A literature survey on the stability and significance of residual stresses during fatigue

Abstract

A B S T R A C T Many manufacturing processes can induce residual stresses in components. These residual stresses influence the mean stress during cyclic loading and so can influence the fatigue life. However, the initial residual stresses induced during manufacturing may not remain stable during the fatigue life. This paper provides a broad and extensive literature survey addressing the stability of surface and near-surface residual stress fields during fatigue, including redistribution and relaxation due to static mechanical load, repeated cyclic loads, thermal exposure and crack extension. The implications of the initial and evolving residual stress state for fatigue behaviour and life prediction are addressed, with special attention to fatigue crack growth. This survey is not a critical analysis; no detailed attempt is made to evaluate the relative merits of the different explanations and models proposed, to propose new explanations or models or to provide quantitative conclusions. Primary attention is given to the residual stresses resulting from four major classes of manufacturing operations: shot peening and related surface treatments, cold expansion of holes, welding and machining. A = function of material and temperature C = empirical constant CX = cold expansion DOD = Department of Defence DR = deep rolling EP = electropolished FAA = Federal Aviation Administration FCG = fatigue crack growth FE = finite element FTI = Fatigue Technology, Inc. GBP = glass bead peening GP = gravity peening JSSG = Joint Service Specification Guide k = Boltzmann's constant LBP = low plasticity burnishing LCF = low-cycle fatigue LSP = laser shock peening m = empirical constant Correspondence: R. C. McClung. Fatigue Fract Engng Mater Struct 30, 173-205 173 174 R. C. McCLUNG Q = effective activation energy for residual stress relaxation R = stress ratio S-N = Stress-Life SP = shot peening SR = stress relieved t = time T = Temperature USAF = United States Air Force WP = water peening σ RS = residual stress 3D = three-dimensional

Effect of Cooling and Shot Peening on Residual Stresses and Fatigue Performance of Milled Inconel 718

“…The beneficial effect of compressive residual stresses in terms of retarding surface cracking during fatigue and increasing the resistance of the component to fatigue failures is well consistent with the previous findings in shot peening of other metallic materials [3,4]. The extent to which the lifetime was prolonged was decreased as the applied load was increased due to the residual stress relaxation in low cycle fatigue resulting from significant cycling strains [10]. …”

The Residual Stress Relaxation Behavior of Weldments During Cyclic Loading

“…[1][2][3][4][5][6][7] There are many ways to reduce potentially harmful residual stress to prolong service life, such as annealing, [8,9] pre-stretching, [6] and shakedown. [10][11][12] For the purpose of accurate assessment of fatigue lifetime, not only the magnitude of the residual stresses, but also their stability factors and evolution during service are of great importance.…”

The Role of Residual Stresses in the Performance and Durability of Prestressing Steel Wires

“…As the development of a dominant crack from the wire surface under high-cycle fatigue occupies the major part of the fatigue lifetime, an accurate calculation of the fatigue life requires an accurate knowledge of the surface stresses, which are dependent on the external loads and on residual stresses [51], An experimental and numerical investigation of the influence of residual stresses in cold-drawn eutectoid steels on the fatigue limit and on the fatigue life was undertaken some years ago [6,[52][53][54][55]. Llorca and Sanchez-Galvez [52,53] performed fatigue tests at a constant stress range and at different nominal stress ratios (R=cr min / cr max ) on wires with different residual stresses.…”