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The present study gives an overview of recent investigations dealing with the fatigue behaviour of the tempered martensitic steel 50CrMo4 (Fe-0.5wt%C-1wt%Cr) in the HCF and VHCF regime by taking into account a variation in material strength, by modifying the heat treatment parameters. The parameters for the tempering treatment were adapted to receive two material conditions with 37HRC and 57HRC, respectively. Subsequently, fatigue specimens were machined from the heat-treated bars for fatigue tests in an ultrasonic (f=20000Hz) and a resonance (f=95Hz) fatigue testing machine under fully reversed loading (R=-1) at laboratory air atmosphere. It was found that the dominant fatigue and fracture mechanisms change with increasing material strength. For 37HRC moderate-strength specimens crack initiation was shown to occur on the specimen surface within Cr depleted bands (segregation bands) as the dominant fatigue damage mechanism. Contrary to that, only internal crack initiation at non-metallic inclusions was observed for the high strength 57HRC condition. Furthermore, the completely different crack initiation mechanisms of the two heat treatment conditions were assessed by applying the Murakami approach relating the fatigue limit with the size of non-metallic inclusions.
By means of comparing the VHCF response of heat-treated alloy steel, several factors governing the transition from surface (type I) to internal (type II) VHCF failure, and, in the case of internal inclusion and non-inclusion type II VHCF failure, are discussed: differences in strength, differences in grain size and strength gradients. Therefore, the steel grades (i) 50CrMo4 (0.5 wt%C–1.0 wt%Cr–0.2 wt%Mo) in two different tempering conditions (37HRC and 57HRC) but of the same prior austenite grain size, and (ii) 16MnCrV7 7 (0.16 wt%C–1.25 wt%Mn–1.7 wt%Cr) in the bainitic and martensitic thermomechanical treatment state, were studied. It is concluded that steels of moderate strength (37HRC) exhibit a real endurance limit (109 cycles), while the fatigue strength of high strength (43–57HRC) or coarse-grained steels (37HRC) decreases with increasing number of load cycles.
In this study, we investigate the influence of control type and strain rate on the lifetime of specimens manufactured from 50CrMo4. This influence is described by a strain rate dependent method that uses cyclic stress strain curves to correct displacement-controlled cyclic test results. The objective of this correction is to eliminate the stress related differences between displacement-controlled cyclic test results and force-controlled cyclic test results. The method is applied to the results of ultrasonic fatigue tests of six different combinations of heat treatment, specimen geometry (notch factor) and atmosphere. In a statistical analysis, the corrected results show an improved agreement with test results obtained on conventional fatigue testing equipment with similar specimens: the standard deviation in combined data sets is significantly reduced (p = 4.1%). We discuss the literature on intrinsic and extrinsic strain rate effects in carbon steels.
Herein, the fatigue damage mechanisms of a low‐alloyed 0.5 wt% carbon steel (50CrMo4) are examined in the high cycle fatigue and very high cycle fatigue regime, taking into account different strength conditions. For this purpose, the heat treatment of the material is conducted using two different batches at two different tempering temperatures, which lead to hardnesses of 37HRC and 57HRC, respectively. The fatigue tests are conducted accounting for different test frequencies of f = 95 Hz and f = 20 kHz, as well as size effects. It is found that the fatigue behavior of the tempered steel 50CrMo4 can be subdivided into type I (surface cracks) and type II (internal cracks) VHCF damage behavior depending on the material strength condition. With the aid of in situ test equipment, the influence of microstructural banding on the local fatigue strength is demonstrated by high‐resolution thermography. By implementing an ultrasonic testing machine in a high‐resolution scanning electron microscope, the development of a fine granular area (FGA) at an artificial defect in vacuum atmosphere is demonstrated.