Fatigue Life Prediction for Porosity-Containing Cast 319-T7 Aluminum Alloy

In this study, the linear elastic fracture mechanics (LEFM) approach, including use of the equivalent initial flaw size (EIFS) concept and fatigue crack propagation (FCP) rates, da/dN, as a function of either ΔK or ΔKeff, was used to predict the fatigue life of a porosity-containing 319-T7 specimen. The uniaxial fatigue tests were conducted on a 319-T7 specimen at a stress ratio (R) of −1. For the LEFM-based fatigue life prediction, da/dN-ΔK data were obtained for the 319-T7 specimen at R = 0.1. The shape and the size of the porosity were analyzed based on the fractographic and the micrographic analyses for each fatigued specimen. The LEFM concept, including the use of the EIFS value, back-calculated by using da/dN-ΔKeff data, successfully predicts the porosity-affected stress vs the number of cycles to failure (S-N) fatigue behavior of cast 319-T7 specimens. The LEFM models presently available for predicting the fatigue life of porosity-containing alloys were evaluated and a simple modification was proposed based on extensive fractographic analysis results.