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A Probabilistic Model of Fatigue Strength Controlled by Porosity Population in a 319-Type Cast Aluminum Alloy: Part I. Model Development

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Abstract

The very high-cycle fatigue behavior of a 319-type cast aluminum alloy was investigated using ultrasonic fatigue instrumentation operating at 20 kHz. An endurance limit was demonstrated in the lifetime regime beyond 107 cycles. Accordingly, the fatigue strength at 108 cycles was determined using the staircase test method. Large pores at or close to the specimen surface or in the specimen interior were responsible for crack initiation in all specimens, and the staircase results were associated with both size and location of the initiating pores through a critical stress intensity factor for fatigue crack growth. Based on the experimental observations, a probabilistic model was developed to establish the relationship between the porosity population and the fatigue strength of the alloy. Good agreement was obtained between the modeling results and experiments.

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Acknowledgments

Financial support provided by the United States National Science Foundation (Grant No. DMR 0211067) and Ford Motor Company is gratefully acknowledged. The authors thank Dr. J. Zindel and L. Godlewski for their assistance with the casting of the materials; Christopher J. Torbet for his technical assistance; and Charles Annis, P.E., for comments on probabilistic modeling.

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Authors and Affiliations

  1. Department of Materials Science & Engineering, University of Michigan, Ann Arbor, MI, 48109, USA

    X. Zhu (Postdoctoral Student), J.Z. Yi (Research Fellow) & J.W. Jones (Professor)

  2. Ford Motor Company, Dearborn, MI, 48124, USA

    J.E. Allison (Senior Technical Leader)

Authors
  1. X. Zhu
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  2. J.Z. Yi
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  3. J.W. Jones
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  4. J.E. Allison
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Corresponding author

Correspondence to J.Z. Yi.

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Manuscript submitted: May 31, 2006.

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Zhu, X., Yi, J., Jones, J. et al. A Probabilistic Model of Fatigue Strength Controlled by Porosity Population in a 319-Type Cast Aluminum Alloy: Part I. Model Development. Metall Mater Trans A 38, 1111–1122 (2007). https://doi.org/10.1007/s11661-006-9070-9

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