Cyclic load response producing

crack initiation (Stage I), crack

propagation (Stage II) and overload
(Stage III).
 Crack initiation sites
at keyway
Classic Stage II and III
regions
Beach Marks or crack
arrest lines evident
 Uni-directional
bending
Low nominal stress
Classic Stages II and
III
Smaller arrows
designate radial lines
& unstable crack
growth
 Date
references
indicate Stage II
progression
 Arrow locates surface
stress concentration &
radial lines
Uni-directional
bending
Cyclic crack growth in
surge (back pressure)
conditions
 Non-classic evidence
in Stage II
Distinct radial texture
from initiation through
Stage III
Uni-directional
bending
 Important reference
information
Help assign service
load information
From pre-existing mechanical or
materials surface defects
From slip band intersections with free
surfaces
 Crack Initiation in
absence of surface
defect
Crack formation
follows deformation
bands
Deformation bands
formed by localized
slip deformation
 Schematic for Stage I
crack formation
Polished Al surface
showing surface-
intersecting slip
bands after
approximately 1000
cycles
 Evidenceof slip band
penetration of grain
boundaries
 Modeled as single
load application
Striations represent
the essence of cyclic
crack growth
Microscopic
fractographic
evidence
V8 engine failure
Failed after 12,451-miles
Warranty coverage 12,000-miles or one-
year on drive train
Manufacturer and local dealership failed
to respond
Law suit filed
Plaintiff s experts said #1 connecting rod
was defective?
Failed by fatigue?
Did events induce the connecting rods to
fail or did they initiate the failure?
Driver s & owner s responsibilities?
 Femoral fixation
device
Fractured ~6 months
after installation
 Modified Type 309
Stainless Steel
Scratches & fatigue
cracks
Surgeon induced scratches during
fixation
Patient s normal daily life provided
cyclic loading
High-cycle fatigue failure under uni-
directional bending
Stage III separation was VERY painful for
the patient!!!
 Stages I-III Stages I-III?
Distinct crack initiation Distinct crack initiation
site(s) site(s)?
Crack arrest lines No crack arrest lines
Striations No striations
TC or TMVC TC or TMVC or IG
Confirmation of cyclic Confirmation of cyclic
loading loading
Gas Transmission Pipeline
As-received photography
WFMP
Sectioning
Metallography
SEM/EDS
10.75-inch ODx0.203-inch WT installed in
1940s
Originally met API 5L specifications for
Grade 42
Crack detected by gas leak survey
Primary & secondary cracks associated
with a dent
Fracture evidence & staining infer both
OD & ID crack initiation/propagation
TC fracture mode predominates
Fatigue striations consistent with high-
cycle fatigue
Pipe steel consists of fine-grained ferrite/
pearlite
OD & ID surfaces show moderate
decarburization
Transgranular & intergranular crack
paths observed
 TC mode=high-cycle fatigue
IG mode=high-pH SCC
Dent facilitated localized flexural loading &
development of tensile strain on OD surface
The tensile strain either initiates a crack or propagates
a crack through the work hardened zone
Crack propagation proceeds incrementally in
accordance with pipe properties & pressure cycles
Unrestrained dents typically crack in the center of the
damage zone
Alldents should be examined for cracks
Dents with gouges are more
susceptibility to cracking