Microcrack propagation under multiaxial loading - experiment and simulation

The accuracy of lifetime prediction for technical components subjected to cyclic loading is still not satisfying. One essential reason for the deviation between the results of the lifetime calculation and experimental results is that it is not yet possible to generate a model capable to describe the microstructural damage process which occurs in the tested material and to integrate this model in the calculation. All of the present research results recognize that the growth of microcracks is significantly influenced by the microstructure of the material. In order to take into account the influence of the microstructure on the damage process a simulation model is suggested in this paper which considers the local stress state in addition to the random nature of the material structure in the form of grain boundaries and slip systems. The results generated by means of the simulation model are compared and verified with those experiences obtained from multiaxial fatigue testing of the investigated aluminum material. For this purpose the surfaces of the tested specimens are carefully observed to discover and analyze microcracks which are classified according to their number, length, and orientation. Moreover the mechanisms of crack initiation and propagation are major points of interest for the comparison of theoretical and experimental results. The developed computer software is suitable to simulate the microcrack initiation, the propagation and coalescence of microcracks as well as the transition of stage I cracks to stage II cracks for uniaxial and multiaxial loading. Results obtained from the simulation model could be verified with the experiment. The future aim to be emphasized is the utilization of the parameter investigations carried out with the computer simulation model in order to improve the lifetime prediction. (orig.)