Skip to Main Content
Skip Nav Destination
ASTM Selected Technical Papers
Residual Stress Effects on Fatigue and Fracture Testing and Incorporation of Results into Design
By
Jeffrey O. Bunch
Jeffrey O. Bunch
1
Boeing Integrated Defense Systems
?
Seattle, WA Symposium Chairman and Editor
Search for other works by this author on:
Michael R. Mitchell
Michael R. Mitchell
2
Northern Arizona University
?
Flagstaff, AZ Symposium Co-chair and Editor
Search for other works by this author on:
ISBN-10:
0-8031-4472-5
ISBN:
978-0-8031-4472-9
No. of Pages:
165
Publisher:
ASTM International
Publication date:
2007

High cycle fatigue (HCF) performance of turbine engine components has been known for decades to benefit from compressive surface residual stresses produced by shot peening. Recently laser shocking and low plasticity burnishing (LPB) have been shown to provide spectacular fatigue and damage tolerance improvement by introducing deep or through-thickness compression in fatigue critical areas. However, the lack of a comprehensive design method that defines the depth and magnitude of compression required to achieve a design fatigue life has prevented surface enhancement from being used for more than a safeguard against HCF damage initiation. The present paper describes a design methodology and testing protocol to allow credit to be taken for the beneficial compression introduced by surface enhancement in component design to achieve a required or optimal fatigue performance.

A detailed design method has been developed that relates the required fatigue life, the mean and alternating applied stresses, and the damage in terms of Kf to the residual stress at the fatigue initiation site required for the targeted HCF performance. The method is applied to feature specimens designed to simulate the fatigue conditions in the trailing edge of a first stage low pressure Ti-6-4 compressor vane to provide the optimal trailing edge damage tolerance. A novel adaptation of the traditional Haigh diagram to estimate the compressive residual stress magnitude for optimal fatigue performance is introduced. Fatigue results on blade-edge feature samples are compared with analytical predictions provided by the design methodology.

1.
Frost
,
N. E.
,
Marsh
,
K. J.
, and
Pook
,
L. P.
,
Metal Fatigue
,
Oxford University Press
,
1974
.
2.
Fuchs
,
H. O.
and
Stephens
,
R. I.
,
Metal Fatigue In Engineering
,
John Wiley & Sons
,
1980
.
3.
Berns
,
H.
and
Weber
,
L.
, “
Influence of Residual Stresses on Crack Growth
,”
Impact Surface Treatment
,
Meguid
S.A.
, Ed.,
Elsevier
,
1984
, pp. 33–44.
4.
Ferreira
,
J. A. M.
,
Boorrego
,
L. F. P.
, and
Costa
,
J. D. M.
, “
Effects of Surface Treatments on the Fatigue of Notched Bend Specimens
,”
Fatigue, Fract. Engng. Mater., Struct.
 8756-758X, Vol.
19
, No.
1
,
1996
, pp. 111–117.
5.
Prevéy
,
P. S.
,
Telesman
,
J.
,
Gabb
,
T.
, and
Kantzos
,
P.
, “
FOD Resistance and Fatigue Crack Arrest in Low Plasticity Burnished IN718
,”
Proceedings of the 5th National High Cycle Fatigue Conference
,
Chandler, AZ
,
03
2000
.
6.
Clauer
,
A. H.
, “
Laser Shock Peening for Fatigue Resistance
,”
Surface Performance of Titanium
,
Gregory
J. K.
, et al., Eds.,
TMS Warrendale
,
PA
,
1996
, pp. 217–230.
7.
Prevéy
,
P.
,
Jayaraman
,
N.
, and
Ravindranath
,
R.
, “
Effect of Surface Treatments on HCF Performance and FOD Tolerance of a Ti-6Al-4V Vane
,”
Proceedings 8th National Turbine Engine HCF Conference
,
Monterey, CA
,
04
2003
.
8.
Prevéy
,
P. S.
, et al
., “
The Effect of Low Plasticity Burnishing (LPB) on the HCF Performance and FOD Resistance of Ti-6Al-4V
,”
Proceedings: 6th National Turbine Engine High Cycle Fatigue (HCF) Conference
,
Jacksonville, FL
,
03
2001
.
9.
Shepard
,
M.
,
Prevéy
,
P.
, and
Jayaraman
,
N.
, “
Effect of Surface Treatments on Fretting Fatigue Performance of Ti-6Al-4V
,” submitted to
International Journal of Fatigue
 0142-1123.
10.
Jayaraman
,
N.
,
Prevéy
,
P. S.
, and
Mahoney
,
M.
, “
Fatigue Life Improvement of an Aluminum Alloy FSW with Low Plasticity Burnishing
,”
Proceedings 132nd TMS Annual Meeting
,
San Diego, CA
,
03
2003
.
11.
Prevéy
,
P. S.
and
Cammett
,
J. T.
, “
The Influence of Surface Enhancement by Low Plasticity Burnishing on the Corrosion Fatigue Performance of AA7075-T6
,” to appear in
International Journal of Fatigue
 0142-1123.
12.
Suresh
,
S.
,
Fatigue of Materials
,
Cambridge University Press
,
2001
, pp. 226–227.
13.
O'Connor
,
H. C.
and
Morrison
,
J. L. M.
,
International Conference on Fatigue
,
Institution of Mechanical Engineers
,
1956
, pp. 102–109.
14.
Woodward
,
A. R.
,
Gunn
,
K. W.
, and
Forrest
,
G.
, “
The Effect of Mean Stress on the Fatigue of Aluminum Alloys
,”
International Conference on Fatigue
,
Institution of Mechanical Engineers
,
1956
, pp. 158–170.
15.
Findley
,
W. N.
, “
Experiments in Fatigue Under Ranges of Stress in Torsion and Axial Load from Tension to Extreme Compression
,” Vol.
54
,
ASTM International
,
West Conshohocken, PA
,
1954
, pp. 836–846.
16.
Howell
,
F. M.
and
Miller
,
J. L.
, “
Axial-Stress Fatigue Strengths of Several Structural Aluminum Alloys
,”
ASEM
, Vol.
55
,
1955
, pp. 955–968.
17.
Smith
,
K. N.
,
Watson
,
P.
, and
Topper
,
T. H.
, “
A Stress-Strain Function for the Fatigue of Metals
,”
Journal of Materials
 0022-2453, Vol.
5
, No.
4
,
12
1970
, pp. 767–778.
18.
Fuchs
,
H. O.
and
Stephens
,
R. L.
, “
Metal Fatigue
,”
John Wiley & Sons
,
New York
,
1980
, p. 153.
19.
Aerospace Structural Metals Handbook
, 3704.
20.
Nicholas
,
T.
and
Maxwell
,
D. C.
, “
Mean Stress Effects on the High Cycle Fatigue Limit Stress in Ti-6Al-4V
,”
Fatigue and Fracture Mechanics: 33rd Vol.
, ASTM STP 1417,
Reuter
W. G.
and
Piascik
R. S.
, Eds.,
ASTM International
,
West Conshohocken, PA
,
2002
.
21.
Patent pending.
22.
Dieter
,
Mechanical Metallurgy
, Mil-hbdk-5, 3rd Ed.,
U.S. Dept. Of Defense
,
Mcgraw-hill
, Figure 12-9,
1986
, P. 386.
This content is only available via PDF.
You do not currently have access to this chapter.
Close Modal

or Create an Account

Close Modal
Close Modal