awards Committee PKII and has been elected an Honorary Member of DGM. Hael Mughrabi is the holder of an Honorary Doctoral degree from the Ruhr University Bochum and the recipient of several national and international awards, including the highest award of DGM, the Heyn–Denkmünze.

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Mughrabi, H. Cyclic Slip Irreversibilities and the Evolution of Fatigue Damage. Metall Mater Trans A 40, 1257–1279 (2009). https://doi.org/10.1007/s11661-009-9839-8

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