Hostname: page-component-cd9895bd7-7cvxr Total loading time: 0 Render date: 2024-12-18T16:14:01.841Z Has data issue: false hasContentIssue false
  • English
  • Français

Ex and in situ investigations on the role of persistent slip bands and grain boundaries in fatigue crack initiation

Published online by Cambridge University Press:  05 September 2017

Heinz Werner Höppel ,
Philip Goik ,
Christian Krechel  and
Mathias Göken
Heinz Werner Höppel*
Affiliation:
Friedrich-Alexander-University Erlangen-Nürnberg FAU, Materials Science & Engineering, Institute I, Erlangen 91058, Germany; and Joint Institute for New Materials and Processes ZMP, Fürth 90762, Germany
Philip Goik
Affiliation:
Friedrich-Alexander-University Erlangen-Nürnberg FAU, Materials Science & Engineering, Institute I, Erlangen 91058, Germany; and Joint Institute for New Materials and Processes ZMP, Fürth 90762, Germany
Christian Krechel
Affiliation:
Friedrich-Alexander-University Erlangen-Nürnberg FAU, Materials Science & Engineering, Institute I, Erlangen 91058, Germany; and Joint Institute for New Materials and Processes ZMP, Fürth 90762, Germany
Mathias Göken
Affiliation:
Friedrich-Alexander-University Erlangen-Nürnberg FAU, Materials Science & Engineering, Institute I, Erlangen 91058, Germany; and Joint Institute for New Materials and Processes ZMP, Fürth 90762, Germany
*
a) Address all correspondence to this author. e-mail: hwe.hoeppel@fau.de
Get access

Abstract

Polycrystalline copper (99.9%) was fatigued at a total strain amplitude of 0.1 and 0.2%, respectively. The tests were performed in situ under vacuum in a Large Chamber-Scanning Electron Microscope. By a repeated combination of in situ fatigue testing and ex situ focused ion beam milling, a deep insight into the mechanism of fatigue crack initiation and early stages of crack initiation at persistent slip bands (PSBs) and their interaction with grain boundaries was obtained. The EBSD-technique showed early slip activation and the exclusive formation of extrusions in favorably oriented grains until a certain extrusion height was reached. At the total strain amplitude of 0.2%, extrusions are formed not only in favorably oriented grains but also in grains with a lower Schmid factor due to high compatibility stresses at the grain boundaries. Extrusion growth through grain boundaries is affected by the orientation of the primary slip systems in the neighboring grains and the additional anisotropy stresses. It is concluded that early stages of crack initiation are the consequence of the formation of extrusions at PSBs in combination with the clustering of vacancies along the PSB boundaries, as it was proposed by the well-known Essmann–Gösele–Mughrabi model.

Keywords

fatiguemicrostructureCu
Type
Review
Information
Journal of Materials Research , Volume 32 , Issue 23: Focus Issue: Mechanical Properties and Microstructure of Advanced Metallic Alloys—in Honor of Prof. Haël Mughrabi PART A , 14 December 2017 , pp. 4276 - 4286
Check for updates
Copyright
Copyright © Materials Research Society 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

b)

This author was an editor of this journal during the review and decision stage. For the JMR policy on review and publication of manuscripts authored by editors, please refer to http://www.mrs.org/editor-manuscripts/.

Contributing Editor: Lei Lu

This section of Journal of Materials Research is reserved for papers that are reviews of literature in a given area.

Dedicated to Prof. Dr. Haël Mughrabi on the occasion of his 80th birthday.

References

REFERENCES

Wöhler, A.: Über die Festigkeitsversuche mit Eisen und Stahl. Z. Bauwes. 20, 73 (1870).Google Scholar
Ewing, J.A. and Humphrey, J.C.: The fracture of metals under repeated alternation of stress. Philos. Trans. R. Soc. London 200, 321 (1903).Google Scholar
Forsyth, P.J.E.: Exudation of material from slip bands at the surface of fatigued crystals of an aluminum–copper alloy. Nature 171, 172 (1953).CrossRefGoogle Scholar
Manson, S.S.: Behavior of materials under conditions of thermal stress. NACA Rep. 1170, 1 (1954). (Supersedes NACA TN 2933 (1953)).Google Scholar
Coffin, L.F.: A study of the effects of cyclic thermal stresses on a ductile metal. Trans. ASME 76, 931 (1954).Google Scholar
Thompson, N., Wadsworthand, N., and Louat, N.: The origin of fatigue fracture in copper. Philos. Mag. 1–2, 113 (1956).CrossRefGoogle Scholar
Mughrabi, H.: Dislocations in fatigue. In Dislocations and Properties of Real Materials, Institute of Metals Vol. 323 (The Institute of Metals, London, 1985); p. 244.Google Scholar
Paris, P. and Erdogan, F.: A critical analysis of crack propagation laws. J. Basic Eng. 85, 528 (1963).CrossRefGoogle Scholar
Erdogan, F. and Sih, G.C.: On the crack extension in plates under plane loading and transverse shear. J. Basic Eng. 85, 519 (1963).CrossRefGoogle Scholar
Faber, K.T. and Evans, A.G.: Crack deflection processes—I. Theory. Acta Metall. 31, 565 (1983).CrossRefGoogle Scholar
Suresh, S. and Ritchie, R.O.: Geometric model for fatigue crack closure induced by fracture surface roughness. Metall. Trans. A 13, 1627 (1982).CrossRefGoogle Scholar
Tanaka, K., Nakai, Y., and Yamashita, M.: Fatigue growth threshold of small cracks. Int. J. Fract. 17, 519 (1981).CrossRefGoogle Scholar
Pippan, R., Zelger, C., Gach, E., Bichler, C., and Weinhandl, H.: On the mechanism of fatigue crack propagation in ductile metallic materials. Fatigue Fract. Eng. Mater. Struct. 34, 1 (2010).CrossRefGoogle Scholar
Lukáš, P., Klesnil, M., and Krejčí, J.: Dislocations and persistent slip bands in copper single crystals fatigued at low stress amplitude. Phys. Status Solidi B 27, 545 (1968).CrossRefGoogle Scholar
Lukáš, P. and Klesnil, M.: Dislocation structures in fatigued single crystals of Cu–Zn system. Phys. Status Solidi A 5, 247 (1971).CrossRefGoogle Scholar
Mughrabi, H.: The cyclic hardening and saturation behaviour of copper single crystals. Mater. Sci. Eng. 33, 207 (1978).CrossRefGoogle Scholar
Essmann, U., Gösele, U., and Mughrabi, H.: A model of extrusions and intrusions in fatigued metals I. Point-defect production and the growth of extrusions. Philos. Mag. A 44, 405 (1981).CrossRefGoogle Scholar
Feltner, C.E. and Laird, C.: The role of slip character in steady state cyclic stress–strain behavior. Trans. TMS-AIME 245, 1372 (1969).Google Scholar
Wang, R. and Mughrabi, H.: Cyclic deformation of face-centred polycrystals: A comparison with observations on single crystals. In Deformation of Polycrystals: Mechanisms and Microstructures: Proceedings of the 2nd Risø International Symposium on Metallurgy and Materials Science, Hansen, N. and Riso, D.K., eds. (1981); p. 87.Google Scholar
Wang, R., Mughrabi, H., McGovern, S., and Rapp, M.: Fatigue of copper single crystals in vacuum and in air I: Persistent slip bands and dislocation microstructures. Mater. Sci. Eng. 65, 219 (1984).CrossRefGoogle Scholar
Lukas, P. and Kunz, L.: Role of persistent slip bands in fatigue. Philos. Mag. 84(3–5), 317 (2004).CrossRefGoogle Scholar
Mughrabi, H., Ackermann, F., and Herz, K.: Fatigue mechanisms. In ASTM Special Technical Publication 675, Fong, J.T., ed. (ASTM, Philadelphia, 1978); p. 69.Google Scholar
Neumann, P.: Fatigue. In Physical Metallurgy, 3rd ed., Cahn, R.W. and Haasen, P., eds. (Elsevier, Amsterdam, 1983); part 2, p. 1554.Google Scholar
Basinski, Z.S. and Basinski, S.J.: Low amplitude fatigue of copper single crystals—II. Surface observations. Acta Metall. 33, 1307 (1985).CrossRefGoogle Scholar
Laird, C., Charsely, P., and Mughrabi, H.: Low energy dislocation structures produced by cyclic deformation. Mater. Sci. Eng. 81, 433 (1986).CrossRefGoogle Scholar
Bach, J., Möller, J.J., Göken, M., Bitzek, E., and Höppel, H.W.: On the transition from plastic deformation to crack initiation in the high- and very high-cycle fatigue regimes in plain carbon steels. Int. J. Fatigue 93, 281 (2016).CrossRefGoogle Scholar
Mughrabi, H., Bayerlein, M., and Wang, R.: Direct measurement of the rate of extrusion growth in fatigued copper mono- and polycrystals. In Proceedings of 9th International Conference on Strength of Materials ICSMA-9, Brandon, D.G., Chaim, R., and Rosen, A., eds. (Freund Publishing Company Ltd., London, 1991); p. 879.Google Scholar
Mughrabi, H.: Cyclic slip irreversibilities and the evolution of fatigue damage. Metall. Mater. Trans. A 40, 1257 (2009).CrossRefGoogle Scholar
Mughrabi, H.: Damage mechanisms and fatigue lives: From the low to the very high cycle fatigue regime. Procedia Eng. 55, 636 (2013).CrossRefGoogle Scholar
Man, J., Petrenec, M., Obrtlík, K., and Polak, J.: AFM and TEM study of cyclic slip localization in fatigued ferritic X10CrAl24 stainless steel. Acta Mater. 52, 5551 (2004).CrossRefGoogle Scholar
Wang, R. and Mughrabi, H.: Fatigue of copper single crystals in vacuum and in air II: Fatigue crack propagation. Mater. Sci. Eng. 65, 235 (1984).CrossRefGoogle Scholar
Neumann, P.: New experiments concerning the slip processes at propagating fatigue cracks. Acta Metall. 22, 1155 (1974).CrossRefGoogle Scholar
Dörr, G. and Blochwitz, C.: Microcracks in fatigued FCC polycrystals by interaction between persistent slip bands and grain boundaries. Cryst. Res. Technol. 22, 113 (1987).CrossRefGoogle Scholar
Neumann, P. and Tönnessen, A.: Crack initiation at grain boundaries in f.c.c. materials. In Strength of Metals and Alloys (ICSMA 8), Kettunen, P.O., Lepistö, T.K., and Lehtonen, M.E., eds. (Pergamon, Oxford, 1989); p. 743.CrossRefGoogle Scholar
Man, J., Vystavěl, T., Weidner, A., Kuběna, I., Petrenec, M., Kruml, T., and Polák, J.: Study of cyclic strain localization and fatigue crack initiation using FIB-technique. Int. J. Fatigue 39, 44 (2012).CrossRefGoogle Scholar
Tanaka, K. and Mura, T.: A dislocation model for fatigue crack initiation. J. Appl. Mech. 48, 97 (1981).CrossRefGoogle Scholar
Mura, T. and Nakasone, Y.: A theory of fatigue crack initiation in solids. J. Appl. Mech. 57, 1 (1990).CrossRefGoogle Scholar
Differt, K., Esmann, U., and Mughrabi, H.: A model of extrusions and intrusions in fatigued metals II. Surface roughening by random irreversible slip. Philos. Mag. A 54, 237 (1986).CrossRefGoogle Scholar
Polák, J.: On the role of point defects in fatigue crack initiation. Mater. Sci. Eng. 92, 71 (1987).CrossRefGoogle Scholar
Polák, J. and Man, J.: Fatigue crack initiation—The role of point defects. Int. J. Fatigue 65, 18 (2014).CrossRefGoogle Scholar
Stalling, D., Westerhoff, M., and Hege, H-C.: Amira: A highly interactive system for visual data analysis. In The Visualization Handbook, Hansen, C.D. and Johnson, C.R., eds. (Elsevier, Amsterdam, 2005); p. 749.CrossRefGoogle Scholar
Schmid, E. and Boas, W.: Plasticity of Crystals with Special Reference to Metals (Springer US, Halsted Press, New York, USA, 1968).Google Scholar
Polák, J., Man, J., Vystavěl, T., and Petrenec, M.: The shape of extrusions and intrusions and initiation of stage I fatigue cracks. Mater. Sci. Eng., A 517, 204 (2009).CrossRefGoogle Scholar
Weidner, A., Beyer, R., Blochwitz, C., Holste, C., Schwab, A., and Tirschler, W.: Slip activity of persistent slip bands in polycrystalline nickel. Mater. Sci. Eng., A 435–436, 540 (2006).CrossRefGoogle Scholar
Weidner, A. and Skrotzki, W.: Cyclic slip activity of PSBs in bulk and surface grains. Int. J. Fatigue 32, 851 (2010).CrossRefGoogle Scholar
Mughrabi, H. and Wang, R.: Cyclic stress–strain response and high-cycle fatigue behaviour of copper polycrystals. In Basic Mechanisms in Fatigue, Lukáš, P. and Polák, J., eds. (Academia/Elsevier, Amsterdam, 1988); p. 1.Google Scholar
Man, J., Klapetek, P., Man, O., Weidner, A., Obrtlík, K., and Polák, J.: Extrusions and intrusions in fatigued metals. Part 2. AFM and EBSD study of the early growth of extrusions and intrusions in 316L steel fatigued at room temperature. Philos. Mag. 89, 1337 (2009).CrossRefGoogle Scholar
Zauter, R., Petry, F., Bayerlein, M., Sommer, C., Christ, H.J., and Mughrabi, H.: Electron channelling contrast as a supplementary method for microstructural investigations in deformed metals. Philos. Mag. A 66, 425 (1992).CrossRefGoogle Scholar
Ahmed, J., Wilkinson, A.J., and Roberts, S.G.: Electron channeling contrast imaging characterization of dislocation structures associated with extrusion and intrusion systems and fatigue cracks in copper single crystals. Philos. Mag. A 81, 1473 (2001).CrossRefGoogle Scholar
Schwab, A., Bretschneider, J., Buque, C., Blochwitz, C., and Holste, C.: Application of electron channelling contrast to the investigation of strain localization effects in cyclically deformed fcc crystals. Philos. Mag. Lett. 74, 449 (1996).CrossRefGoogle Scholar
Weidner, A., Blochwitz, C., Skrotzki, W., and Tirschler, W.: Formation of slip steps and growth of extrusions within persistent slip bands in cyclically deformed polycrystals. Mater. Sci. Eng., A 479, 181 (2008).CrossRefGoogle Scholar
Mecke, K. and Blochwitz, C.: Internal displacements of persistent slip bands in cyclically deformed nickel single crystals. Phys. Status Solidi A 61, K5 (1980).CrossRefGoogle Scholar
Höppel, H.W., Zhou, Z.M., Mughrabi, H., and Valiev, R.Z.: Microstructural study of the parameters governing coarsening and cyclic softening in fatigued ultrafine-grained copper. Philos. Mag. A 82, 1781 (2002).CrossRefGoogle Scholar
Brown, L.M. and Ogin, S.L.: Role of internal stresses in the nucleation of fatigue cracks. In Fundamentals of Deformation and Fracture, Willis, J.R., Bilby, B.A., and Miller, K.J., eds. (Eshelby Memorial Symposium, Cambridge University Press, Cambridge, 1984); p. 501.Google Scholar
Brinckmann, S. and Van der Giessen, E.: A discrete dislocation dynamics study aiming at understanding fatigue crack initiation. Mater. Sci. Eng., A 387–389, 461 (2004).CrossRefGoogle Scholar
Polák, J.: Mechanisms and kinetics of the early fatigue damage in crystalline materials. Mater. Sci. Eng., A 468–470, 33–39 (2007).CrossRefGoogle Scholar
Heinz, A. and Neumann, P.: Crack initiation during high cycle fatigue of an austenitic steel. Acta Metall. Mater. 38, 1933 (1990).CrossRefGoogle Scholar
Li, L.L., Zhang, P., Zhang, Z.J., Zhou, H.F., Qu, S.X., Yang, J.B., and Zhang, Z.F.: Strain localization and fatigue cracking behaviors of Cu bicrystal with an inclined twin boundary. Acta Metall. Mater. 73, 167 (2014).CrossRefGoogle Scholar
Zhang, Z.J., Zhang, P., Li, L.L., and Zhang, Z.F.: Fatigue cracking at twin boundaries: Effects of crystallographic orientation and stacking fault energy. Acta Metall. Mater. 60, 3113 (2012).CrossRefGoogle Scholar