Jtam.dvi JOURNAL OF THEORETICAL AND APPLIED MECHANICS 41, 1, pp. 55-73, Warsaw 2003 ESTIMATION OF HIGH TEMPERATURE FATIGUE LIFETIME OF SUS304 STEEL WITH AN ENERGY PARAMETER IN THE CRITICAL PLANE Tadeusz Łagoda Ewald Macha Technical University of Opole e-mail: tlag@po.opole.pl; emac@po.opole.pl Masao Sakane Ritsumeikan University, Nojihigashi Kusatsu-shi Shiga, Japan The paper studies the application of the energy parameter, a sumof ela- stic and plastic strain energy densities in the critical plane, for the corre- lation of two series of proportional biaxial low-cycle lives using SUS304 stainless steel at elevated temperature. The first data used thin-walled cylinder specimens subjected to 7 proportional strain paths of combi- ned tension-torsion and the other used cruciform specimens subjected to 5 proportional strain paths of biaxial tension-compression. These tests were done at the temperature of 923K. The normal total strain energy density in theplanewith themaximumdamagewasa suitableparameter for describing the test results. Key words: low-cycle fatigue, multiaxial fatigue, energy approach, lifetime, high temperature Notations E – Young’s modulus k – strain ratio (k= ε3/ε1 or k= εxx/εyy) K′,n′ – cyclic strain hardening coefficient and exponent lη,mη,nη – direction cosines of unit vector η against coordinates (x,y,z) Nf – number of cycles to failure 56 T.Łagoda et al. sij – components of stress tensor deviator Waη – amplitude of strain energy density in critical plane with normal vector η Waηε – amplitude of strain energy density in critical plane when stress has been calculated frommeasured strain Waησ – amplitude of strain energy density in critical plane when strain has been calculated frommeasured stress x,y,z – spatial coordinates of specimen α – angle between vector normal to critical plane η and the x axis δij – Kronecker delta ∆ση,∆εη – normal stress and strain ranges in η direction ε1,ε2,ε3 – principal strains εij(i,j =x,y,z) – strain tensor components (γij =2εij, i 6= j) ε′f,c – fatigue ductility coefficient and exponent εpeq – equivalent plastic strain η – unit vector normal to critical plane ν – Poisson’s ratio γ – engineering shear strain σ1,σ2,σ3 – principal stresses σaη,εaη – normal stress and strain amplitudes in η direction σij – stress tensor components σkk – sum of normal stresses (σkk =σxx+σyy +σzz) σeq – equivalent stress σ′f,b – fatigue strength coefficient and exponent Subscripts a – amplitude exp – experimental cal – calculation p – plastic e – elastic t – total 1. Introduction The oldest models of multiaxial fatigue were based on stress. Later, the models using strain were introduced in order to calculate the fatigue life in high- and low-cycle regimes. However, both models have a limited range of application and they cannot be used in some situations. Thus, newmodels are still being sought. For about thirty years, the energy approach to multiaxial Estimation of high temperature fatigue lifetime... 57 fatigue has been developed. Recently, some very successful experimental data descriptions and useful algorithms for fatigue life estimation have been propo- sed. In these algorithms themultiaxial fatigue criteria play themost important role. The strain energy criteria used for multiaxial fatigue failure can be clas- sified into three groups depending on the type of strain energy density per cycle as a damage parameter (Andrews andBrown, 1989; Curioni andFreddi, 1991; Ellyin, 1974, 1989; Ellyin and Gołoś, 1988; Garud, 1981; Glinka et al., 1995; Gołoś, 1988; Gołoś and Osiński, 1994; Lefebvre et al., 1988; Leis, 1977; Macha, 1979; Nitta et al., 1989). They are: • criteria based on elastic strain energy density for high-cycle fatigue (HCF), • criteria based on plastic strain energy density for low-cycle fatigue (LCF), • criteria based on the sum of plastic and elastic strain energy densities for both low- and high-cycle fatigue (LCF and HCF). However, the criteria including strain energy density in fracture planes or critical planes are a dominating parameter for describing multiaxial fatigue, and they seem to bemost promising. Ellyin (1974) was the first to propose an energy approach to multiaxial fatigue. His approach includes not only the elastic strain energy density (as generalised Huber-Mises-Hencky hypothesis or Beltrami hypothesis) but also the plastic strain energy density. The Ellyin’s parameter is understood as an elastic and plastic strain energy in octahedral planes for HCF and LCF. For HCF,Macha (1979) proposed elastic shear strain energy density in the maxi- mum shear stress plane. Garud’s proposal (1981) concerns the sum of plastic strain energy density for all strain components in a cycle under proportio- nal and non-proportional loading for LCF. However, the in- and out-of-phase tension-torsion experimental results verified that the sum of plastic normal and shear strain energy densities in the critical plane is a parameter strongly influencing the fatigue life. Socie (1987) successfullyused theSmith-Watson-Topperparameter (SWT) (Smith et al., 1970), i.e. the normal elastic and plastic strain energy densities in the plane where the maximum normal strain range occurs in proportio- nal and non-proportional tension-torsion HCF and LCF for SUS304 at room temperature. Lefebvre et al. (1988) used the plastic effective strain energy density in a cycle as a LCF damage parameter. This parameter is equivalent to the shear strain energy in the octahedral plane. 58 T.Łagoda et al. Nitta et al. (1989) applied the energy fatigue parameters related with the fracture plane by analysing the experimental results in tension-torsion propor- tional and non-proportional HCF and LCF. They proposed: • elastic andplastic normal strain energydensities in themaximumnormal strain range plane, • elastic and plastic shear strain energy densities in the maximum shear strain range plane, • non-linear sum of the two above energies in the fracture plane. Theseparameters dependon the strain ratio, phasedifferences and fracture mode. Hoffman and Seeger (1989) proposed the modified SWT parameters for proportional HCF and LCF. The authors suggested that the fatigue damage parameter should be the elastic and plastic normal strain energy in themaxi- mum normal strain plane or the elastic and plastic shear strain energy in the maximum shear strain plane.The choice of either the former or latter depends on the material property. Chu et al. (1993) proposed the sumof elastic andplastic strain energyden- sities of normal and shear components in the critical plane (for themaximum sum of both energies) for proportional and non-proportional HCF and LCF. For the same loading, Liu (1993) proposed a sum of the elastic and plastic energy densities of normal and shear strains (virtual strain energy, VSE para- meter) in the critical plane. The plane is determined by seeking themaximum value of one energy component, according to Mode I or Mode II. Chen et al. (1999) also used VSE parameter for proportional and non-proportional LCF in the critical planes of maximum normal strain or maximum shear strain. For proportional HCF and LCF, Glinka et al (1995) used a sum of the elastic and plastic strain energy densities of the normal and shear components in the maximum shear strain plane. The parameter proposed by Glinka et al. has been recently modified and extended to non-proportional loading by Pan et al. (1999). An energy based critical plane approach was proposed by Rolovic and Tipton (1999), Varvani-Farahani andTopper (2000), Park andNelson (2000), and Jiang (2000) tomultiaxial cycle fatigue and tomultiaxial random fatigue by Łagoda (2001), Łagoda andMacha (2000, 2001), Łagoda et al. (1999). An extensive review of energy-based criteria of multiaxial fatigue failure has been published by Macha and Sonsino (1999). From the above papers, the proposed energy models have two aspects; the definition of strain energy density and the introduction of the critical plane. It should be emphasised that there exists no universal critical plane Estimation of high temperature fatigue lifetime... 59 applicable towidely variedmultiaxial stress states (Łagoda, 2001; Łagoda and Macha, 2000, 2001; Łagoda et al., 1999). The experimental verification of the proposed energymodels is still a scientific open question. Many experimental data should be obtained in order to prove the validity of these models for various materials, loading conditions, temperature and so on. The objective of this paper is to examine the strain energy density para- meter by applying the parameter to the proportional LCF data using SUS304 stainless steel hollow cylinder and cruciform specimens at elevated tempera- tures. For the case of SUS 304 steel in tension-torsion LCF of cylindrical spe- cimens, Socie (1987), and Nitta et al. (1989) showed that the normal strain energy density in the critical plane of the maximum normal strain range was a suitable parameter at room temperature and 1096K, respectively. Theauthorswill examine the suitability of the energyparameter for descri- bing the tension-torsion and biaxial tension LCF behaviour of SUS304 steel at 923K. The energy parameter considered in the paper is also based on the SWT idea (Smith et al., 1970) but it uses a newly defined critical plane. InŁa- goda (2001), Łagoda andMacha (2000, 2001), Łagoda et al. (1999) it has been shown that the normal strain energy density in the critical plane (the plane of the maximum damage) may be successfully used for evaluation of the fatigue life of 10HNAP steel under randombiaxial tension of cruciform specimens and tension-compression with torsion for 35NCD16 steel andGGG40 andGGG60 cast irons. This parameter will be subjected to another assessment using two series of data for SUS304 steel. 2. Fatigue tests The test material used was SUS 304 stainless steel of which the chemical composition is presented inTable 1.This paper analysed two fatigue data sets. One is the tension-torsion LCF data using hollow cylinder specimens shown in Fig.1 in the principal strain ratio range of −1 ¬ k ¬ 0.5 (Sakane et al., 1987) and the other is the tension-tensionLCFdatausing cruciformspecimens shown in Fig.2 in the normal strain ratio range of −1¬ k¬−1 (Itoh et al., 1994). The experimentswere done in loading phase. The strainwave usedwas a fully reversed triangular strain wave with theMises equivalent strain rate of 0.1%/s at 923K. 60 T.Łagoda et al. Table 1.Chemical composition of SUS304 steel in weight percent ratio C Mn Si P S Cr Ni Fe 0.06 1.13 0.38 0.008 0.021 18.52 8.74 bal. Fig. 1. Cylinder specimen Fig. 2. Cruciform specimen Tables 2 and 3 summarize the experimental results in tension-torsion and tension-tension data, respectively. Graphical representations of these results are shown in Fig.3 and Fig.4. The value of Young’s modulus was assumed (Itoh et al., 1994; Sakane et al., 1987) to be 158GPa and that of Poisson’s ratio 0.3 in the following analysis. The relationship between the strain ranges and cycles to failure in the uniaxial stress state was approximated by the following equation according to the ASTMmethod (Socie, 1987) εa = εae+εap = σ′f E (2Nf) b+ε′f(2Nf) c (2.1) Estimation of high temperature fatigue lifetime... 61 Table 2. Fatigue test results for thin-walled cylindrical specimens k= εa3 εa1 εayy σayy γaxy τaxy Nf Waη Ncal Waησ Waηε [%0] [MPa] [%0] [MPa] [cycles] [MJ/m 3] [cycles] [MJ/m3] [MJ/m3] −0.50 7.50 319 0 0 200 1.196 185 1.303 1.121 5.00 246 0 0 720 0.615 718 0.533 0.627 3.50 219 0 0 1200 0.384 1963 0.365 0.375 2.50 201 0 0 7600 0.252 5029 0.278 0.226 −0.52 7.25 286 3.35 76 270 1.145 202 1.200 1.106 4.90 256 2.25 62 820 0.678 586 0.776 0.615 3.40 213 1.55 56 1480 0.398 1815 0.436 0.369 −0.57 6.50 234 6.50 106 280 1.035 247 0.928 1.061 4.35 161 4.35 103 1240 0.529 985 0.419 0.598 3.00 152 3.05 96 3280 0.347 2452 0.339 0.359 −0.64 5.03 229 9.20 112 530 1.020 255 0.947 0.995 3.55 182 6.15 112 1180 0.581 808 0.595 0.559 2.50 198 4.30 80 2100 0.391 1887 0.463 0.340 −0.74 3.75 172 11.25 160 510 0.971 281 1.106 0.884 2.50 140 7.50 147 730 0.559 877 0.984 0.497 1.75 101 5.25 128 2720 0.315 3039 0.368 0.295 −0.86 1.95 103 12.55 178 1050 0.823 393 0.930 0.744 1.30 135 8.35 129 1750 0.490 1160 0.502 0.419 0.90 87 5.85 118 8900∗ 0.277 4056 0.266 0.253 −1.00 0 9 13.00 191 500 0.635 671 0.746 0.585 0 24 8.65 157 2000 0.368 2154 0.401 0.335 0 16 6.05 139 8600 0.225 6527 0.256 0.203 ∗ – no crack Table 3. Fatigue test results for cruciform specimens k= εaxx εayy εayy σayy σaxx Nf Waη Ncal [%0] [MPa] [MPa] [cycles] [MJ/m 3] [cycles] −1 5.0 163 −163 2100 0.408 1720 3.5 141 −141 6200 0.247 5265 2.5 122 −122 35000 0.153 16278 1.5 95∗ −95∗ > 100000 0.071 115300 −0.5 5.0 251 −21 1100 0.628 687 3.5 212 −21 3200 0.371 2116 2.5 181 −22 13500 0.226 6461 2.0 161∗ −22∗ > 100000 0.161 14391 1.5 137∗ −21∗ > 120000 0.103 43571 62 T.Łagoda et al. 0 5.0 310 135 600 0.775 444 3.5 264 111 2800 0.462 1315 2.5 224 90 7200 0.280 3959 2.0 200 79 40000 0.200 8590 1.5 170 65 80000 0.128 25217 0.5 5.0 329 254 350 0.823 393 3.5 282 216 700 0.494 1140 2.5 241 182 4700 0.301 3364 2.0 216 163 4800 0.216 7176 1.5 185 138 38000 0.139 20574 1 3.5 287 287 700 0.502 1101 2.5 247 247 2800 0.300 3389 2.0 222 222 2200 0.222 6734 1.5 192 192 10000 0.144 18868 ∗ – no crack Fig. 3. Fatigue test results using tube specimens under tension-torsionmultiaxial stress states Estimation of high temperature fatigue lifetime... 63 Fig. 4. Fatigue test results using cruciform specimens under biaxial tension-compressionmultiaxial stress states Fig. 5. Correlation of uniaxial tension fatigue lives of tube specimens with total, elastic and plastic strain range 64 T.Łagoda et al. Thematerial constants determined in the low-cycle range (200-7600 cycles) are σ′f =722MPa, ε ′ f =0.075, b=−0.42, c=−0.436, (Fig.5). The followingRamberg-Osgoodmodelwasused toexpress the cyclic stress- strain curve εa = εae+εap = σa E + (σa K′ ) 1 n′ (2.2) Comparing the amplitudes of the elastic and plastic strains, εae and εap, from equations (2.1) and (2.2) we have σa E = σ′f E (2Nf) b (σa K′ ) 1 n′ = ε′f(2Nf) c (2.3) Substituting σa in Eq. (2.3)1 into Eq. (2.3)2 and slightly modifying, gives (σ′f K′ ) 1 n′ (2Nf) b n′ = ε′f(2Nf) c (2.4) Since Eq. (2.4) holds for every Nf, we can obtain the two independent equ- ations (σ′f K′ ) 1 n′ = ε′f b n′ = c (2.5) The value of K′ is 1680MPa and that of n′ is 0.326, so that K′ = σ′f (ε′ f )n ′ =1680MPa n′ = b c =0.326 (2.6) 3. Mathematical model For determining the amplitudes of normal stresses in cruciform specimens we used the Hencky total elastic-plastic deformation theory, as suggested by Moftakhar et al. (1995) εij = ε e ij +ε p ij = 1+ν E σij − ν E σkkδij + 3 2 εpeq σeq sij (3.1) where σeq = √ 3 2 sijsij sij =σij − 1 3 σkkδij (3.2) Estimation of high temperature fatigue lifetime... 65 To express the stress-strain relationship in multiaxial proportional loading, the Mises equivalent values were used as follows, where the same K′ and n′ values in Eq. (2.2) were used εpeq = (σeq K′ ) 1 n′ (3.3) From Eqs (3.2) and (3.3), the principal strains εa1, εa2, εa3 can be written with the principal stresses σa1, σa2, σa3 in plane stress conditions as εa1 = 1 E (σa1−νσa3)+ 1 2 (K′) −1 n′ (2σa1−σa3)(σ 2 a1+σ 2 a3−σa1σa3) 1−n′ 2n′ εa2 =− ν E (σa1+σa3)− 1 2 (K′) −1 n′ (σa1+σa3)(σ 2 a1+σ 2 a3−σa1σa3) 1−n ′ 2n′ (3.4) εa3 = 1 E (σa3−νσa1)+ 1 2 (K′) −1 n′ (2σa3−σa1)(σ 2 a1+σ 2 a3−σa1σa3) 1−n ′ 2n′ Since the stresses for the cruciform specimen cannot be directly determined from the applied load, they were determined using Eqs (3.4)1,3 and they are listed in Table 3. For the cruciform specimens the calculated stresses σ3 =σx and σ1 = σy. The z direction stress σz was equal to zero, so the strain energy density in the same direction was also equal to zero for the cruciform specimens. The energyparameter used in this paper includes themaximumelastic and plastic normal strain energy densities in the critical plane. Under proportional loading the amplitude of energy Waη in the critical plane with the normal vector η(lη,mη,nη) is written as Waη = 1 2 σaηεaη = 1 8 ∆σaη∆εaη (3.5) where σaη = ∆ση 2 = l2ησaxx+m 2 ησayy +n 2 ησazz +2lηmητaxy + + 2lηnητaxz +2mηnητayz (3.6) εaη = ∆εη 2 = l2ηεaxx+m 2 ηεayy +n 2 ηεazz +2lηmηεaxy + + 2lηnηεaxz +2mηnηεayz σaη and εaη are the normal stress and strain amplitudes in direction η, respec- tively. (lη,mη,nη) are the direction cosines of η against coordinates (x,y,z). 66 T.Łagoda et al. Fig. 6. Graphical interpretation of energy A graphical presentation of the energy parameter is shown in Fig.6. In uniaxial tension tests, the strain amplitude-failure cycle (εa −Nf) relation- ship can be rewritten with the strain energy density-failure cycle (Wa−Nf) relationship. From Eqs (2.1) and (3.5) we obtain Wa = 1 2 σaεa = σa 2 [σ′f E (2Nf) b+ε′f(2Nf) c ] (3.7) From (2.3)1 we have σa =σ ′ f(2Nf) b (3.8) then Eq. (3.7) becomes a new fatigue equation between Wa and Nf Wa = (σ′f) 2 2E (2Nf) 2b+ 1 2 ε′fσ ′ f(2Nf) b+c (3.9) 4. Algorithm for determination of fatigue lifetime Figure 7 shows the algorithm for determination of fatigue lifetime using this parameter. At first (stage 1) we measure the strain state components being controlled during the experiments. Estimation of high temperature fatigue lifetime... 67 Fig. 7. Algorithm for fatigue lifetime determination Next (stage 2), we calculate the stress amplitudes. In the case of cylinder specimens it was possible to measure the stress amplitude experimentally, so the experimentally measured stress was used. Having the stress and strain amplitudes, we can determine the energy amplitude by (3.5) in any plane with the normal vector η (stage 3). The normal stress and strain at any plane can be determined by the follo- wing equations for the plane stress conditions from (3.6) σaη = l 2 ησaxx+m 2 ησayy +2lηmητaxy (4.1) εaη = l 2 ηεaxx+m 2 ηεayy +n 2 ηεazz + lηmηγaxy Note that in the thin-walled cylinder specimen σayy = σazz = τaxz = τayz = γaxz = γayz = 0 and in the cruciform specimen σazz = τaxy = τaxz = τayz = γaxy = γaxz = γayz =0. For a plane stress state, the direction cosines of the vector normal to the critical plane η can be described with the angle α between the η direction and x axis lη =cosα mη =sinα nη =0 (4.2) The critical plane was searched by the damage cumulation method (Łagoda, 2001; Łagoda andMacha, 2000, 2001; Łagoda et al., 1999; Sakane et al., 1987). The critical plane is the plane which has themaximum energy Waη (stage 4). Generally, energy parameter (3.5) agrees with the energy parameter used by Socie (1987) and Nitta et al. (1989). The difference concerns only the defini- tion of the critical plane. Socie and Nitta et al. assumed the plane with the maximum range of normal strains, and in model (3.5) the critical plane is a 68 T.Łagoda et al. planewith themaximumamplitude of the energydensity of normal strains.At our critical plane the accumulated fatigue damage is the maximum according to the assumed fatigue parameter. It should be also stated that in the case of cruciform specimens under the assumed loading, verified energy parameter (3.5) is the same as that resulting fromthe criterion proposedbyLiu (1993) for thin-walled cylindrical specimens under crack mode I. At the final step (stage 5), we can calculate a number of cycles to failure, Nf based on Eq. (3.9). 5. Comparison of calculated life time with actual life time Figure 8 compares the calculated lives with the experimental ones for the cylindrical and cruciform specimens. Fig. 8. Comparison of predicted and experimental fatigue lives for cylinder and cruciform specimens In the figure a factor of 3 scatter band based on the experimental data is presented. For 200-10000 failure cycles, all the results are located within that scatter band. For higher numbers of cycles they are greater, but in both Estimation of high temperature fatigue lifetime... 69 cases we observe a trend to overestimate the energy amplitude. It is probably because the parameters of curve (2.1) for uniaxial tension-compression have been determined from the tests for a lower number of cycles to failure. The parameter of plastic and elastic energy of normal strains in the cri- tical plane can be assumed effective for low-cycle fatigue life evaluation for the cylinder and cruciform specimens tested under the biaxial proportional loading at elevated temperature. Since the parameter is effective in the case of correlation of the experimental data obtained for the cruciform specimens of 10HNAP steel under random non-proportional biaxial tension-compression in the range of medium and high numbers of cycles at room temperature (Ła- goda, 2001; Łagoda andMacha, 2000, 2001; Łagoda et al., 1999), it should be verified in further tests. Hencky’s constitutive equations (3.1)-(3.4) and theparameters of the cyclic stress-strain curve of Ramberg-Osgood’s type are used to determine the stres- ses on the basis of the given strains.While applying the energy parameter no additional measurements are required to calculate the stresses. In order to prove that statement we calculated the amplitudes of energy density in the critical planes Waη for: (a) experimental strains εayy and γaxy (Table 2) and stresses determined according to equations (3.1)-(3.4), (b) experimental stresses σayy and τaxy (Table 2) and strains determined according to equations (3.1)-(3.4). The correlation shown in Fig.9 is equated from (3.9) as Wa =1.65(2Nf) −0.284+27.075(2Nf) −0.578 (5.1) The comparison shows that both calculationmethods usingEqs (3.1)-(3.4) are efficient, although the first one (measurement of strains and stress calculation) is more precise. 6. Conclusion An elastic and plastic strain energy parameter normal to the critical plane was proposed. This parameter can be evaluated from the stress and strain components applied to specimens. If only the strain components are given, the stress components can be calculated by using Hencky’s equation. 70 T.Łagoda et al. Fig. 9. Correlation of fatigue lives of tube specimens with three energy parameters Waη,Waησ and Waηε The proposed energy parameter correlated the tension-torsion and biaxial tension low cycle fatigue life of SUS304 steel within a factor of three scatter band.Theparameterwasproved tobeeffective for the correlation ofmultiaxial low cycle fatigue lives in the principal strain range of −1¬ k¬ 1. 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Varvani-Farahani A., Topper T.H., 2000, A new multiaxial fatigue life and crack growth rate model for various in-phase and out-of-phase strain paths, Multiaxial Fatigue and Deformation: Testing and Prediction, ASTM STP, 1387, S. Kalluri and P.J. Bonacuse, Eds., American Society for Testing andMaterials,West Conshohocken, PA, 305-322 Ocena wysokotemperaturowej trwałości zmęczeniowej stali SUS304 za pomocą parametru energetycznego w płaszczyźnie krytycznej Streszczenie Praca dotyczy zastosowania parametru energetycznego, sumy gęstości energii sprężystej i plastycznej odkształcenia w płaszczyźnie krytycznej do korelacji dwóch serii proporcjonalnych, dwuosiowych, niskocyklowych trwałości zmęczeniowych sta- li nierdzewnej SUS303 w podwyższonej temperaturze. Badano cienkościenne próbki cylindryczne poddane siedmiu proporcjonalnym torom odkształcenia w warunkach kombinacji rozciągania-skręcania oraz próbki krzyżowe poddane pięciu proporcjonal- nym torom odkształcenia w warunkach dwuosiowego rozciągania-ściskania. Badania prowadzono w temperaturze 923K. Gęstość energii całkowitego odkształcenia nor- malnego w płaszczyźnie maksymalnego uszkodzenia była odpowiednim parametrem do opisania wyników badań. Manuscript received March 20, 2002; accepted for print August 14, 2002