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Fatigue Crack Prognostics by Optical Quantification of Defect Frequency

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Abstract

Defect frequency, a fatigue crack prognostics indicator, is defined as the number of microcracks per second detected using a laser beam that is scanned across a surface at a constant predetermined frequency. In the present article, a mechanistic approach was taken to develop a methodology for deducing crack length and crack growth information from defect frequency data generated from laser scanning measurements made on fatigued surfaces. The method was developed by considering a defect frequency vs fatigue cycle curve that comprised three regions: (i) a crack initiation regime of rising defect frequency, (ii) a plateau region of a relatively constant defect frequency, and (iii) a region of rapid rising defect frequency due to crack growth. Relations between defect frequency and fatigue cycle were developed for each of these three regions and utilized to deduce crack depth information from laser scanning data of 7075-T6 notched specimens. The proposed method was validated using experimental data of crack density and crack length data from the literature for a structural steel. The proposed approach was successful in predicting the length or depth of small fatigue cracks in notched 7075-T6 specimens and in smooth fatigue specimens of a structural steel.

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Acknowledgments

This material is based upon work supported by the contractors under Contract No. W31P4Q-09-C-0258 with MetroLaser Inc. (Irvine, CA) and through Subcontract SwRI02AM09 with SwRI and a subcontract with UC-Irvine. The views, opinions, and/or findings expressed are those of the author(s) and should not be interpreted as representing the official views or policies of the Department of Defense or the U.S. Government.

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Author notes

  1. B. D. Buckner

    Present address: Spectabit Optics LLC, Laguna Hills, CA, 92653, USA

Authors and Affiliations

  1. Southwest Research Institute, San Antonio, TX, 78238, USA

    K. S. Chan

  2. MetroLaser Inc, Laguna Hills, CA, 92653, USA

    B. D. Buckner

  3. Departments of Chemical Engineering & Materials Science and Biomedical Engineering, University of California, Irvine, CA, 92697, USA

    J. C. Earthman

Authors
  1. K. S. Chan
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Correspondence to K. S. Chan.

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Distribution A. Approved for public release: distribution unlimited.

Manuscript submitted June 12, 2017.

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Chan, K.S., Buckner, B.D. & Earthman, J.C. Fatigue Crack Prognostics by Optical Quantification of Defect Frequency. Metall Mater Trans A 49, 117–127 (2018). https://doi.org/10.1007/s11661-017-4393-2

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  • DOI: https://doi.org/10.1007/s11661-017-4393-2

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