See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/223600875 Fatigue strength of spring steel under axial and torsional loading in the very high cycle regime Article in International Journal of Fatigue · December 2008 DOI: 10.1016/j.ijfatigue.2008.07.004 CITATIONS READS 73 2,076 5 authors, including: Yoshiaki Akiniwa S. Stanzl-Tschegg Yokohama National University University of Natural Resources and Life Sciences Vienna 97 PUBLICATIONS 949 CITATIONS 248 PUBLICATIONS 7,560 CITATIONS SEE PROFILE Kazuo A Tanaka Extreme Light Infrastructure - Nuclear Physics 803 PUBLICATIONS 14,593 CITATIONS SEE PROFILE Some of the authors of this publication are also working on these related projects: Cyclic slip activity of persistent slip bands View project Christian Doppler Laboratory for Fundamentals of Wood Machining View project All content following this page was uploaded by S. Stanzl-Tschegg on 12 May 2019. The user has requested enhancement of the downloaded file. SEE PROFILE International Journal of Fatigue 30 (2008) 2057–2063 Contents lists available at ScienceDirect International Journal of Fatigue journal homepage: www.elsevier.com/locate/ijfatigue Fatigue strength of spring steel under axial and torsional loading in the very high cycle regime Y. Akiniwa a,*, S. Stanzl-Tschegg b, H. Mayer b, M. Wakita c, K. Tanaka d a Department of Mechanical Science and Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan Institute of Physics and Materials Science, BOKU, Peter-Jordan-Street 82, A-1190 Vienna, Austria c Research and Development Division, Chuo Spring Co. Ltd., 43-1 Miyashita, Fukuta, Miyoshi-cho, Nishikamo-gun, Aichi 470-0225, Japan d Department of Mechanical Engineering, Meijyo University, 1-501 Shiogamaguchi, Tenpaku-ku, Nagoya 468-8502, Japan b a r t i c l e i n f o Article history: Received 9 January 2008 Received in revised form 7 July 2008 Accepted 8 July 2008 Available online 16 July 2008 Keywords: Giga cycle fatigue Axial loading Torsional loading Spring steel Non-damaging defect a b s t r a c t The fatigue strength of an oil-tempered Si–Cr steel for valve springs (JIS G3561, SWOSC-V) was investigated. Smooth specimens without residual surface stresses were fatigued with two kinds of ultrasonic fatigue testing machines to clarify the fatigue properties up to very high numbers of cycles (giga cycle regime) under axial and torsional loading. The maximum inclusion size in the critical volume of a specimen predicted by the extremal statistics is 7.9 lm. Although scatter is somewhat large, the S–N data could be approximated by linear lines in double logarithmic plots for both loading conditions up to the giga cycle regime. The ratio of fatigue strength under torsional and axial loading at the same number of stress cycles is about 0.68 and is almost constant even in the giga cycle regime. Cracks were initiated from the specimen surface under tension–compression as well as torsion loading. No specimen showed crack initiation from the interior. Inclusions and granular facet areas could not be observed. Under torsional loading, cracks initiated either perpendicular or parallel to the longitudinal direction of the specimens. After shear crack propagation to a crack length of about 30 lm, crack branching and mode I propagation took place. The size of characteristic defects calculated on the basis of the propagation threshold of long cracks is much larger than the inclusion size calculated by the extremal statistics. Ó 2008 Elsevier Ltd. All rights reserved. 1. Introduction For structural materials, the fatigue strength is the most important factor to ensure a long-term reliability. In recent years, it is required that materials used in several applications can sustain very high numbers of load cycles without failure due to the ageing management of engineering plants and high-speed operation of engineering machines. In conventional fatigue design, the fatigue limit was determined by the strength at a specified number of stress cycles of 107. High strength steels, however, have shown anomalous two-step or duplex S–N curves under rotating bending, and fatigue fracture can take place at numbers of stress cycles beyond 107. In that case, inclusions in components play a significant role for crack initiation and fatigue life [1–5]. Many components of engineering structures such as axles and crankshafts are stressed not only with axial tension–compression loads but also with cyclic torsion loads. So the fatigue strength under torsional loading is also important for the design of such components [6–11]. For coil springs, the loading mode is mostly torsion, and it is often required that automotive valves operate without failure in the giga cycle regime [12]. * Corresponding author. Tel.: +81 52 789 4673; fax: +81 52 789 3109. E-mail address: akiniwa@mech.nagoya-u.ac.jp (Y. Akiniwa). 0142-1123/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.ijfatigue.2008.07.004 Since long testing times are necessary to investigate the regime of very long fatigue life by using conventional fatigue testing machines operating with several tens of Hertz, testing machines operating with higher frequency are required. Ultrasonic fatigue testing machines are very useful for accelerated fatigue testing [13–18]. Fatigue properties under torsional loading in the giga cycle regime using ultrasonic fatigue testing machines were reported by StanzlTschegg [19], Mayer [20,21] and Bathias [22,23]. However, torsion fatigue data available until now are not sufficient to understand the fatigue properties in the giga cycle regime. In the present study, ultrasonic fatigue tests under axial and torsional loading were carried out with smooth specimens of a spring steel (SWOSC-V). The fatigue strength for torsional loading was compared with that for axial loading. The experimental results, considering the crack initiation site are discussed on the basis of the size of non-damaging defects. 2. Experimental procedure 2.1. Material and specimen The material used in this study was an oil-tempered Si–Cr steel wire used for valve springs (JIS G3561, SWOSC-V). The chemical composition of the material was as follows (wt%): C0.56, Si1.44, 2058 Y. Akiniwa et al. / International Journal of Fatigue 30 (2008) 2057–2063 Mn0.68, P0.012, S0.005, Cr0.70, Cu0.01. Fig. 1 shows shape and dimensions of the specimens. The diameter in the center of the specimens is 3 mm for axial tension–compression fatigue tests, and 5 mm for torsional loading. The specimens were annealed at 1143 K, oil quenched, tempered at 683 K for 1 h and cooled in N2 gas. After heat treatment, the specimen surface was polished with emery paper #800. Then a surface layer of 50 lm was removed by electro-polishing in order to eliminate residual stresses. Finally, the specimens were polished with alumina powder of 0.3 lm. As a result, the residual stress measured with the X-ray method was nearly zero. The Vickers hardness after heat treatment is nearly uniform over the cross-section, and the mean value is 598 HV. The prior austenitic grain size is 16 lm. The polished cross-sections of specimens were investigated with a scanning electron microscope to measure the distribution of the inclusion size. The inclusions identified by energy dispersive spectroscopy were Al2O3, SiO2 and TiN. Fig. 2 shows the distribution of the inclusion size plotted in an extreme probability diagram. In a standard inspection area, S0 (0.242 0.182 mm2), the inclusion of maximum size, (areamax)1/2, was measured and this procedure was repeated 20 times. The largest inclusion expected to exist in a critical volume of specimen was estimated with the statistics of extreme value method [6,24] based on the double exponential distribution. The standard inspection volume is defined by a b Fig. 1. Shape and dimensions of specimens. (a) Axial loading. (b) Torsional loading. V 0 ¼ h0 S0 ð1Þ 1/2 where h0 (1.4 lm) is the average value of (areamax) . The critical volume, V (26.2 mm3) was defined as the region where the stress is larger than 90% of the maximum stress in specimens used in axial loading tests, and it was calculated using FEM. The return period was calculated by T ¼ V=V 0 ð2Þ Then the largest inclusion of 7.9 lm could be obtained by the linear extrapolation as shown in Fig. 2. 2.2. Fatigue test Fatigue tests were conducted with an ultrasonic fatigue testing machine under axial tension–compression and torsional loading, as described in [20]. In these tests, specimens are stimulated to resonance tension–compression or torsion vibrations, respectively, which causes fatigue loading of the sample. The cycling frequency used is about 20 kHz and the stress ratio R = 1 in both experiments. Specimens were cooled with compressive air and fatigued intermittently [17,25]. The operating time was selected to be 100 ms for axial loading and 150 ms for torsional loading. The pause times were chosen in the range from 300 to 2500 ms depending on the applied stress. The applied stress amplitudes were determined from the measured strains using strain gauges attached in the centers of the specimens. For the stress calibration, the stress amplitude was selected to be between 10% and 50% of that of the fatigue test. The fatigue tests were stopped when the endured number of stress cycles exceeded about 109 cycles, or when a fatigue crack has formed. Initiation of a fatigue crack increases the specimen’s compliance and reduces the resonance frequency, and the experiments were stopped when the resonance frequency dropped by 115 Hz in axial loading and 35 Hz in torsional loading tests. After the fatigue tests, the fracture surfaces were investigated in a scanning electron microscope. Single-edge-notched specimens with a width of 8 mm and a thickness of 2 mm were fatigued at 30 Hz under axial tension– compression. The crack propagation behavior was determined using the load shedding technique. The rate of load shedding with increasing crack length was set to be 0.08 mm1. The crack opening displacement was measured with an extensometer with a gage length of 12.5 mm. The crack length was calculated by the unloading elastic compliance method [26] during the fatigue tests. 3. Experimental results and discussion 3.1. S–N curves The S–N diagram for axial tension–compression is shown in Fig. 3. Open symbols characterize failures and closed symbols with arrows indicate run-outs. The scatter is somewhat large, however, no duplex S–N curve can be observed. At a stress amplitude of 780 MPa, the shortest fatigue life is 7.0 106 cycles. On the other hand, another specimen did not break within 1.1 109 cycles. The fatigue strength at N = 109 cycles is between ra = 650 MPa and 810 MPa. The regression line shown in Fig. 3 approximates data of failed specimens assuming power law dependence of tension–compression stress amplitudes, ra, and cycles to failure, Nf, according to Eq. (3). ra ¼ 1:21 103 Nf0:027 Fig. 2. Distribution of inclusion size. ð3Þ Although the analysis based on the statistics was necessary to estimate the detailed S–N data, the results were simply approximated by the power function in this study. The broken lines in the figure show the 90% confidence interval. Although the hardness of all Y. Akiniwa et al. / International Journal of Fatigue 30 (2008) 2057–2063 Fig. 5. Comparison of axial and torsional data in terms of equivalent stresses. Fig. 3. S–N curve for axial loading. specimens was measured again after fatigue tests, the value was almost constant. The reason why the scatter is so large is not clear. The results obtained for torsional loading are shown in Fig. 4. The scatter is larger than that of axial loading. A clear knee point cannot be seen. The fatigue strength at N = 109 cycles is between sa = 468 MPa and 520 MPa. These stresses are smaller than those of axial loading, and the ratio of torsional and axial cyclic strength is between 0.64 and 0.72. Data of failed specimens are approximated assuming power law dependence of torsion stress amplitudes, sa, and cycles to failure according to Eq. (4). sa ¼ 7:79 102 N0:024 f ð4Þ The mean ratio of torsional, sa and axial stress, ra at the same number of load cycles calculated with the two experimental equations is about 0.68. The influence of number of stress cycles on the strength ratio is small. Ratios of sa and ra reported for steel in the literature vary between 0.58 and 0.72 [6–11]. In ultrasonic tests, ratios of 0.67 for the aluminum alloy 2024-T351 [20] and 0.60 for 0.15%C steel [21] have been found. In Fig. 5, the fatigue data measured in both testing series are presented vs. equivalent stresses. In this work, the equivalent stress amplitude of the von Mises type was adopted, and calculated as follows. req ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi r2a þ 3s2a ð5Þ The S–N curve obtained for torsional loading is at about 17% higher equivalent stresses compared with axial loading even in the giga cycle regime. This tendency is quite similar to that for the aluminum alloy 2024-T351 [20]. 3.2. Fracture surfaces After fatigue testing, cracks with a few millimeters length could be observed on the surface of failed specimens (indicated with open symbols in Figs. 3 and 4). On the other hand, no non-propagating cracks could be observed on the surface of run-out specimens (characterized with solid symbols in the S–N diagrams). Fig. 6a shows the fracture surface of a specimen broken after Nf = 1.02 105 cycles in a tension–compression test at the stress amplitude ra = 900 MPa, and Fig. 6b shows a specimen broken at ra = 650 MPa in the giga cycle regime, at Nf = 1.76 109 cycles. Although there is a rough region near the surface, the crack origin was at the specimen surface. It is interesting to note that neither inclusions nor granular facet areas could be observed even in the giga cycle regime. All specimens broke from the surface, and inclusions do not influence the crack initiation process. In a bearing steel [27] and a nickel chromium molybdenum steel [28], interior fatigue crack initiation from both, inclusions and microstructurally weak sites were found. In those cases, granular facet regions could be observed in the giga cycle regime, in contrast to the presently investigated material. In general, a fatigue limit under axial loading can be predicted from the Vickers hardness with the following equation [29]. rw0 ¼ 1:6 HV Fig. 4. S–N curve for torsional loading. 2059 ð6Þ The fatigue limit of the investigated steel calculated according to Eq. (6) and using the Vickers hardness of 598 is 957 MPa. This value is much higher than the experimental data as shown in Fig. 3. For high strength steels, the fatigue limit becomes smaller than the calculated value due to fracture from inclusions [29]. Although the crack origin is the specimen surface in this material, the fatigue limit is smaller than the expected value. Fig. 7a shows the surface of a specimen which broke after Nf = 6.98 105 cycles at the torsion stress amplitude sa = 577 MPa. Crack initiation was perpendicular to the longitudinal direction. After the crack propagated about 28 lm in shear mode, it branched and propagated in a mode I manner. Fig. 7b shows the fracture surface of this specimen. The fracture surface is smooth by ablation due to shear motion. In the very high cycle fatigue regime, the stage I crack was also initiated perpendicular to the longitudinal direction as shown in Fig. 8a. The specimen broke after Nf = 1.04 108 cycles at sa = 468 MPa. The length of the shear 2060 Y. Akiniwa et al. / International Journal of Fatigue 30 (2008) 2057–2063 Fig. 6. Fracture surface of specimens broken under axial loading. (a) Nf = 1.02 105, ra = 900 MPa. (b) Nf = 1.76 109, ra = 650 MPa. mode crack is 25 lm. Fig. 8b shows the fracture surface. In the stage I region, the fracture surface is also smooth. On the other hand, the roughness in the stage II region is larger than that of the specimen broken at shorter fatigue life (see Fig. 7b), because the ablation is not so pronounced at the lower stress level. Typical fracture surfaces of mode I cracks are shown in Fig. 9a (sa = 491 MPa, Nf = 1.65 107 cycles) and Fig. 9b (sa = 468 MPa, Nf = 6.28 107 cycles). The fracture surfaces look similar to that of Fig. 8b. No inclusions or granular facet areas are visible on the fracture surfaces. No correlation between length of the shear crack and applied stress or stress intensity range could be detected. For the spring steel investigated in this study, fatigue fracture did not occur from internal defects. Namely, inclusions in the material did not affect the fatigue strength, and the fatigue strength was determined by the strength of specimen surface up to the giga cycle regime. The relation between the fatigue strength and the fatigue life could be estimated by a power law relationship for both axial and torsional loading. The ratio of torsional and axial stress at the same number of load cycles is almost constant irrespective of fatigue life. However, it is necessary to note that the fatigue strength for axial tension–compression is much lower than the value expected from the hardness. 3.3. Non-damaging defect size As described above, fatigue crack initiation was at the surface in all specimens fractured in axial and torsion loading tests, and no Fig. 7. Scanning electron micrographs of a specimen broken after Nf = 6.98 105 under torsional loading at sa = 577 MPa. (a) Specimen surface. (b) Fracture surface. inclusions were found at the crack initiation sites. When the defect is less than the critical size, specimens do not break from the internal defect. Then the critical condition of crack propagation is investigated from the viewpoint of non-damaging defect size to explain why no specimen broke from internal inclusions. The threshold value of the stress intensity factor was determined in crack propagation tests under tension–compression. Fig. 10 shows the relation between crack propagation rate and maximum stress intensity factor. The triangles indicate the data obtained for a nickel chromium molybdenum steel (JIS SNCM439) [28]. The resistance against fatigue crack propagation of the spring steel is larger than that of the nickel chromium molybdenum steel. For the spring steel, the threshold value of the maximum stress intensity factor, Kmaxth is 4.5 MPa m1/2. Although the threshold value has also a statistical property as well as fatigue strength, obtained value was used in this study as a representative value. The fatigue strength calculated according to Eq. (3) at the number of stress cycles of 109 is 691 MPa. The diameter of the characteristic defect calculated with these values is 60.9 lm as shown in Fig. 11, where the stress intensity factor for the internal defect was calculated according to the following equation [29,30]: qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi pffiffiffiffiffiffiffiffiffiffi K ¼ 0:5r p area ð7Þ 2061 Y. Akiniwa et al. / International Journal of Fatigue 30 (2008) 2057–2063 Fig. 9. Fracture surface of torsional loading. (a) sa = 491 MPa, Nf = 1.65 107. (b) sa = 468 MPa, Nf = 6.28 107. -6 The size of the characteristic defect of high strength steels corresponds to that of a non-damaging defect. The maximum inclusion size in the critical volume of a specimen is 7.9 lm as shown in Fig. 2. Thus, the size of the maximum inclusion is much smaller than the characteristic defect size. On the other hand, for the nickel chromium molybdenum steel, the fatigue strength at Nf = 109 and the threshold stress intensity factor are 750 MPa and 2.1 MPa m1/ 2 , respectively [28]. In this case, the characteristic defect size is 11.3 lm. The value is close to the inclusion size of about 7–10 lm observed on the fracture surface. For the internal fracture, the granular facet size is also important. Fig. 12 shows the change in the facet size with the inclusion size obtained for several high strength steels [27,31,32], where the values of (area)1/2 are plotted in the figure. The facet size is strongly associated with the inclusion size. If the inclusion size in the critical volume is 7.9 lm, the facet size expected from Fig. 11 will be maximum about 40 lm. The stress intensity factor corresponding to the facet crack at Nf = 109 cycles (rw = 691 MPa) is 3.9 MPa m1/2. This value is smaller than the propagation threshold of 4.5 MPa m1/2. For the internal cracks, since the crack propagates without environmental effects of atmospheric air, the threshold value of long cracks should be larger than 4.5 MPa m1/2 [28]. There- 10 Crack propagation rate. da/dN m/cycle Fig. 8. Scanning electron micrographs of a specimen broken after Nf = 1.04 108 under torsional loading at sa = 468 MPa. (a) Specimen surface. (b) Fracture surface. R=-1 SWOSC-V SNCM439 -7 10 -8 10 -9 10 -10 10 -11 10 2 1 3 4 5 6 78 2 3 10 1/2 Stress intensity factors, Kmax MPam Fig. 10. Relation between crack propagation rate and stress intensity factor under axial loading. fore, no internal crack can propagate at the stress intensity factor of 3.9 MPa m1/2. On the other hand, for the nickel chromium molybdenum steel, the calculated stress intensity factor for the same facet size at Nf = 109 cycles (rw = 750 MPa) is 4.2 MPa m1/2. The value 2062 Y. Akiniwa et al. / International Journal of Fatigue 30 (2008) 2057–2063 regime irrespective of fatigue life. The fatigue strength for axial tension–compression is much lower than the value expected from the hardness. (3) Fatigue cracks were initiated in all specimens at the surface, and no inclusions or granular facet areas could be detected at the crack initiation site. Since the resistance against crack propagation from internal inclusions was relatively large, the inclusions did not affect the decrease in fatigue strength up to the giga cycle regime. Acknowledgement The authors are thankful to Miss A. Nakamura of Nagoya University for her help concerning some experiments. References Fig. 11. Kitagawa diagram for SWOSC-V and SNCM439. Fig. 12. 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