This chapter familiarizes readers with the mechanisms involved in creep and how they are related to fatigue behavior. It explains that what we observe as creep deformation is the gradual displacement of atoms in the direction of an applied stress aided by diffusion, dislocation movement, and grain boundary sliding. It describes these mechanisms in qualitative terms, explaining how they are driven by thermal energy and how they can be analyzed using creep curves and deformation maps. In addition, it examines the types of damage associated with creep, presents a number of creep strain and strain rate equations, explains how to determine creep constants, and reviews the findings of several studies on cyclic loading. It also discusses the development of a novel test that measures the cyclic creep-rupture resistance of materials in tension and compression.

This chapter discusses the concept of mean stress and explains how it is used in fatigue analysis and design. It begins by examining the stress-strain response of test samples subjected to cyclic forces and strains, noting important features and what they reveal about materials and their fatigue behaviors. It then discusses the challenge of developing hysteresis loops for complex loading patterns and accounting for effects such as ratcheting and stress relaxation. The sections that follow provide a summary of the various ways mean stress is described in the literature and the methods used to calculate or predict its effect on the fatigue life of machine components. The discussion also sheds light on why tensile mean stress is detrimental to both fatigue life and ductility, while compressive mean stress is highly beneficial.

This chapter provides a detailed analysis of the cyclic stress-strain behavior of materials under uniaxial stress and strain cycling. It first considers the case of a stable material under constant-amplitude strain cycling then broadens the discussion to materials that harden or soften with continued strain reversals. It compares and contrasts the response patterns of such materials, explaining how the movement of dispersed particles and dislocations influences their behavior. It then examines the behavior of materials under uniaxial strain reversals of varying amplitude and explains how to construct double-amplitude stress-strain curves that account for complex straining histories. For special cases, those involving complex materials such as gray cast iron or highly complex straining patterns, the chapter presents other methods of analysis, including the rainflow cycle counting method, mechanical modeling based on displacement-limited elements, Wetzel’s method, and deformation modeling. It also explains the difference between force cycling and stress cycling and presents alternate techniques for predicting whether a material will become harder or softer in response to strain cycling.

This chapter explains why it is sometimes necessary to separate inelastic from elastic strains and how to do it using one of two methods. It first discusses the direct calculation of strain-range components from experimental data associated with large strains. It then explains how the method can be extended to the treatment of very low inelastic strains by adjusting tensile and compressive hold periods and continuous cycling frequencies. The chapter then begins the presentation of the second approach, called the total strain-range method, so named because it combines elastic and inelastic strain into a total strain range. The discussion covers important features, procedures, and correlations as well as the use of models and the steps involved in predicting thermomechanical fatigue (TMF) life. It also includes information on isothermal fatigue, bithermal creep-fatigue testing, and the predictability of the method for TMF cycling.

This chapter examines the stress-strain characteristics of metals and alloys subjected to cyclic loading and the cumulative effects of fatigue. It begins by explaining how a single load reversal can lower the yield stress of a material and how repeated reversals can cause strain hardening and softening, both of which lead to premature failure. It then discusses the stages of fatigue fracture, using detailed images to show how cracks initiate and grow and how they leave telltale marks on fracture surfaces. It goes on to describe fatigue life assessment methods and demonstrate their use on different metals and alloys. The chapter also discusses design-based approaches for preventing fatigue failures.

This chapter discusses the effect of fatigue on polymers, ceramics, composites, and bone. It begins with a general comparison of polymers and metals, noting important differences in microstructure and cyclic loading response. It then presents the results of several studies that shed light on the fatigue behavior and crack growth mechanisms of common structural polymers and moves on from there to discuss the fatigue behavior of bone and how it compares to stable and cyclically softening metals. It also discusses the fatigue characteristics of engineered and composited ceramics and ceramic fiber-reinforced metal-matrix composites.

This chapter familiarizes readers with the methods used to quantify the effects of fatigue on component lifetime and failure. It discusses the development and use of S-N (stress amplitude vs. cycles to failure) curves, the emergence of strain-based approaches to fatigue analysis, and important refinements and modifications. It demonstrates the use of approximate equations, including the method of universal slopes and the four-point correlation technique, which provides reasonable estimates of elastic and plastic lines from information obtained in standard tensile tests. It also discusses high-cycle, low-cycle, and ultra-high cycle fatigue and presents several models that are useful for fatigue life predictions.

Strain-range partitioning is a method for assessing the effects of creep fatigue based on inelastic strain paths or strain reversals. The first part of the chapter defines four distinct strain paths that can be used to model any cyclic loading pattern and describes the microstructural damages associated with each of the four basic loading cycles. The discussion then turns to fatigue life prediction for different types of materials and more realistic loading conditions, particularly those in which hysteresis loops have more than one strain-range component. To that end, the chapter considers two cases. In one, the relationship between strain range and cyclic life is established from test data. In the other, a rule is required to determine the damage of each concurrent strain and the total damage of the cycle is used to predict creep-fatigue life. The chapter presents several such damage rules and discusses their applicability in different situations.

The stress-strain curves in this data set are representative examples of the behavior of several cast alloys under tensile or compressive loads. The curves are arranged by alloy designation. Each figure cites the original source of the curve and provides pertinent background information as available. Compressive tangent modulus curves are presented for certain alloys. The effects of cyclic loading are given on several curves.

This article reviews fatigue test methodologies, provides an overview of general fatigue behavior (crack initiation and propagation) in engineering plastics, and discusses some of the factors affecting the fatigue performance of polymers. In addition, it provides information on fractography that provides useful insight into the nature of fracture processes.

This chapter describes the phenomenological aspects of fatigue and how to assess its effect on the life of components operating in high-temperature environments. It explains how fatigue is measured and expressed and how it is affected by loading conditions (stress cycles, amplitude, and frequency) and factors such as temperature, material defects, component geometry, and processing history. It provides a detailed overview of the damage mechanisms associated with high-cycle and low-cycle fatigue as well as thermal fatigue, creep-fatigue, and fatigue-crack growth. It also demonstrates the use of tools and techniques that have been developed to quantify fatigue-related damage and its effect on the remaining life of components.

This chapter compares and contrasts empirical approaches for partitioning hysteresis loops and predicting creep-fatigue life. The first part of the chapter presents experimental partitioning methods, explaining how they can be used to partition any loading cycle into its basic strain-range components. The methods covered include rapid cycling between peak stress extremes, half-cycle rapid loading and unloading, and variations of the incremental step-stress approach. The methods are then compared based on their ability to predict creep-fatigue life. The chapter goes on from there to describe how fatigue life can be estimated from ductility measurements when cyclic data are unavailable or are likely to change. It also explains how cyclic life is influenced by the time-dependent nature of creep-plasticity and the physical and metallurgical effects of environmental exposure.

Fiber-reinforced metal-matrix composites have carved out a niche in applications requiring high strength to weight ratios, but they are susceptible to failure when exposed to high temperatures and cyclic loads. This chapter discusses the obstacles that must be overcome to improve the creep-fatigue behavior of these otherwise promising materials. It addresses six areas that have been the focus of intense research, including thermal-expansion and elastic-viscoplastic mismatch, thermally induced biaxiality and interply stresses, creep and cyclic relaxation of residual stresses, and enhanced interfaces for oxidation.

This chapter explains how the authors assessed the potential risks of creep-fatigue in several aerospace applications using the tools and techniques presented in earlier chapters. It begins by identifying the fatigue regimes encountered in the main engines of the Space Shuttle. It then describes the types of damage observed in engine components and the methods used to mitigate problems. It also discusses the results of analyses that led to changes in design or approach and examines fatigue-related issues in turbine engines used in commercial aircraft.

This chapter provides an overview of factors that must be considered in the design of structural components for satisfactory service performance in terms of mechanical behavior of steel castings. The chapter discusses designing against yielding, excessive deflection, and creep and stress rupture. The chapter describes the three main approaches to evaluating and designing structures relative to fatigue resistance: the S-N curve approach for high cycle fatigue, the strain range approach for low cycle fatigue, and the fracture mechanics approach. Two approaches to design against brittle fracture are described, the ductile to brittle transition concept and the fracture mechanics approach. The chapter also discusses several types of corrosion behavior and emphasizes the need to interact with corrosion specialists in the design process. It illustrates the unique advantages that designers may gain by designing components as castings to achieve low stress concentrations economically.