Modeling of fatigue crack growth threshold development for a microstructurally small crack

A method for predicting the fatigue crack growth threshold using finite element analysis is investigated. The proposed method consists of monitoring the plastic strain hysteresis energy dissipation in the crack tip plastic zone, with the threshold being defined in terms of a critical value of this dissipated energy. Two-dimensional plane-strain elastic–plastic finite element analyses are conducted to model fatigue crack growth in a middle-crack tension M(T) specimen. A single-crystal constitutive relationship is employed to simulate the anisotropic plastic deformation near the tip of a microstructurally small crack without grain boundary interactions. Variable amplitude loading with a continual load reduction is used to generate the load history associated with fatigue crack growth threshold measurement. Load reductions with both constant load ratio R and constant maximum stress intensity Kmax are simulated. In comparison with a fixed Kmax load reduction, a fixed R load reduction is predicted to generate a 35% to 110% larger fatigue crack growth threshold value.