The study of the effect of overload-induced residual stresses on fatigue
crack growth considering residual stress relaxation
Abstract
A numerical and experimental study was conducted on fatigue crack growth
(FCG) of metallic components to investigate the effect of redistribution
of mechanical residual stresses induced by single overloading during FCG
on the fatigue life of notched specimens. For this purpose, the compact
tension specimens of an aluminium alloy were used. In addition,
mechanical residual stresses were introduced near the crack tip by
applying tensile overload (OL), followed by fatigue loading of the
specimens. In the numerical simulation, the modified cyclic J-integral
was used as the crack growth fracture parameter and a good agreement was
observed between the numerical and experimental results. The results of
the finite element method demonstrated a clear redistribution of
mechanical residual stresses and so the variation of the overload
plastic zone size during FCG. After a few cycles, the residual stress
field around the crack tip reached a lower magnitude value confined in a
smaller zone, although this zone was stable during the remaining fatigue
process. Finally, the present study evaluated the effects of stress
ratio, load amplitude, and overload ratio on the redistribution of
residual stresses and the size of the plastic zone around the crack tip.
It was observed that the residual stresses are mainly released during
the first steps of fatigue loading.