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UNIVERSITI PUTRA MALAYSIA
FATIGUE CRACK PROPAGATION IN ALUMINIUM 6063 TUBES
AZIM ATAOLLAHI OSHKOUR
FK 2009 9
FATIGUE CRACK PROPAGATION IN ALUMINIUM 6063 TUBES
By
AZIM ATAOLLAHI OSHKOUR
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia,
in Fulfilment of the Requirement for the Degree of Master of Science
January 2009
iii
Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment
of the requirement for the degree of Master of Science
FATIGUE CRACK PROPAGATION IN ALUMINIUM 6063 TUBES
By
AZIM ATAOLLAHI OSHKOUR
January 2009
Chairman: Prof. Ir. Barkawi b. Sahari, PhD
Faculty: Engineering
Tubular structures have extensive usage from domestic to aviation. Therefore
estimate of life and safety are essential for design and use. Fatigue is one the most
frequent cause for failure in components. Beside fatigue, external surfaces of
structures are always in contact with environment and due to imperfection during
product fabrication, surface crack may exist. Therefore surface crack is the most
common form of crack in engineering structures. To overcome the fatigue problem
the design approaches should be considered. The fatigue design approaches are
divided in two categories which are safe life approach and damage tolerant design.
Due to the importance of tubular structure and possible effect of fatigue in structural
damage, the present work has focused on fatigue and fatigue crack propagation
behavior in cylindrical structures.
The fatigue design approaches utilized stress based safe life and damage tolerant
design approach. The finite element software, ABAQUS used to analyze fatigue and
determine fracture parameters. At the beginning fatigue test in finite life was carried
out based on Japanese standard. The fatigue tests were done at room temperature and
iv
about 350°C under stress ratio equal to -1 and 0.1. Following experimental part, a
3-D fatigue analysis was carried out by ABAQUS. In fatigue analysis by ABAQUS,
the linear material is considered and the results of finite element analysis are plotted
in maximum stress versus number of cycles to failure graph. Fatigue analysis was
carried out in same condition as experimental part at room temperature and 350°C
under stress ratio equal to -1 and 0.1. Subsequent to fatigue analysis, the fatigue
crack propagation tests were also carried out. The fatigue crack propagation test was
carried out under increasing stress intensity factor or constant amplitude stress. In
fatigue crack propagation test, a cracked tubular specimen was used. The crack is
located in specimen by wire cut. The crack was an external and circumferential with
straight front with depth of 0.37mm. The results of fatigue crack propagation were
plotted in two types of graphs; first is crack length ,a, versus the number of cycles, N
at each crack length and second is the crack growth rate which plotted as function of
rate of crack length upon the number of cycles, da/dN versus the stress intensity
factor as fracture parameter. Moreover ABAQUS was used to derive the fracture
parameters. Two types 3-D tubes with crack were modeled. In first model assumed
as sharp and thin crack, but in the second type the blunt crack considered. Material of
tube in ABAQUS assumed to be a linear elastic and elastic prefect plastic. The
results of crack modeling include fracture parameters as stress intensity factor, and J-
integral which were plotted as a function of crack front.
The experimental results of fatigue showed a good agreement with finite element
fatigue results. Based on fatigue results the fully reversed fatigue is more severe than
fatigue with stress ratio equal to 0.1. Temperature does affect fatigue life which is
shown by a decrease in yield strength and ultimate strength of material which
v
resulted in reduction in the fatigue life of specimens with increasing temperature.
The fatigue crack propagation results indicated crack growth rate in loading with
stress ratio equal to 0.1 is more than stress ratio equal to -1. Crack first grew through
the thickness followed by the surface of specimen. This was verified by the results
from finite element that show maximum fracture parameters in the deepest point of
the crack.
vi
Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia
sebagai memenuhi keperluan untuk ijazah Master Sains
PERTAMBAHAN KERETAKAN LSUE DALAM TIUB ALUMINIUM
Oleh
AZIM ATAOLLAHI OSHKOUR
Januari 2009
Pengerusi: Prof. Ir. Barkawi b. Sahari, PhD
Fakulti: Kejuruteraan
Kegunaan sturktur berbentuk tiub begitu luas, dari kegunaan rumah hingga bidang
penerbangan. Oleh hal yang demikian, anggaran/kiraan jangka hayat dan
keselamatan adalah penting dalam merekabentuk dan kegunaannya. Factor kelesuan
adalah salah satu penymbang kepada kegagalan sesuatu komponen. Di samping itu
permukaan luar yang sentiasa terdedah kepada persekitaran dan kesan dari fakbrikasi
yang kurang memuaskan, keretakaan permukan boleh wujud. Dalam struktur
kejuruteraan, retakan permukaan merupakan bentuk keretakan yang biasa wujud.
Untuk mengatasi masalah kelesuan ini, pendekatan kelesuan rekabentuk perlu
diambil kira. Pendekatan kelesuan rekabentuk terbahagi kepada dua kategori, iaitu
pendekatan jangkahayat selamat dan ketahanan rekabentuk retak. Oleh yang
demikian, kerja penyelidikan ini tertumpu kepada ujian kelesuan dan kelakuan lesu
dengan penambahan retakan dalam struktur silinder.
Pendekatan kelesuan rekabentuk menggunakan tegasan jangkahayat selamat dan
pendekatan ketahanan rekebentuk di lakukan. ABAQUS merupakan satu perisian
unsur terhingga untuk menganalisis kelesuan struktur dan penghasilan parameter
vii
retakan. Pada permulaan kagian, kaedah terhingga ini berdasarkan Japanese
Standard. Ujian kelesuan telah dijalankan dalam suhu bilik dan pada 350°C di bawah
nisbah tegasan bersamaan dengan -1 dan 1.0.
Untuk ujian yang seterusnya, analisis lesu 3-D dilaksanakan dengan ABAQUS.
Analisis kelesuan dengan perisian unsur terhingga ini, bahan linar diambil kira dan
keputusan tersebut diplotkan dalam graf tegasan maksimum hingga gagal terhadap
bilangan kitaran. Ujian kelesuan dijalankan dengan keadaan yang sama dalam suhu
bilik dan 350°C di bawah nisbah tegasan bersamaan dengan -1 dan 1.0. Setelah ujian
kelesuan dijalankan, ujian kelakuan lesu dengan penambahan retakan dijalankan.
Ujian ini dijalankan di bawah faktor tumpuan tegasan atau amplitud tegasan
berterusan. Dalam ujian kelakuan lesu dengan penambahan retakan, spesimen tiub
bertakuk di buat dengan mesin Wire Cut. Tiub tersebut dilekuk sedalam 0.37mm di
permukaan luar tiub. Ujian kelakuan lesu dengan penambahan retakan ini diplotkan
kepada 2 jenis graf; panjang retakan terhadap jumlah kitaran di setiap panjang
retakan dan berikutnya adalah kadar penambahan keretakan diplotkan sebagai fungsi
kadar panjang retakan keatas bilangan kitaran melawan faktor tegasan sebagai
parameter keretakan. Disamping itu ABAQUS digunakan untuk memperolehi
parameter retakan. Dua jenis tiub 3-D dengan retakan dimodelkan. Model pertama
menganggapkan retakan tajam dan nipis. Model kedua menganggapkan retakan
tumpul. Bahan tiub dalam ABAQUS memperkenalkan kengal linar dan kengal linar
platci unggul. Keputusan model retakan mengandungi parameter retakan sebagai
faktor kekuatan tegasan dan J-intergral yang diplotkan sebagai suatu fungsi
kepelbaaian retakan hadapan.
viii
Keputusan ujian kelesuan dan kelesuan unsur terhingga menunjukkan hwdungan
yang baik. Berdasarkan ujian kelesuan, ujian berbalikan penuh lebih
menyumbangkan tegasan berbanding nisbah tegasan bersamaan dengan 0.1. Kesan
peningkatan suhu jangkahayat menunjiukkan peningkatan suhu mengurangkan
kekuatan dan takat alah bahan tersebut. Keputusan penambahan retakan lesu
menunjukkan penambahan kadar retakan dalam bebanan beserta nisbah tegasan
bersamaan dengan 0.1 adalah lebih berbanding nisbah tegasan bersamaan dengan -1.
Pembesaran retakan bermula dari ketebalan seterusnya ke atas permukaan spesimen.
Ini dibuktikan melalui keputusan unsur terhingga yang menunjunkkan parameter
retakan maksimum berlaku dalam kedalaman yang paling dalam daripada retakan
tersebut.
ix
ACKNOWLEDGEMENTS
First and foremost I would like to express my deep gratefulness to my supervisor
Professor Dr. Ir. Barkawi b. Sahari providing me the wonderful opportunity to
continue my master’s program. I am also very thankful for his tireless, kind
assistance, support, critical advice, encouragement and suggestions during the study
and preparation of this thesis.
I would also like to express my gratitude towards my members of my supervisory
committee Dr. Aidy Ali and Associate Professor Dr. Wong Shaw Voon, whom I am
grateful for their practical experience and knowledge that made an invaluable
contribution to this thesis. I truly appreciate the time they devoted in advising me and
showing me the proper directions to continue this research and for their openness,
honesty and sincerity.
I owe thank to Mr. Wildan Ilyas Mohd Ghazali, technician in Strength of Material
Laboratory, Department of Mechanical and Manufacturing Universiti Putra Malaysia
who has always been willing to provide assistance, give advice, and be a friend.
Last but not least the deepest appreciation goes to my very close friends, Hossin,
Mehdi, Ali and Hamid and for their contentious support and encouragement.
x
I certify that an Examination Committee has met on date of viva to conduct the final
examination of Azim Ataollahi Oshkour on his Master of Science entitled "Fatigue
and Crack Propagation in Aluminium 6063 Tubes" in accordance with Universiti
Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia
(Higher Degree) Regulations 1981. The Committee recommends that the candidate
be awarded the relevant degree. Members of the Examination Committee are as
follows:
Chairman, PhD Associate Prof. Ir. Dr. Nor Mariah Adam
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Examiner 1, PhD Prof. Ir. Dr. Mohd Sapuan Salit
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
Examiner 2, PhD Dr. Abdul Aziz Jafar
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
External Examiner, PhD Associate Prof. Ir. Dr. Shahrum bin Abdullah
Faculty of Engineering
Universiti Kebangsaan Malaysia
(External Examiner)
HASANAH MOHD GHAZALI, PhD
Professor/Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
xi
This thesis was submitted to the Senate of Universiti Putra Malaysia and has been
accepted as fulfilment of the requirement for the degree of Master of Science. The
members of the Supervisory Committee were as follows:
Barkawi b. Sahari, PhD Professor
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Aidy Ali, PhD
Lecturer
Faculty of Engineering
Universiti Putra Malaysia
(Member)
Wong Shaw Voon, PhD Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Member)
HASANAH MOHD GHAZALI, PhD Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date: 14 May 2009
xii
I hereby declare that the thesis is based on my original work except for quotations
and citations which have been duly acknowledged. I also declare that it has not been
previously, and is not concurrently, submitted for any other degree at Universiti
Putra Malaysia or at any other institution
Azim Ataollahi Oshkour
Date: 1 April 2009
xiii
TABLE OF CONTENTS
Page
ABSTRACT iii
ABSTRAK vi
ACKNOWLEDGMENT ix
APPROVAL x
DECLARATION xii
LIST IF TABLES xiii
LIST OF FIGURES xiv
LIST OF ABBREVIATIONS xix
CHAPTER
1
1 INTRODUCTION
2 LITERATURE REVIEW
2.1 Introduction 5
2.2 Material Behaviour 5
2.2.1 Hooke’s Law 6
2.2.2 Failure Criteria 7
2.3 Fatigue 9
2.3.1 Mechanism of Fatigue Damage 10
2.3.2 Stress Based Approach 13
2.3.3 Strain Based Approach 15
2.3.4 Mean Stress Models on Fatigue Life 18
2.3.5 Fracture Mechanics Base Approach 22
2.3.5.1 Fracture Mechanics Approach and
Fatigue Crack Propagation Analysis
22
2.3.5.2 Fracture Mechanics 27
2.4 Numerical Evaluation J-integral 35
2.4.1 J-Integral in 2D 35
2.4.2 J-Integral in 3D 39
2.5 Tubes and Cracks 42
2.6 Discussion 48
3 METHODOLOGY
3.1 Introduction 49
3.2 Finite Element Analysis 50
3.2.1 Finite Element Modelling of Evaluation Fracture
Parameter
50
3.2.2 Construction of 3-D Singular Elements at the
Crack Tip
51
3.2.3 Validation of Finite Element Model 53
3.2.4 Model Geometries 55
3.2.5 Other Model Attributes 56
3.2.6 Material Model 56
3.2.7 Boundary Conditions 56
3.2.8 Fatigue Finite Element Analysis 57
xiv
3.2.9 Model Geometries 58
3.2.10 Mesh Generation 59
3.2.11 Other Model Attributes 59
3.3 Experimental Procedure 60
3.3.1 Test Material - Composition and Properties 60
3.3.2 Test Specimens Preparation 62
3.3.3 Static Test Specimens 62
3.3.4 Fatigue Test Specimens 63
3.3.5 Fatigue and Fatigue Crack Growth Experiments 64
3.3.6 Crack Length Measurement 66
3.3.7 High Temperature Environment and Controlling 67
3.4 Discussion 68
4 Results and discussion
4.1 Introduction 69
4.2 Static Tension Properties 69
4.3 Fatigue Test at Room Temperature with R=-1 72
4.4 Fatigue Test at Room Temperature with R=0.1 75
4.5 Fatigue Test at 350°C with R=-1 78
4.6 Fatigue Test at 350°C with R=0.1 79
4.7 Tube Modelling 83
4.8 Fatigue Crack Propagation Test with R=-1 and Maximum
Load 10kN
95
4.9 Fatigue Crack Propagation Test with R=0.1 and Maximum
Load 10kN
98
4.10 Fatigue Crack Propagation test with R=-1 and Maximum
Load 15kN
101
4.11 Fatigue Crack Propagation test with R=0.1 and Maximum
Load 15kN
103
4.12 Summary 105
5 Conclusion and Recommendations
5.1 Conclusion 108
5.2 Recommendations 112
REFERENCES 114
BIODATA OF THE STUDENT 119
LIST OF TABLES
Table Pages
1 Basic material mechanical property 6
2 Classification of various types of fatigue analysis (Schijve,
2004 )
9
3 Characteristics of the three regimes of fatigue crack
propagation
23
4 Some type of defect in tube 43
5 Typical chemical composition of 6063 60
6 Fatigue and Fatigue crack growth test plan 66
7 Average static mechanical properties of specimens at room
temperature and 350°C
72
8 Exponential equation parameters used in fit curve with crack
propagation under maximum load equal to 10kN with R=-1
97
9 Exponential equation parameters used in fit curve with crack
propagation under maximum load equal to 10kN with R=0.1
99
10 Exponential equation parameters used in fit curve with crack
propagation under maximum load equal to 15kN with R=-1
101
11 Exponential equation parameters used in fit curve with crack
propagation under maximum load equal to 15kNwith R=0.1
103
xvi
LIST OF FIGURES
Figure Pages
1 A typical stress-strain curve (Martin, 2005) 6
2 Comparing failure criteria (Dieter, 1986) 8
3 Schematic of the slip band formation in a single grain. The
external loading is acting vertically, in tension-compression
cycling (Yung, Jwo, Richard, and Mark, 2005)
13
4 The stage I and stage II crack growth processes in a
polycrystalline material (Yung et al., 2005)
13
5 Typical a fNσ − curve plotted on log-log axes (Yung et al.,
2005)
14
6 Typical −ap f
Nε curve plotted on log-log axes (Yung et al.,
2005)
16
7 Comparison of −ae f
Nε , −ap f
Nε and −a f
Nε (Yung et al.,
2005)
17
8 Nomenclature for fatigue stress designators (Jung, 2002) 18
9 Typical stress amplitude-life plots for different mean stress
values (Choi, 2002)
20
10 A plot representing the Goodman, Soderberg, and Gerber
relations for the effect of mean stress on the stress amplitude
for fatigue failure (Choi, 2002)
20
11 A schematic representation of the Haigh diagram showing
constant life curves for different mean stress levels in terms of
the maximum and minimum stresses of the fatigue cycle
(Suresh, 1991)
21
12 Principle propagation behavior of a long crack and Paris’
idealization (Anderson, 1994)
25
13 Strain energy release rate: (a) crack growth da due to applied
load P ; (b) Strain energy released dU with crack growth da
(Anderson, 1994)
29
14 Typical mode of fracture (mode of loading) (Anderson, 1994) 30
15 Crack tip opening displacement (CTOD) Model (Dowling,
1999)
33
xvii
16 Application of J-integral approach to crack growth (Saxena,
1992).
34
17 Contour for evaluation of the J-integral 36
18 Closed contour C C C+ −+ + Γ + encloses a domain A that
includes the crack-tip region as 0Γ →
37
19 Definition of local orthogonal Cartesian coordinates at the
point s on the crack front; the crack is in the 1 3x x− plane
39
20 Surface t o ends cracksA A A A A= + + + encloses a domain
volume V that includes the crack-front region as 0Γ →
41
21 Geometry of an external circumferential crack in a hollow
cylinder (Varfolomeyev, 1998)
44
22 Circumferential external surface flaw in a round pipe(A.
Carpinteri and Brighenti, 1998)
45
23 External surface 2aw in a circumferentially notched pipe:
geometrical parameters (Andrea Carpinteri et al., 2003)
47
24 Internal and external semi-elliptical surface cracks in a
pressurized cylinder (Guozhong et al., 2004)
47
25 General description of the methodology adopted in the study 50
26 20 nodes brick element collapse into wage elastic singular
element
52
27 Flow of making the general finite element model 53
28 Three dimensional geometric of model 54
29 Meshing around crack front in 3D model 55
30 Boundary condition applied on model 57
31 Flow of making the general fatigue finite element model 58
32 Geometry of model in fatigue analysis 59
33 Meshing of model 59
34 Tensile test Specimen 63
35 Tensile test Specimen 63
xviii
36 Fatigue specimen 64
37 Fatigue specimen 64
38 Front view of crack 65
39 Side view of crack 65
40 Microscopy video based on rigid platform 66
41 Graded Specimen with crack 67
42 Crack propagation monitoring 67
43 View of furnace 68
44 Stress-strain behaviour of Aluminium 6063 in tension at room
temperature
70
45 Stress-strain behaviour of Aluminium 6063 in tension at
350°C
71
46 Comparison of static behaviour Aluminium 6063 at room
temperature and 350°C
71
47 Stress ratio 73
48 Stress amplitude 73
49 Fully reversed fatigue S-N Curve at room temperature 73
50 Fully reversed fatigue S-N Curve at room temperature in log-
log scale
74
51 Fatigue S-N curve at room temperature for R=0.1 75
52 Fatigue S-N curve at room temperature for R=0.1 in log-log
scale
76
53 Comparing log-log scale fatigue in room temperature with R =
-1 and 0.1
77
54 A fully reversed fatigue S-N Curve at 350°C 78
55 A fully reversed fatigue S-N Curve at 350°C in log-log scale 79
56 A fatigue S-N curve at 350°C for R=0.1 80
57 A fatigue S-N curve at 350°C for R=0.1 in log-log scale 80
xix
58 Comparing log-log scale fatigue at 350°C with R equal to -1
and 0.1
81
59 Comparing log-log scale fatigue at room temperature and
350°C with R= -1 and 0.1
82
60 3D-Crack surface circumferential crack with straight front
modelling in ABAQUS for tube
84
61 3D-Crack surface circumferential crack with straight front
modelling in ABAQUS for tube
85
62 x
σ at crack front 85
63 y
σ at crack front 86
64 z
σ at crack front 86
65 xy
τ at crack front 87
66 xz
τ direction at crack front 88
67 yz
τ at crack front 89
68 Variation of Min J-integral along the crack front under
107.48MPa
89
69 Variation of maximum J-integral along the crack front under
107.48MPa
90
70 Comparing Minimum J-integral 91
71 Comparing Maximum J-integral 91
72 Variation of stress intensity factor along the crack front under
107.48MPa
92
73 Variation of stress intensity factor along the crack front under
205.95MPa
93
74 Comparing minimum stress intensity factor under different
load
94
75 Comparing maximum stress intensity factor under different
load.
94
xx
76 Fully reversed fatigue crack propagation with amplitude stress
equal to 10kN
96
77 The variation of da/dN versus maximum stress intensity factor
(Kmax) for fully reversed fatigue crack propagation with
amplitude stress equal to 10kN
97
78 Fatigue crack propagation with amplitude stress equal to 10kN
and stress ratio equal to 0.1
98
79 The variation of da/dN versus maximum stress intensity factor
(Kmax) for fatigue crack propagation with amplitude stress
equal to 10kN with R=0.1
99
80 Comparing fatigue crack growth with R=0.1 and R=-1 under
10kN maximum stress
100
81 Comparing da/dN versus maximum stress intensity factor
(Kmax) under 10kN and load ratio equal to 0.1 & -1
100
82 Fully reversed fatigue crack propagation with amplitude stress
equal to 15kN
102
83 The variation of da/dN versus maximum stress intensity factor
(Kmax) for fully reversed fatigue crack propagation with
amplitude stress equal to 15kN
102
84 Fatigue crack propagation with amplitude stress equal to
161.96MPa and stress ratio equal to 0.1
103
85 The variation of da/dN versus maximum stress intensity factor
(Kmax) for fatigue crack propagation with maximum load equal
to 15kN with R=0.1
104
86 Comparing fatigue crack growth with R=0.1 and R=-1 under
15kN maximum load
105
87 Comparing da/dN versus maximum stress intensity factor
(Kmax) under 15kN and load ratio equal to 0.1 & -1
105
CHAPTER 1
INTRODUCTION
1.1 Introduction
Many critical mechanical components experience cyclic loadings during their service
life. Fundamental understanding of fatigue problem is important for the reliability
assessment under realistic service condition and is valuable for the design and
maintenance versus fatigue failure. Fatigue life prediction is one of the oldest
problems which concern scientists and engineers. Due to the complicated nature of
fatigue mechanisms and the large number of factors that influence fatigue life, there
is so far no unified approach that can treat all fatigue problems (Weixing, 1993). It
has been estimated that as large as ninety percent of all engineering structural and
component failures may be attributed to fatigue failure (Dieter, 1986).
The well known approaches which concern fatigue and fatigue crack propagation
analysis can be categorized in two groups. These include damage tolerant design and
safe life approaches. Based on damage tolerant design, structures are designed to
allow limited crack propagation so that growing cracks can be located and remedied.
The safe life approaches are such as stress base or strain based approach. Damage
tolerance is based on the likelihood of finding cracks and their estimated propagation
rates (Lawson, Chen, and Meshii, 1999).
2
The accuracy of estimated life and safety of engineering components which in oil,
gas, aviation and nuclear industries requires good understanding of fatigue property
such as fatigue crack propagation rate (da/dN) and fatigue strength curve (S-N) is
essential. In the case of existing crack in structure, damage tolerant design can be
used to obtain accurate crack growth data. It mainly estimates the residual fatigue life
of cracked structures on the basis of known crack propagation rates. To carry out this
assessment, it is necessary to have reliable fracture parameters such as stress
intensity factor and J-integral. There are two ways for calculating fracture
parameters, namely analytical and finite element methods. By using finite element
methods, it provides time and commercial benefit. Hence fracture parameters can be
derived by carrying out crack simulation on two dimensional or three dimensional
numerical modeling. Following which the finite element model was developed for
calculating fracture parameters for cracks. Based on crack growth rate (da/dN) data
obtained from fatigue tests and the results of finite element analysis, fatigue crack
growth behavior can be predicted.
1.2 Problem Statement
Cylindrical components such as pressure vessels, pipes, borers, and driving shafts are
commonly used parts of engineering structure. Due to a wide range of usage of this
type of structures such as transmission or storage of fluid as in pipes and high
pressure vessels, it is necessary that these structures be assessed with different
conditions such as materials, temperature and loading. Fatigue caused a structure to
fail and it is known to be one of the major reasons of failure in engineering
structures. Some of the failures by fatigue happened suddenly and unexpectedly at
stresses lower than their design strength, resulting in extensive property damage and
3
loss of life. A lot of efforts have been done to understand why and how materials fail
by fatigue and what are the main parameters and factors in fatigue. In the present
days these economic and life cost of failure and fracture become greater due to
structures become more complexes. Therefore it required special consideration on
safety and life prediction. Based on the importance of fatigue and tubular structures,
the present work focused on analysis and investigating fatigue and fatigue crack
propagation this structures.
1.3 Research Objectives
The objectives of this study are:
1. To determine the fatigue behavior of Aluminum 6063 tube at room and
350°C by using of experimental and finite element methods.
2. To determine the parameters of fracture in aluminum tubes by using of finite
element methods.
3. To determine the mechanisms of fracture associated with fatigue and develop
a model to predict crack propagation length versus number of cycles.
1.4 Thesis Layout
This thesis is divided into six chapters. Following this introductory chapter, chapter
two gives a critical review of relevant literature, from overview of fatigue, creep and
fracture mechanics. Chapter three outlines the underlying theory as well as