Corrosion Fatigue - Crack-propagation Studies in Corrosion Fatigue

Crack-propagation Studies in Corrosion Fatigue

In normal fatigue-testing of smooth specimens, about 90 percent is spent in crack nucleation and only the remaining 10 percent in crack propagation. However, in corrosion fatigue crack nucleation is facilitated by corrosion; typically, about 10 percent of life is sufficient for this stage. The rest (90 percent) of life is spent in crack propagation. Thus, it is more useful to evaluate crack-propagation behavior during corrosion fatigue. Fracture mechanics uses pre-cracked specimens, effectively measuring crack-propagation behavior. For this reason, emphasis is given to crack-propagation velocity measurements (using fracture mechanics) to study corrosion fatigue. Since fatigue crack grows in a stable fashion below the critical stress-intensity factor for fracture (fracture toughness), the process is called sub-critical crack growth. The diagram on the right shows typical fatigue-crack-growth behavior.

In this log-log plot, the crack-propagation velocity is plotted against the applied stress-intensity range. Generally there is a threshold stress-intensity range, below which crack-propagation velocity is insignificant. Three stages may be visualized in this plot. Near the threshold, crack-propagation velocity increases with increasing stress-intensity range. In the second region, the curve is nearly linear and follows Paris' law(6); in the third region crack-propagation velocity increases rapidly, with the stress-intensity range leading to fracture at the fracture-toughness value. Crack propagation under corrosion fatigue may be classified as a) true corrosion fatigue, b) stress corrosion fatigue or c) a combination of true, stress and corrosion fatigue.