materials
Article Fatigue Life for Different Stress Concentration Factors for Stainless Steel 1.4301
Przemysław Strzelecki 1,* , Adam Mazurkiewicz 1, Janusz Musiał 1, Tomasz Tomaszewski 1 and Małgorzata Słomion 2
1 Mechanical Engineering Department, University of Science and Technology, Kaliskiego 7 Street, 85-789 Bydgoszcz, Poland; [email protected] (A.M.); [email protected] (J.M.); [email protected] (T.T.) 2 Faculty of Management, University of Science and Technology, Kaliskiego 7 Street, 85-789 Bydgoszcz, Poland; [email protected] * Correspondence: [email protected]; Tel.: +48-52-340-86-72
Received: 26 September 2019; Accepted: 5 November 2019; Published: 8 November 2019
Abstract: This paper presents the results of the static tensile and fatigue life tests under rotating bending of round 1.4301 (AISI 304) steel samples. The fatigue tests were carried out on smooth and notched samples with three different rounding angles with a shape factor of 1.4, 2 and 2.6. A fatigue life was determined for samples with different shape factors subject to identical loads. The results showed that the scatter of fatigue test results decreases with an increase in shape factor. To evaluate the cracking properties (cracking mode and mechanism), microstructure and fractographic tests of the fractured samples were carried out.
Keywords: fatigue design; S–N curve; high-cycle fatigue; stainless steel
1. Introduction The use of stainless steel in engineering has grown significantly in recent years. In 2018, the use of stainless steel in the industry has grown over 60% compared to 2010 [1], estimated at 50.7 Mt [2]. Due to the common use of this material in engineering, tests to evaluate its structure and properties are crucial. As a result, several articles on its properties have been published [3–7]. Since the material is often used in mechanical engineering, evaluation of its basic mechanical properties, including tensile strength and fatigue life, is crucial. To determine the fatigue life of a material, an S–N curve (stress vs. number of cycles) is often determined for the smooth samples and a stress concentration factor is calculated to correct the results for a specific structural component [8]. S–N curves can be determined by different models, the comparison of which is presented in [9–11]. The last square method is the most simple and commonly used method to estimate model parameters and it is presented in standard [12] and [13]. Other methods, such as the maximum likelihood method [14–16] and bootstrap method [17], are also used. Recently, a new method to calculate the fatigue strength for different geometries was presented by Ai et al. [9]. Some of the authors also conducted tests with stepwise increasing amplitude [18]. To increase the reliability of the estimated fatigue life, a reliability factor is also determined depending on the required probability of failure [8,12,19]. The procedure assumes a constant scatter of results for each geometry of the tested component; however, no such relation was shown by the researchers. A study [20] (pp. 377–380) by Schijve presents the tests carried out on two structural components in which the fatigue life at 50% failure probability was 8.5 times higher for two different components. For the same components, at the failure probability of 1%, the difference in fatigue life was 2.3 times.
Materials 2019, 12, 3677; doi:10.3390/ma12223677 www.mdpi.com/journal/materials Materials 2019, 12, 3677 2 of 9
The study aimed to verify whether the scatter of fatigue test results varies depending on the stress concentration factor. The 1.4301 stainless steel samples, a material commonly used in mechanical engineering, were used as a test material. The test results showed that the scatter of fatigue life depends on the geometry of the components.
2. Materials and Methods Austenitic 1.4301 (AISI 304) stainless steel was used in the tests [2]. The chemical composition of steel was measured by using a spectrometer, the Oxford Instrument Foundry-Master UV (Oxford Materials 2019, 12, x FOR PEER REVIEW 2 of 9 Instrument, Abingdon, UK), which fulfils the standard requirements [21] and is shown in Table1. The samples were made from a 10 mm drawn bar in a raw state, with the dimensions consistent with mechanical engineering, were used as a test material. The test results showed that the scatter of the standard requirements [22]. The drawing was made at room temperature. The smooth samples for fatigue life depends on the geometry of the components. fatigue tests were prepared in accordance with Figure1a, and the notched samples were prepared in 2.accordance Materials withand Methods Figure1b with the dimensions specified in Table2.
AusteniticTable 1. Chemical 1.4301 (AISI composition 304) stainless of austenitic steel was steel used 1.4301 in the (X5CrNi18-10) tests [2]. The accordingchemical composition to [21] and of steel wasmeasured measured value. by using a spectrometer, the Oxford Instrument Foundry-Master UV (Oxford Instrument, Abingdon, UK), which fulfils the standard requirements [21] and is shown in Table 1. % by Mass The samples were made from a 10 mm drawn bar in a raw state, with the dimensions consistent with the standard requirementsItem [22]. The drawing C was Si made Mn at room P temperature. S Cr The smooth Ni samples for fatigueStandard tests were requirements prepared [in21 accordance] 0.07 with1.00 Figure2.00 1a, and0.045 the notched0.015 17.5–19.5 samples 8.0–10.5were prepared ≤ ≤ ≤ ≤ ≤ in accordance withMeasured Figure value 1b with the dimensions 0.05 0.75 specified 1.56 in 0.043 Table 0.0102. 18.1 9.7
(a) (b)
FigureFigure 1. 1. GeometryGeometry of of the the specimen specimen for for fatigue fatigue testing testing ( (aa)) Smooth; Smooth; ( (bb)) Notched. Notched.
Table 2. Dimensions of the notched specimens. Table 1. Chemical composition of austenitic steel 1.4301 (X5CrNi18-10) according to [21] and
measured value. No. r [mm] Kt [-] 1% by 1.5 Mass 1.4 Item C 2Si 0.5Mn P 2 S Cr Ni Standard requirements [21] ≤0.073 ≤1.00 0.25≤2.00 ≤0.045 2.6 ≤0.015 17.5–19.5 8.0–10.5 Measured value 0.05 0.75 1.56 0.043 0.010 18.1 9.7 A static tension test was carried out on an Instron 8874 testing machine in accordance with the standard requirements [23]. TheTable strain 2. Dimensions rate was 0.0198of the notched mm/s, whichspecimens. is similar to that presented in [24].
A rotating bending machine described inNo. [25 ]r was[mm] used Kt in[-] the fatigue tests. Figure2 shows the test stand diagram. On one side, the sample was1 attached1.5 to the1.4 test stand shaft via a clamp and on the other 1 side a bearing with a load m was mounted.2 The shaft0.5 speed 2 Mo was 3000 min− at a loading frequency of 50 Hz. The bending moment Mg was equal3 to0.25 the load2.6m suspended on the bearing multiplied by the distance between the bearing center and the point of minimum cross-section l, which was 46 mm. A loadA static weighing tension between test was 5 kgcarried and 13.8out kgon wasan Inst applied.ron 8874 A rotatingtesting machine bending in test accordance was carried with out the in standardaccordance requirements with the standard [23]. The procedure strain rate [26 ].was The 0.0198 measuring mm/s, accuracy which is was similar 1.15% to withthat presented a permissible in [24].accuracy A rotating of 1.3% bending [26]. machine described in [25] was used in the fatigue tests. Figure 2 shows the test stand diagram. On one side, the sample was attached to the test stand shaft via a clamp and on the other side a bearing with a load m was mounted. The shaft speed Mo was 3000 min−1 at a loading frequency of 50 Hz. The bending moment Mg was equal to the load m suspended on the bearing multiplied by the distance between the bearing center and the point of minimum cross-section l, which was 46 mm. A load weighing between 5 kg and 13.8 kg was applied. A rotating bending test was carried out in accordance with the standard procedure [26]. The measuring accuracy was 1.15% with a permissible accuracy of 1.3% [26].
Materials 2019, 12, 3677 3 of 9 Materials 2019, 12, x FOR PEER REVIEW 3 of 9
Materials 2019, 12, x FOR PEER REVIEW 3 of 9
Figure 2. Scheme of test equipment for rotating bending. Figure 2. Scheme of test equipment for rotating bending. 3. Results 3. Results Table3 shows the mechanical properties calculated based on an axial tensile test at a constant Table 3 shows the mechanical properties calculated based on an axial tensile test at a constant loading rate. The table showsFigure the 2. Scheme average of valuestest equipment calculated for rotating for 20 tests. bending. Figure 3 shows an example loadingstress–strain rate. The diagram table forshows the the test. average The values values for ca yieldlculated strength for 20 andtests. ultimate Figure 3 strength shows an are example higher stress–strain diagram for the test. The values for yield strength and ultimate strength are higher than than3. Results the minimum requirements in [27] which should be least 350 MPa and 700 MPa for Sy and Su, therespectively. minimum Itrequirements should be mentioned in [27] which that theshould requirements be least 350 for plateMPa and steel 700 according MPa for to S [28y and] are S ofu, Table 3 shows the mechanical properties calculated based on an axial tensile test at a constant respectively.a lower value, It withshould a minimumbe mentioned of 230 that MPa the andrequir 540ements MPa forfor yieldplate strengthsteel according and ultimate to [28] strength,are of a loading rate. The table shows the average values calculated for 20 tests. Figure 3 shows an example lowerrespectively. value, with Mechanical a minimum properties of 230 are MPa diff anderent 540 for MPa drawn for and yield plane strength bars becauseand ultimate a bar strength, has high stress–strain diagram for the test. The values for yield strength and ultimate strength are higher than respectively.plastic strain Mechanical after drawing. properties are different for drawn and plane bars because a bar has high plasticthe minimum strain after requirements drawing. in [27] which should be least 350 MPa and 700 MPa for Sy and Su, respectively. It should be mentionedTable 3. Mechanical that the propertiesrequirements for the for 1.4301 plate steel. steel according to [28] are of a lower value, with a minimum of 230 MPa and 540 MPa for yield strength and ultimate strength, respectively. MechanicalE [MPa] propertiesSu [MPa] are differentSy [MPa] for drawn andA [%] plane barsZ [%]because a bar has high plastic strain after drawing.206 553 803 561 78.3 43.8
Figure 3. Stress–strain curve for static load for exemplary specimen.
The microstructure was tested in a cross section perpendicular to the axis of the sample without a load using a scanning digital microscope, the OLYMPUS LEXT OLS4100 Laser Confocal Microscope Figure 3. Stress–strain curve for static load for exemplary specimen. (Olympus, Tokyo, Japan).Figure 3.Figure Stress–strain 4 shows curve the forexampl static eload image. for exemplary Austenite specimen. grains are dominant in the visibleThe structure microstructure and have was sizes tested between in a cross 20 μ sectionm and 50 perpendicular μm. The mean to the size axis of the of the grains sample was without 38.3 μm a andload theThe using standard microstructure a scanning deviation digital was wastested microscope, equal in a crossto the8.5 section OLYMPUS μm. The perpendicular calculation LEXT OLS4100 towas the Laser maaxisde of Confocalby the ImageJ sample Microscope software without version(Olympus,a load using 1.52a Tokyo, a on scanning four Japan). images, digital Figure taken microscope,4 showsfrom the the the sca example OLYMPUSnning digital image. LEXT microscope Austenite OLS4100 OLYMPUS grainsLaser Confocal are dominant LEXT Microscope OLS4100, in the accordingvisible(Olympus, structure to Tokyo, standard and Japan). have [29]. sizes Figure A betweensmall 4 shows number 20 µ them and examplof 50martensiteµem. image. The meangrains Austenite size (approximate of grains the grains are 6%) wasdominant can 38.3 µalso min andthebe observed.thevisible standard structure deviation and have was sizes equal between to 8.5 µm. 20 The μm calculation and 50 μm. was The made mean by size ImageJ of the software grains versionwas 38.3 1.52a μm onand four the images,standard taken deviation from the was scanning equal to digital 8.5 μ microscopem. The calculation OLYMPUS was LEXT made OLS4100, by ImageJ according software to standardversion 1.52a [29]. on A four small images, number taken of martensite from the sca grainsnning (approximate digital microscope 6%) can OLYMPUS also be observed. LEXT OLS4100, according to standard [29]. A small number of martensite grains (approximate 6%) can also be observed.
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Figure 4. MicrostructureMicrostructure of the 1.4301 stainless steel, transverse section in etched.
A fractography of fatigue fractures was carried out for each sample geometry. Figure 55 showsshows the example fracture images. The The tests tests were were carried carried out on on a a JEOL JEOL JSM-6610 JSM-6610 Series Series Scanning Scanning Electron Electron Microscope (JEOL, Tokyo, Japan). The study aimed to compare the propagation of the fatigue cracks for different different sample geometries. Figure 55aa showsshows thethe fracturefracture ofof aa smoothsmooth sample.sample. ItIt didiffersffers from the fractures in thethe notchednotched samples,samples, whichwhich areare oftenoften usedused inin fatiguefatigue tests.tests. In smooth samples, the crack propagates from several points around the entire sample perimeter, as seen in FigureFigure5 5a.a. InIn notchednotched samples, the crack is initiated in one or two points, as seen in FigureFigure5 5b–d.b–d. TheThe resultsresults areare consistentconsistent with the results presented in in [30] [30] (p. (p. 39). 39). Figure6 6 shows shows thethe relationshiprelationship betweenbetween fatiguefatigue liveslives andand appliedapplied nominalnominal stresses.stresses. TheThe numbernumber of samples and the load range were determined in accordance with [[13].13]. A minimum of 30 tests at fivefive different different load levels, i.e., six samples for a a single single load, load, were were carried carried out out for for each each sample sample geometry. geometry. The load levels were selected to obtain thethe fatiguefatigue lifelife betweenbetween 22 × 104 andand 10 1066 cycles.cycles. × A 3-parameter Weibull distributiondistribution [[31]31] waswas usedused toto plotplot thethe regressionregression line:line: