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Corrosion Fatigue Crack Growth Behavior at Notched Hole in 7075-T6 Under Biaxial and Uniaxial Fatigue with Different Phases Ali Khawagi

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Corrosion Fatigue Crack Growth Behavior at Notched Hole in 7075-T6 Under Biaxial and Uniaxial Fatigue with Different Phases Ali Khawagi Air Force Institute of Technology AFIT Scholar Theses and Dissertations Student Graduate Works 8-17-2015 Corrosion Fatigue Crack Growth Behavior at Notched Hole in 7075-T6 Under Biaxial And Uniaxial Fatigue with Different Phases Ali Khawagi Follow this and additional works at: https://scholar.afit.edu/etd Part of the Materials Science and Engineering Commons Recommended Citation Khawagi, Ali, "Corrosion Fatigue Crack Growth Behavior at Notched Hole in 7075-T6 Under Biaxial And Uniaxial Fatigue with Different Phases" (2015). Theses and Dissertations. 1930. https://scholar.afit.edu/etd/1930 This Thesis is brought to you for free and open access by the Student Graduate Works at AFIT Scholar. It has been accepted for inclusion in Theses and Dissertations by an authorized administrator of AFIT Scholar. For more information, please contact [email protected]. CORROSION FATIGUE CRACK GROWTH BEHAVIOR AT NOTCHED HOLE IN 7075-T6 UNDER BIAXIAL AND UNIAXIAL FATIGUE WITH DIFFERENT PHASES THESIS Khawagi, Ali Captain, Royal Saudi Air Force, RSAF August 2015 DEPARTMENT OF THE AIR FORCE AIR UNIVERSITY AIR FORCE INSTITUTE OF TECHNOLOGY Wright-Patterson Air Force Base, Ohio DISTRIBUTION STATEMENT A APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED AFIT-ENY-MS-15-S-065 CORROSION FATIGUE CRACK GROWTH BEHAVIOR AT NOTCHED HOLE IN 7075-T6 UNDER BIAXIAL AND UNIAXIAL FATIGUE WITH DIFFERENT PHASES THESIS Presented to the Faculty Department of Aeronautics and Astronautics Graduate School of Engineering and Management Air Force Institute of Technology Air University Air Education and Training Command In Partial Fulfillment of the Requirements for the Degree of Master of Science in Materials Science Khawagi, Ali Captain, Royal Saudi Air Force, RSAF Aug 2015 DISTRIBUTION STATEMENT A APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED AFIT-ENY-MS-15-S-065 CORROSION FATIGUE CRACK GROWTH BEHAVIOR AT NOTCHED HOLE IN 7075-T6 UNDER BIAXIAL AND UNIAXIAL FATIGUE WITH DIFFERENT PHASES Khawagi, Ali Captain, Royal Saudi Air Force, RSAF Cummitte Members: Dr. Shankar Mall, PhD (Chair) Dr. Victor Perel, PhD (Member) Dr. Heath Misak, PhD (Member) Abstract This research investigates fatigue crack propagation behavior in both air and saltwater (3.5% NaCl) environments from pre-cracked notched circular hole in a 7075-T6 cruciform specimen. With stress ratio of 0.5, biaxility stress ratio of unity, and frequency of applied load of 10 Hz, the crack growth behavior was investigated under in-plane biaxial tension-tension fatigue with 45⁰, 90⁰ and 180⁰ phase difference conditions and then compared to previous fatigue tests with no phase difference to study the effect of changing the phase differences between the applied loads on the crack growth rate. Finite Element Analysis (FEA) was used to calculate cyclic variation of stress intensity factors (∆K) at the crack tips. The crack growth rate was observed using optical microscopy. This study shows that in the biaxial fatigue tests with phase difference of 45⁰, 90⁰ and 180⁰, two fatigue cracks were shaped, symmetrical in case of 90° and 180°, while it’s unsymmetrical for 45 phase difference case. For each phase difference and at a given average crack growth rate,⁰ the strain energy release rate of the non-split crack is equivalent to the sum of strain energy release rates of the two split cracks. In the saltwater environment, the corrosion accelerates the crack growth rate. iv Acknowledgments First, I would like to thank my advisor, Dr. Shankar Mall, for giving me the opportunity to work on this project. I appreciate his technical insights, guidance, and dedication to his students. Also, I would like to thank Dr. Victor Perel for taking the time to show me how to properly prepare specimens and execute corrosion fatigue experiments, and his help in developing the finite element models by using Abaqus program. I would like to thank my parents for their love and prayers for me, and most importantly, I would like to thank my wife for her support, encouragement, quiet patience. Her unwavering love that was undeniably the foundation upon which the past ten years of my life has been built. Her tolerance of my occasional bad moods is a testament in itself of her unbending loyalty and loves. Khawagi, Ali v Table of Contents Page Abstract .............................................................................................................................. iv Acknowledgments................................................................................................................v List of Tables ................................................................................................................... xix List of Symbols ..................................................................................................................xx I. Introduction ......................................................................................................................1 1.1 Corrosion ................................................................................................................1 1.2 Corrosion Fatigue ...................................................................................................3 1.3 Biaxial Corrosion Fatigue.......................................................................................4 1.4 Problem Statement..................................................................................................5 II. Background .....................................................................................................................8 2.1 Fatigue ....................................................................................................................8 2.2 Corrosion Fatigue ...................................................................................................9 2.3 Effect of Corrosion on Fatigue Life .....................................................................11 2.4 Fracture Mechanics ..............................................................................................13 2.4.1 Stress Intensity Factors for a Crack Originating From a Circular Hole in Thin Plate under Biaxial Loading .....................................................................15 2.4.2 Stress Transformation Formulas In Case Of Plane Stress .......................17 2.4.3 Global and Local Coordinate Systems .....................................................19 2.4.4 Direction of Crack Propagation ...............................................................23 2.5 Previous Research ................................................................................................26 2.6 Why This Thesis? .................................................................................................31 III. Methodology ................................................................................................................32 3.1 Material.................................................................................................................32 vi 3.2 Test Specimens .....................................................................................................34 3.3 Test Procedures ....................................................................................................36 3.4 Finite Element Modeling ......................................................................................37 IV. Results and Discussion ................................................................................................40 4.1 Overview ..............................................................................................................40 4.2 Crack Path ............................................................................................................41 4.2.1 Crack Path of Uniaxial and Biaxial Specimens without Phase Difference in Air and Saltwater Environments ...................................................................41 4.2.2 Crack Path of Biaxial Specimens with Phase Differences .......................43 4.2.2.1 Crack Path of Biaxial Specimens with 45⁰ Phase Difference in Air and Saltwater Environments ....................................................................................43 4.2.2.1 Crack Path of Biaxial Specimens with 90⁰ Phase Difference in Air and Saltwater Environments ....................................................................................53 4.2.2.1 Crack Path of Biaxial Specimens with 180⁰ Phase Difference in Air and Saltwater Environments .............................................................................57 4.3 Crack Growth Rate ...............................................................................................62 4.3.1 Crack Growth Rate of Uniaxial and Biaxial Specimens without Phase Difference in Air and Saltwater Environments .................................................63 4.3.2 Crack Growth Rate of Biaxial Specimens with 45° Phase Difference in Air and Saltwater Environments .......................................................................65 4.3.3 Crack Growth Rate of Biaxial Specimens with 90° Phase Difference in Air and Saltwater Environments .......................................................................70 4.3.2 Crack Growth Rate of Biaxial Specimens with 180° Phase Difference in Air and Saltwater Environments .......................................................................73 4.3.2 Crack Growth Rate of All Specimens with and without Phase Difference in Air and Saltwater Environments ...................................................................76
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