Neutron and X-ray diffraction studies and cohesive interface model of the fatigue crack deformation behavior

The crack-tip deformation behavior during a single overload, fatigue test of ferritic stainless steel, and Ni-based HAYNES 230 superalloy is studied at different structural levels using (1) neutron-diffraction, from which both the elastic-lattice strain and volume-averaged total dislocation densities are obtained, (2) polychromatic X-ray microdiffraction to probe the geometrically necessary dislocations and boundaries distribution, and (3) an irreversible and hysteretic cohesive interface model which has been implemented into a finite element framework to simulate the stress/strain evolution near the fatigue crack tip. Neutron strain measurements and finite element simulations are in qualitative agreement on the macroscopic length scale. Large plastic deformation induced by the overload and the resulting compressive residual strains are observed in front of the crack tip after the overload, and are the principal reason for the fatigue-crack-growth retardation. Strong strain gradients surrounding the crack propagation result in the formation of a high density of geometrically necessary dislocations near the fractured surface and cause local lattice rotations on the submicron level.