Very High Cycle Fatigue

Faculty of Technology and Science
Materials Engineering
Vitaliy Kazymyrovych
Very high cycle fatigue

of tool steels
DISSERTATION
Karlstad University Studies
2010:20

of tool steels

2010:20
Vitaliy Kazymyrovych. Very high cycle fatigue of tool steels

DISSERTATION
Karlstad University Studies 2010:20
ISSN 1403-8099
ISBN 978-91-7063-312-6
The Author
Distribution:
Faculty of Technology and Science
Materials Engineering
SE-651 88 Karlstad
+46 54 700 10 00
www.kau.se
Printed at: Universitetstryckeriet, Karlstad 2010
Abstract
An increasing number of engineering components are expected to have fatigue life in the range of
107 - 1010 load cycles. Some examples of such components are found in airplanes, automobiles and
high speed trains. For many materials the fatigue failures have lately been reported to occur well
after 107 load cycles, namely in the Very High Cycle Fatigue (VHCF) range. This finding contradicts
the established concept of fatigue limit, which postulates that having sustained around 10 7 load
cycles the material is capable of enduring an infinite number of cycles provided that the service
conditions are unchanged. With the development of modern ultrasonic fatigue testing equipment it
became possible to experimentally establish VHCF behaviour of various materials. For most of
them the existence of the fatigue limit at 107 load cycles has been proved wrong and their fatigue
strength continues to decrease with increasing number of load cycles.
High performance steels is an important group of materials used for the production of components
subjected to the VHCF. This study explores the VHCF phenomenon using experimental data
generated by ultrasonic fatigue testing of selected tool steels. The overall aim is to gain knowledge of
VHCF behaviour of some common tool steel grades, while establishing a fundamental
understanding of mechanisms for crack development in the very long life regime. The study
demonstrates that VHCF cracks in tested steels initiate from microstructural defects like slag
inclusions, large carbides or voids. It is established that VHCF life is almost exclusively spent during
crack formation that takes place at below threshold stress intensity values for crack propagation and
results in the specific morphology on the fracture surface, which is unique for VHCF. Relatively
rapid fatigue failure occurs from the point when the crack is still very small, measuring less than
100 m in diameter. This underlines the inherent difficulty in detecting of VHCF cracks and the
associated danger that VHCF represent in critical applications.
Significant attention is devoted in the thesis to the ultrasonic fatigue testing technique, the validity
and applicability of its results. FEM is employed to give an additional perspective to the study. It was
used to calculate local stresses at fatigue initiating defects; examine the effect of material damping on
ultrasonic stresses; and to evaluate various specimen geometries with respect to resulting stress
gradient and material volume subjected to maximum stresses.
Preface
This doctoral thesis is a result of research performed at the Department of Mechanical and Materials
Engineering in Karlstad University. In completing it I am deeply grateful to all the people who in
one or another way contributed to my work.
In particular, I would like to thank my supervisor Prof. Jens Bergstrm for his support, skilful
guidance, encouragement and our lively discussions that brought the research forward. I also
appreciate the positive input that my other supervisor Fredrik Thuvander made to this study.
My gratitude extends to Christer Burman who was most helpful with various technical issues and to
Anna Persson for her assistance in the departments laboratory. Another thank you goes to Jens
Ekengren for our extensive collaboration. Furthermore, in memory of Lars Carlsson, whose
unexpected death was a hurtful loss for everyone who knew him, I would like to acknowledge his
valuable technical support. I also owe my gratitude to Marianne Johansson and Gunnel Fredriksson
for their quick and efficient assistance in various administrative and other issues. In addition, I
would like to thank all the colleagues for creating such a friendly and supportive environment that I
experienced while doing research at Karlstad University.
I am sincerely grateful to the project partners from the steel industry who contributed to the
research with their resources, knowledge and materials.
A special thank you goes to my dear wife Olga and daughter Sofiya for their unconditional love and
kindness.
Karlstad, Sep 2010
iii
List of enclosed papers
Paper I
Evaluation of the giga-cycle fatigue strength, crack initiation and

growth in high strength H13 tool steel.
V.Kazymyrovych, J.Ekengren, J.Bergstrm, C.Burman.
Proceedings of 4th International Conference in Very High Cycle Fatigue.
Aug 2007, Ann-Arbor, USA.
Paper II
The significance of crack initiation stage in very high cycle

fatigue of steels.
V.Kazymyrovych, J.Bergstrm, C.Burman.
Steel Research International 81 (2010), issue 4, 308-314.
Paper III
Local stresses and material damping in very high cycle fatigue.

V.Kazymyrovych, J.Bergstrm, F.Thuvander.
International Journal of Fatigue 32 (2010), issue 10, 1669-1674.
Paper IV
Initial crack growth in very high cycle fatigue of a hot-work

tool steel.
V.Kazymyrovych, J.Bergstrm.
Submitted to Materials Science and Engineering: A.
Paper V
Stress verification and specimen design for ultrasonic

fatigue testing.
V.Kazymyrovych, J.Bergstrm, J.Ekengren.
Submitted to International Journal of Fatigue.
Other publications
Paper A
Assessment of strength and inclusions of tool steels in very high

cycle fatigue.
J.Ekengren, V.Kazymyrovych, J.Bergstrm.
Proceedings of the 8th International Tooling Conference. Jun 2009, Aachen,
Germany.
Paper B
Very high cycle fatigue of high performance steels.

V.Kazymyrovych
Licentiate thesis, Karlstad University Studies, 2008.
Paper C
Very high cycle fatigue of engineering materials.

V.Kazymyrovych
Literature review, Karlstad University Studies, 2009.
vii
Authors contribution to the papers
Paper I
Major part of planning, experimental work, evaluation and writing.
Paper II
Paper III
Paper IV
Paper V
ix
Contents
1. INTRODUCTION ................................................................................................................ 1
2. ULTRASONIC FATIGUE TESTING ................................................................................. 5

2.1 TESTING EQUIPMENT ............................................................................................................................................. 5
2.2 SPECIMENS USED FOR ULTRASONIC TESTING.................................................................................................... 7
2.3 LOCAL STRESSES AT FATIGUE INITIATING DEFECTS ........................................................................................ 9
2.4 EFFECT OF MATERIAL DAMPING IN ULTRASONIC TESTING.......................................................................... 11
3. VHCF OF HIGH PERFORMANCE STEELS .................................................................. 12

3.1 FATIGUE INITIATING DEFECTS........................................................................................................................... 13
3.2 STAGES OF VHCF CRACK DEVELOPMENT ....................................................................................................... 18
3.2.1 Crack growth rate ......................................................................................................................................... 20
3.2.2 Fatigue crack formation from a stringer type inclusion .................................................................................... 22
3.3 ROUGH AREA FORMATION .................................................................................................................................. 23
3.3.1 Rough Area border........................................................................................................................................ 27
3.3.2 Stress intensity factor range at fatigue initiating defects .................................................................................... 28
3.3.3 Mechanisms of Rough Area formation ........................................................................................................... 31
3.4 FATIGUE INITIATING POTENTIAL OF A DEFECT ............................................................................................. 35
SUMMARY .............................................................................................................................. 38
CONCLUSIONS ..................................................................................................................... 40
REFERENCES
42
xi
1. Introduction
The word fatigue is derived from the Latin fatigare which means to tire. In engineering terminology
fatigue is a progressive structural damage of materials under cyclic loads. There are a few main types
of fatigue. Mechanical fatigue is the focus of this study and could be described as damage induced by
application of fluctuating stresses and strains. Among other types of fatigue are: creep fatigue cyclic
loads at high temperatures; thermal fatigue cyclic changes in materials temperature; thermo-mechanical
fatigue a combination of mechanical and thermal fatigue; corrosion fatigue cyclic loads applied in
chemically aggressive or embrittling environment; fretting fatigue cyclic stresses together with the
oscillation motion and frictional sliding between surfaces. The devastating power of the fatigue
phenomenon is underlined by the fact that very often final fatigue failure occurs at stresses that are
well below the yield point of the material.
Fatigue life is an important characteristic of an engineering component and is measured by a number
of load cycles it can withstand before fatigue failure takes place. Based on the fatigue life concept the
mechanical fatigue could be sub-divided into: low cycle fatigue (LCF) up to 104 cycles to failure; high
cycle fatigue (HCF) between 104 and 107 cycles to failure and very high cycle fatigue (VHCF) over 107
cycles to failure. The VHCF of engineering materials is a phenomenon that first became
acknowledged and evoked scientific interest only a few decades ago. It was observed that some
materials when subjected to a sufficiently high number of load cycles (108 1010) fail at stress levels
that traditionally were considered as safe. Prior to this, it was believed that if a material survives
106 107 load cycles than it would never fail with increasing number of cycles at the same stress
level. The highest stress at which a material could sustain infinite number of load cycles is called a
fatigue limit.
In order to investigate the existence of fatigue limit, accelerated fatigue testing equipment was
required. The prototype of the modern ultrasonic fatigue testing machine was developed by Mason
in 1950. However, it was only in late 80th with the appearance of modern computers that the VHCF
testing attracted broader interest in Europe, Japan and the USA. Since then a number of materials
have been tested and proved not to have a fatigue limit at 106 107 load cycles, but instead show a
continuous decrease in fatigue strength with increasing number of cycles. These findings transform
the well known traditional Stress - Fatigue life Whler diagram with a fatigue limit represented by
a horizontal line, Fig.1, into the modified version with continuously decreasing fatigue strength.
Stress
Fatigue limit
1E+03
1E+05
1E+07
1E+09
1E+11
Number of load cycles

Figure 1. Stress Fatigue Life diagram showing conventional fatigue limit and its possible non-existence.
In addition to large scientific interest, the VHCF phenomenon represents a practical problem for
many technical systems. With progress in technological development that advocates energy and
material efficiencies, the required fatigue life for many components has increased to exceed 10 8 load
cycles. Nowadays the VHCF constitutes one of the main design criteria for a number of applications
in aircraft, automobile, railway and other industries. Some examples of such components are: gas
turbine disks (1010 cycles), car engine cylinder heads and blocks (108 cycles), ball bearings, high
frequency drilling machines, diesel engines of ships and high speed trains (109 cycles), etc.
The results of VHCF testing performed by many researches indicate that most of the materials do
not have a fatigue limit at typically 106 107 load cycles, showing gradual decrease in fatigue strength
when number of cycles reaches into giga-cycle range. With respect to VHCF properties the
materials could be categorized into two classes: type-I and type-II materials. For the first class of
materials the difference between the fatigue strength at 106 and 109 cycles is less than 50 MPa [1]. To
this category belong ductile homogeneous single-phase metals (copper and nickel are typical
representatives) and some alloys. Low carbon steels, some stainless steels and spheroid graphite cast
iron also present such behaviour. The type II materials exhibit fatigue strength decrease at 10 9 cycles
compared to 106 cycles typically in the range of 50-300 MPa. This class covers mainly high-strength
steels and other materials containing heterogeneities in the form of inclusions, pores, coarse second
phase particle, all of which could act as internal fatigue crack initiation sites. It appears that the
higher the ultimate tensile strength (UTS) of a material, the steeper is the S-N curve in the giga-cycle
range.
Among the materials which are often studied by VHCF testing are ferrous materials [2-9], titanium
alloys [1,10,11], nickel alloys [11-13], aluminium alloys [14-16] and polycrystalline copper [17,18].
2
These materials are widely used in aeronautics, aerospace, automotive, railway and other industries.
They constitute the base for manufacturing components that operate in VHCF conditions.
The effect of ultrasonic frequency on the estimated fatigue strength has been studied by many
researches in order to make sure that the fatigue results obtained using ultrasonic testing and low
frequency conventional fatigue equipment are comparable. As pointed out in [16] the frequency
influences might be divided into intrinsic and extrinsic. To the former ones belong frequency
influences related to strain rate, dislocation structures, crack formation and propagation. Whereas,
the latter influences include, for example, the relation between test frequency and environmental
effect; influence of creep; specimen heating during ultrasonic testing; etc.
Strain rate influences are most pronounced for pure metals with b.c.c. and h.c.p. crystal structure
[19]. An overview of the intrinsic influences of testing frequency on fatigue properties of f.c.c. and
b.c.c. metals is presented in [20], where it is demonstrated that such influences are more prominent
for b.c.c. metals. On the other hand, a literature review on ultrasonic fatigue testing shows that the
fatigue properties of metallic alloys are relatively insensitive to cyclic frequency. This statement is
valid under condition that time-dependent influences on the fatigue process, such as creep or
environmental effect, could be neglected. For some alloys, however, as for T6A4V in [1] or for
Inconel 718 in [12], significantly higher fatigue strength is observed at ultrasonic frequencies.
In case of steels the fatigue strength estimated using ultrasonic testing is either slightly higher or
approximately the same as the one obtained using conventional equipment. Furuya et al. reported
very little effect of test frequency on the fatigue properties of high strength steels [21,22]. Negligible
effect of frequency on estimated fatigue strength was observed by Marines-Garcia et al. for an AISI
SAE 52100 bearing steel [23]. On the other hand, Tsutsumi et al. showed in [24] that fatigue
strength of a low carbon steel, obtained with 20 kHz ultrasonic equipment, was more than 20 %
higher compared to the fatigue results generated with 10 Hz conventional equipment.
One important group of materials used for the production of high performance components
subjected to the VHCF is tool steels. Due to excellent combination of strength and toughness they
become often the material of choice for many demanding fatigue applications. This study explores
the VHCF phenomenon using experimental data of ultrasonic fatigue testing of some tool steel
grades. The causes and mechanisms of VHCF failures are investigated and analysed in relation to the
existing theories of fatigue crack initiation and growth in very long life regime. The main stages of
VHCF crack development in tool steels are established and discussed in light of their significance. A
particular attention is paid to the fatigue crack initiation, as it has been shown that in the VHCF
range initial crack growth consumes the majority of the total fatigue life. Understanding different
factors influencing the fatigue crack initiation is a key to improve fatigue properties of components
used for very long service lives.
At low stresses and very long lives, when surface crack initiation is prevented by fine finish and
introduction of compressive residual stresses, fatigue failures originate from microstructural defects
existing in the material. For tool steels such defects most often are represented by slag inclusions
3
that are introduced into the material during steel production process. Less frequently, large carbides
that are cracked by fatigue stresses, could act as fatigue initiating defects. In rare cases,
microstructural defects such as voids created by trapped gases in liquid steel lead to VHCF failure.
Moreover, in giga-cycle regime fatigue failures initiate from the largest defects present in the tested
volume. This means that ultrasonic testing provides an efficient tool to analyse a material with
respect to infrequent and unusually large microstructural defects, which are very difficult to find by
conventional defect detection techniques.
As shown in Papper II and [25] the VHCF life in steels is almost exclusively spent during the initial
crack growth, which is characterised by the formation of a particularly rough area on the fracture
surface adjacent to the fatigue initiating defect. The size of that area is comparable to that of the
defect and it was named as Optically Dark Area (ODA) by Murakami et al. [26,27], Granular Bright
Facet (GBF) by Shiozawa et al. [28] and Fine Granular Area (FGA) by Sakai et al. [29]. The exact
mechanisms of this rough area formation are not clear. Among the most cited is a theory proposed
by Murakami et al. in [26,27], where the authors postulate that the ODA is created by the synergistic
effect of cyclic stresses and hydrogen that is trapped at fatigue initiating defect. Shiozawa et al. in
[30] provides evidence in support of GBF formation by de-cohesion of spherical carbides from the
matrix in the region around the fatigue initiating defect. In [31] Sakai describes a model according to
which the FGA is created by formation of subgrains around the defect and eventual boundary
separation of these subgrains.
When designing components subjected to VHCF it would be highly desirable to be able to predict
fatigue strength based on the maximum size of microstructural defects found in the material
microstructure. A number of researches have established practical methods on how to assess the
influence of non-metalic inclusions and other microstructural defects on fatigue strength [5,32-37].
One of the most cited is a model proposed by Murakami [32,38], which allows calculation of fatigue
limit based on the size of fatigue initiating defect and Vickers hardness of the matrix. As described
in [39], this area parameter model uses the following formula to predict fatigue strength in case of
internal crack origin:
(1)
where:
HV R
predicted fatigue limit, MPa

Vickers hardness of the matrix, kgf/mm2
- square root of the projected area of the fatigue initiating defect, m
load ratio
According to the results presented in [38-40], the models predictions are in good agreement with
the experimental data, but as noted in [39] and described in [41], for fatigue lives above 108 load
cycles the fatigue limit predicted by the model is higher compared to the experimental data. It would
be fair to say that none of the above mentioned models is designed to predict fatigue strength in
giga-cycle regime.
4
The fundamental aim of this study is to gain knowledge about VHCF behaviour of high
performance steels. In the thesis the VHCF phenomenon is explored using experimental data
generated by ultrasonic fatigue testing of selected tool steels. Different stages and mechanisms of
fatigue crack formation and growth in giga-cycles regime are examined with focus on small crack
initiation and growth. The most common VHCF origins in steels are studied and their fatigue
initiating potential is assessed in relation to stress level and resulting fatigue life. Finite element
modelling of VHCF testing has added an additional perspective to the study. It enabled verification
of ultrasonic fatigue stresses and monitoring of material damping effect on generated stresses during
testing. In addition, using FEM the stress gradient in the specimen was established, which allowed
local stress estimation at fatigue initiating defects. Furthermore, based on FEM results material
volume subjected to critical fatigue stresses was calculated. A separate attention in the thesis is
devoted to the ultrasonic fatigue testing technique, the application of its results and ultrasonic
specimen design issues.
2. Ultrasonic fatigue testing

2.1 Testing equipment
As mentioned earlier the conventional fatigue testing does not have practical capability to provide
fatigue results in the VHCF range. This could be successfully accomplished using ultrasonic fatigue
testing equipment, which is the focus of this section. The frequency of ultrasonic fatigue testing
ranges from 15 to 30 kHz with the typical one being 20 kHz. This offers drastic decrease in time and
subsequently cost of fatigue testing, Table 1.
Table 1
Ultrasonic versus conventional fatigue testing
Number of cycles
Ultrasonic (20 kHz)
107 cycles
9 minutes
109 cycles
14 hours
1010 cycles
6 days
Conventional (100 Hz)

1 day
4 months
3 years
The concept of ultrasonic fatigue testing was initiated at the beginning of 20th century by
Hopkinson who developed the first electromagnetic resonance system of 116 Hz [1]. At that time
the highest attainable fatigue testing frequency of a mechanically driven system was 33 Hz. Then in
1925 Jenkin applied similar technique to test copper, iron and steel wires at the frequency of 2.5
kHz. Later in 1929 together with Lehmann he produced pulsating air resonance system and reached
the frequency of 10 kHz. In 1950 Mason marked an important development in the ultrasonic fatigue
5
testing technique. He introduced piezo-electric transducers that transformed 20 kHz electrical

signals into mechanical vibrations of the same frequency. Mason made use of high power ultrasonic
waves to induce material fracture by fatigue. Afterwards, even higher frequencies for fatigue testing
were reached by Girald (1959, 92 kHz) and Kikukawa (1965, 199 kHz). However, the prototype of
Mansons 20 kHz machine is used as a basis for most modern ultrasonic fatigue testing equipment.
Since the first ultrasonic fatigue machine was constructed by Mason in 1950, with the development
of computer sciences, several laboratories have produced their own machines and designed practical
test procedures. Laboratories of Willertz in the US, Stanzl in Austria, Bathias in France, Ishii in
Japan and Puskar in Slovakia, were among pioneer laboratories in this field. The progress in
ultrasonic testing, made during the last three decades, enables fatigue testing with variable amplitude
loading conditions, at different temperatures and in variety of environments. In addition to this,
using ultrasonic technique, it is now possible to evaluate fatigue properties of materials in terms of
torsion, bending, fretting or multi-axial loading [42].
Due to the lack of standardization the ultrasonic test machines differ from laboratory to laboratory,
but we can distinguish the following main components that are common to all of them, Fig. 2:
1. A power generator that transforms 50 or 60 Hz voltage signal into 20 kHz ultrasonic
electrical sinusoidal signal.
2. A piezoelectric converter excited by the power generator, which transforms the electrical
signal into longitudinal ultrasonic waves and mechanical vibration of the same frequency.
3. An ultrasonic horn that amplifies the vibration coming from the converter in order to obtain
the required strain amplitude in the middle section of the specimen.
Figure 2. Ultrasonic fatigue test system and stress-displacement field [1].

6
The specimen, horn and converter form a mechanical resonance system with four stress nodes (zero
stress) and three displacement nodes (zero displacement) at an intrinsic frequency of 20 kHz. As
could be seen from Fig.2 the maximum stress is in the specimens centre, which is one of the
displacement nodes, while the displacement reaches its maximum at the specimens ends (points A
and B). The above three parts are essential for the production of ultrasonic fatigue load. Other
components of the ultrasonic fatigue test machine may include recording systems (amplitude and
control units, cycle counter, oscilloscope etc.) and measuring systems (displacement sensor, videocamera).
During ultrasonic fatigue testing, due to the effect of internal friction, the specimens temperature
can significantly increase. This would influence the fatigue behaviour of tested material. Therefore,
the specimen should be cooled with clean and dry compressed air. In order to maximize the effect
of cold air the adjustable gun should be installed.
The setup presented in Fig.2 allows fatigue testing with the minimum to maximum load ratio R=-1.
In order to obtain another load ratio, an additional horn, identical to the first one, is attached to the
bottom of a specimen. Tensile pre-stress is then applied to the specimen, which is followed by
superposing of an ultrasonic load. In all tested series described in this thesis constant amplitude
fatigue loads with the load ratio R=0.1 have been applied.
2.2 Specimens used for ultrasonic testing

In this study the VHCF tests have been conducted using hour-glass specimens with the 6 mm
diameter of the smallest cross-section, Fig.3. In the literature describing the VHCF research most
often specimens with the smallest cross-section of 3 and sometimes 4 mm are used. The choice of
larger specimen was made in order to increase the material volume subjected to maximum fatigue
stresses. Both specimen ends are attached to the amplification horns using 8 mm internal threading.
Figure 3. Specimens used for VHCF testing described in this thesis.
The specimens were extracted from the hot-worked steel billets in the transverse direction,
representing the worst case for fatigue properties as the microstructural defects were elongated
perpendicular to the loading direction. The hour-glass section of the specimen was fine ground and
then polished in order to eliminate surface defects and inflict internal crack initiation.
7
Following austenitizing, quenching and tempering no residual stresses of significance are expected in
the specimens. However, the machining of the hour-glass section introduces surface residual stresses
in the range of 300 600 MPa.
The material volume subjected to the maximum stresses is one of the most important ultrasonic
fatigue specimens characteristics. The larger this volume is the lower would be the estimated fatigue
strength in the very long life regime [43]. This behaviour is explained by the fact that in larger
volume there is a higher probability of finding a big enough microstructural defect that could initiate
fatigue failure. For the specimen shown in Fig.3 the material volume subjected to at least 90 % of
the maximum stress is around 140 mm3, Fig.4.
Material volume, mm3
350
300
250
200
150
100
50
0
70
75
80
85
90
95
100
% of maximum stress
Figure 4. Material volume subjected to fatigue stresses that are equal or higher than a certain percentage of
the maximum stress in a specimen.
In literature other ultrasonic tensile specimen geometries could be found [3,43-45]. They differ
mainly by the diameter of the smallest cross-section and by the radius of the hour-glass section. An
increase in material volume subjected to maximum stresses could be achieved by the increase of the
diameter of the smallest cross-section and the hour-glass radius. Alternatively, the smallest crosssection could be extended over a certain length, forming a so-called dog-bone specimen.
However, the volume increase comes at a price of increased specimen heating during testing due to
internal friction. The heating also increases with increased amplitude of vibrations that are applied to
the specimen. For the specimen in Fig.3 the temperature development in the specimen with
increased stress (amplitude of vibration) is presented in Fig.5. For a given amplitude of vibration the
level of maximum stress produced in the specimen depends on its geometry. Namely, the decrease
in hour-glass radius and the diameter of the smallest cross-section result in higher stresses for the
same vibration amplitude. Therefore, if it is necessary to generate high stresses in the specimen and
at the same time minimize specimen heating, the hour-glass radius producing the required notch
effect should be chosen.
Figure 5. a) infra-red camera picture showing specimen temperature during ultrasonic fatigue testing with
300 MPa in nominal stress amplitude; b) temperature evolution in the specimen with increased ultrasonic
stresses. Measurements are taken with active specimen air cooling.
In general, ultrasonic specimen choice should be tailored to achieve the main objective of the VHCF
testing. If the aim is to examine a components behavior in VHCF regime, then specimen should be
chosen to reflect as close as possible the geometry of the component. Should the aim be to find the
largest microstructural defects within a material, then maximum specimen volume is preferred while
ensuring sufficient specimen cooling during testing.
2.3 Local stresses at fatigue initiating defects

In the giga-cycle range fatigue failures most often initiate from the microstructural defects present in
the material. Such defects are randomly distributed within a specimen and during testing one of
them initiates a crack that leads to fatigue failure. Which one would it be depends on defect size and
local stress conditions.
The hour-glass geometry of the specimen introduces a stress gradient within a specimen, which
means that the local stress acting at a fatigue initiating defect might be different from the nominal
depending on the defect location within the specimen (Paper III, V). By the local stress in this thesis
is meant the variation of stress within the specimen caused exclusively by specimen geometry. This
is not to be confused with the resulting stress at fatigue initiating defects due to their stress raising
capacity.
Using FEM it has been shown that stress variation in the smallest cross-section is about 8 %, with
the highest stress acting at the specimen surface. Whereas, in the axial direction this variation is
much greater due to difference in the cross-section area, Fig.6. As shown in the figure fatigue
initiating defects that cause fatigue failure are not always located in the most stressed volume of the
specimen. Moreover, the difference between the nominal stress, which is obtained using analytical
solution described in [1], and the local stress could be significant. From over 500 VHCF
experiments the lowest recorded local stress was less than a half of the nominal stress, Fig.6. Even
though this case is extreme, almost in each test series consisting of 20 specimens there are a few
where local stress is by 10 20 % lower than the nominal. This difference is especially important for
research purposes when fatigue initiating defects, corresponding fatigue lives, crack growth rates and
mechanisms are compared. Even for practical applications when nominal stresses are used instead of
local the long life fatigue strength might be overestimated.
Smax
Figure 6. One quarter of the hour-glass section showing stress gradient in the specimen and the locations of
the VHCF initiating defects. Slocal min indicates the fatigue failure origin where local stress was less than 50 %
of the maximum stress in the specimen.
10
2.4 Effect of material damping in ultrasonic testing

Due to high frequency of ultrasonic fatigue testing, the results obtained using such equipment have
been questioned by many researches as to their comparability to fatigue data received using
conventional fatigue testing equipment. As discussed earlier, in most reported works on this subject
the effect of frequency on the fatigue strength is either insignificant or the fatigue strength estimated
using ultrasonic equipment was higher compared to low frequency fatigue results [1,12,17,21-24,46].
One of the possible explanations for a bit higher fatigue strength obtained by ultrasonic testing is
proposed in this thesis. It is based on the observation that the actual stresses produced during high
frequency testing are slightly lower than the calculated nominal stresses. The nominal stresses for
ultrasonic testing are commonly calculated using analytical solution as in [1]. This solution takes no
consideration to the fact that some of the vibration energy that a specimen receives is lost to internal
friction, which becomes significant at high test frequencies. During testing this energy manifests
itself in excessive specimen heating, which requires external cooling in order to keep the specimen
temperature in the range of room temperature.
In Papers III and V it is attempted to account for this phenomenon by introducing material damping
into the FEM. The calculated stresses were found to be by 13 % lower than the nominal, Fig.7.
Moreover, they were in good agreement with the stresses calculated using micro-strain-gage
measurements taken during ultrasonic testing.
Stress amplitude, MPa
300
Analytical
250
200
FEM (no damping)
150
FEM (damped)
100
50
0
0
10
20
30
40
50
60
70
80
Distance along the specimen, mm

Figure 7. Calculated stress distribution along the axis of an hour-glass ultrasonic fatigue specimen subjected
to 16 m sinusoidal displacement at the ends. Load ratio R=-1.
From the literature review it appears that a frequency effect on the estimated fatigue strength is
generally greater for materials with higher damping capacity. For example, significant variation of
11
estimated fatigue strength with test frequency is observed for a T6A4V titanium alloy [1], nickelbased super-alloy Inconel 718 [12] or pure copper [17]. On the other hand, high strength steels,
which have worse damping properties, exhibit little frequency dependence [1].
3. VHCF of high performance steels

Advanced properties of tool steels make them suitable for many demanding fatigue applications with
the expected fatigue life varying from thousands to a few billions of load cycles. While it has always
been desirable to have high fatigue strength and long service life of components subjected to cyclic
loading, nowadays the increasing number of engineering system have structural parts for which a
very long fatigue life is an essential design criteria. Therefore, today the VHCF properties of high
performance steels are being studied more extensively than ever before. A very important finding is
that for many steels a fatigue limit at 106 load cycles does not exist and fatigue failures continue to
occur at lives as long as 109 and more load cycles. This means that fatigue strength for most steels
continue to decrease well into the giga-cycle range.
In Paper I and A it is demonstrated how fatigue strength deteriorate with longer fatigue lives for an
AISI H13 hot-work tool steel, Fig.8. Here, the fatigue strengths for three series made from one steel
production heat were estimated to be 52533, 42045 and 34524 MPa at 105, 2106 and 109 load
cycles, respectively. The traditional fatigue limit for steel is usually found at about 2106 load cycles,
which means that fatigue failures would not be expected at stresses below 42045 MPa. However,
as demonstrated, the fatigue limit for this material does not exist at 2106 load cycles and the
difference between the estimated fatigue strength at 2106 and 109 load cycles is 75 MPa in stress
amplitude.
12
Stress amplitude, MPa
600
500
400
1E+05 cycles
300
2E+06 cycles
1E+09 cycles
200
1E+03
1E+04
1E+05
1E+06
1E+07
1E+08
1E+09
1E+10
Number of cycles
Figure 8. Fatigue strength of an AISI H13 steel at 105, 2106 (testing at 10 Hz) and 109 (testing at 20 kHz)
load cycles. Load ratio R = 0.1.
3.1 Fatigue initiating defects

One of the special characteristics of the VHCF is that very often the fatigue crack has an internal
origin. Most materials have microstructural weaknesses or defects that become critical only if the
material is subjected to low fatigue loads in the very long life regime. Even during LCF and HCF the
cracks are likely to develop from those microstructural defects. At relatively high stresses the
irreversible bulk deformation that accumulates with each load cycle leads to crack initiation on the
surface of a specimen or component. This initiation is followed by the crack growth and eventual
failure. As the stresses are lowered the bulk deformation is prevented. Under such conditions the
microstructural defects become the most likely sites for fatigue crack initiation because they have the
stress raising capacity which favours fatigue crack nucleation. Consequently, in the VHCF regime
the crack initiation is shifted from the surface into the bulk.
In case of steels the most likely microstructural defects are slag inclusions that represent by-products
of steel production and are difficult to get rid of completely. In the vast majority of fatigue
experiments described in this study the slag inclusion that initiated failure had a stringer type shape,
Fig.9, and consisted of a mixture of aluminium-, silicon-, magnesium- oxides and calcium-sulphides
with aluminium oxide being the dominant one. The cigar-like shape of a stringer is a direct
consequence of hot-working and numerous individual inclusions found in the stringer are also likely
to be the result of crashing larger slag inclusions during steel forging operation. The cohesion
13
between the matrix and the constituents of the stringer type slag inclusion is limited, which is why
such microstructural defects could be viewed as cavities of the same dimensions.
Figure 9. Stringer type slag inclusions which resulted in fatigue failures in an AISI H11 tool steel specimens
after a) 4.29108 and b) 3.88108 load cycles.
Such stringers are significantly bigger than the slag inclusions found in steels with traditional means
of material cleanness inspection, like Optical Microscopy (OM). This is explained by the fact that
during VHCF testing, which is carried out at low stresses, only the largest defects within tested
material volume have the potential to initiate fatigue failure. Because their occurrence is relatively
rare, the probability of identifying them using OM is very small considering the tiny material volume
that could be analysed by OM. Therefore, the application of ultrasonic fatigue testing technique
could be extended from estimating fatigue strength at high number of load cycles to evaluating the
cleanness of materials with respect to the largest available microstructural defects. The knowledge
about such extreme defects in a material is crucial and should be considered when the material is
chosen for one or another technical application. As to the engineering components subjected to
VHCF, the presence of one such defect in the critical section of a component could lead to
catastrophic failure.
Typical chemical composition of a slag inclusion stringer that caused VHCF failure is shown in
Fig.10, where Energy Dispersive Spectroscopy (EDS) in the mapping mode was used to identify the
main constituents of the defect.
14
Figure 10. Typical chemical composition of a stringer type slag inclusion in steels.
In some fatigue experiments the crack initiated from single slag inclusions as shown in Fig.11. Such
fatigue initiating defects were found in high purity steels that are produced by advanced methods
like, for example, Vacuum Arc Re-melting (VAR) to obtain enhanced cleanness, homogeneity and
mechanical properties. The chemistry of such inclusions remains the same as they largely are
aluminium-oxides or calcium-sulphides.
15
Figure 11. Single slag inclusions as VHCF initiating defects in an extra clean hot-work tool steel: a) fatigue
life 3.68108 load cycles at 470 MPa in stress amplitude; b) fatigue life 1.94107 load cycles at 470 MPa in
stress amplitude.
In a few instances internal voids created by trapped gases during steel production initiated the
fatigue failure, Fig.12. During hot-working the voids of trapped gases are deformed and split into
smaller ones, forming void segregation region as shown in the figure. The largest of the voids would
then have a potential ability to cause the VHCF failure if no other defect found in the material is
more critical.
Figure 12. VHCF failures initiated from voids that could be created in an AISI H13 steel by trapped gases
during solidification: a) fatigue life 9.74108 load cycles at 310 MPa in stress amplitude; b) fatigue life
1.72108 load cycles at 330 MPa in stress amplitude.
The tool steels that have large primary carbides in the microstructure run the risk to have the VHCF
crack initiation at one of them, Fig.13. Such fatigue failures are relatively rare as the slag inclusions,
which co-exist in the material, are often larger than such carbides. Moreover, there is rather good
16
cohesion between the matrix and the carbide, which means that in order for such carbide to become
a defect this cohesion should be overcome or the carbide be split in two to form a crack in the
microstructure.
Figure 13. Large carbides that caused fatigue failure in an AISI H13 hot-work tool steel: a) after 1.91109 load
cycles at 360 MPa in stress amplitude; b) after 2.59105 load cycles at 450 MPa in stress amplitude.
A very good way to get advanced quality steel with high cleanness and enhanced properties is
powder metallurgy. In some cases, however, powder sintering might not result in fully dense
material, leaving micro-pores in the material. For most applications the existence of a few such pores
would not lead to decrease in performance. However, with lack of microstructural defects in the
microstructure, even a very small pore can result in the VHCF failure, Fig.14.
Figure 14. Pores in a cold-work tool steel causing VHCF failure.
17
3.2 Stages of VHCF crack development

The characteristic feature of VHCF fracture surface in steels is the formation of the so called fisheye. It could be defined as the circular area that surrounds fatigue initiating site and was formed as a
result of internal circular crack propagation, Fig.15. The fish-eye boundary is more distinct if it
marks the point when the fatigue crack reaches the surface. In that case there is a sharp change from
internal to external fatigue crack with air-assisted growth, Fig.15a). This change is reflected by the
shift in appearance on the fracture surface. On the other hand, the fish-eye boundary could still be
observed even if it is located at some distance from the specimen surface, Fig.15b). This boundary
marks the change in fatigue crack propagation mechanism. Therefore, if the size of the fish-eye is
to be considered as an evaluating parameter of the fatigue process, then it is only the latter types of
the fish-eyes (located away from the surface) that should be used. As to the fish-eyes reaching
the surface, their size is largely defined by the distance from the fatigue initiating defect to the
surface, rather than by a critical crack size that marks the shift in growth mechanism for the internal
crack.
It might appear that the fish-eye boundary in Fig.15b) is more distinct than in Fig.15a) even
though it does not mark the transition to air-assisted growth. It should be pointed out that the image
in Fig.15b) was deliberately taken with in-lense SEM detector to enhance visual contrast between the
fishe-eye and the remaining fracture surface.
Figure 15. Circular fish-eye feature formed on the fracture surface after
a) 3.82109 and b) 7.51108 load cycles.
18
Fatigue failure process in the very long life regime could be divided into the following stages, Fig.16:
1. Crack formation from a microstructural defect
Depending on the type of microstructural defect, the fatigue crack could be formed by
either cracking or de-cohesion of the defect from the matrix followed by early crack
formation from the defect cavity. The duration of this stage is expected to be shortened
by high notch severity of the defect cavity. At the end of this stage the defect could be
approximated to a crack of the same dimensions.
2. Initial Crack Growth
It has been shown in Paper II that during this stage more than 99 % of the total VHCF
life is consumed. It covers initial crack propagation from the microstructural defect which
is governed by an extremely slow mechanism of crack growth and results in the formation
of a Rough Area on the fracture surface adjacent to the fatigue initiating defect. This
critical stage in the VHCF crack development is described in detail in the section Rough
Area formation and Paper IV.
3. Crack growth within the fish-eye
As the Rough Area is formed the crack has reached the size representative of the
threshold stress intensity factor range
for crack propagation. From that point a
steady crack growth within the fish-eye begins resulting in rather smooth fracture
surface morphology. The crack growth rates are slowly increasing as the crack approaches
the fish-eye border.
4. Crack growth outside the fish-eye
From the fish-eye border the increase in crack growth rate becomes steeper until the
crack reaches its critical size.
5. Final fracture.
Figure 16. Schematic illustration of a fracture surface showing different stages of VHCF crack development
in an hour-glass shaped specimen.
19
The Initial Crack Growth stage is only characteristic for VHCF failures. Technically, this stage is a
part of fatigue crack growth within the fish-eye. However, because it is life-controlling and due to
uncertainties as to the mechanisms of crack formation within this zone, it is reasonable to investigate
it separately. Fig.17 shows fatigue fracture surfaces where transitions between the stages of crack
development are very clear. Even though the Initial Crack Growth stage will be treated in detail in
the latter section, it could still be seen from Fig.17b) that the area adjacent to the fatigue initiating
defect is lighter when compared to the remaining fracture surface within the fish-eye. This effect
is achieved in SEM due to greater roughness of that area, which is representative of the Initial Crack
Growth stage.
Figure 17. a) fracture surface of a hot-work tool steel specimen showing distinct fish-eye and the final
crack borders; b) fatigue initiating defect and the fish-eye in a cold-work tool steel specimen.
3.2.1 Crack growth rate

In order to estimate fatigue crack growth rate during different stages of crack development, striation
spacing measuraments have been performed along the crack growth direction on the fracture
surfaces (Paper I,II). The measurements were taken on SEM images obtained with in-lens detector at
5 m working distance. To find striations outside the fish-eye was relatively easy, Fig.18a),
especially when the crack approaches the critical size, whereas, within the fish-eye it is a laborious
task that requires patience. Nevertheless, striations with spacing of just over 10 nm, Fig.18b) were
detected on the fracture surface just outside the Rough Area region representing the initial crack
growth stage.
20
Figure 18. Striations observed in an H11 tool steel specimen that failed after 1.59108 load cycles. They were
found at a distance of a) 900 m and b) 60 m from fatigue initiating defect. The crack growth direction is
from the bottom and upwards.
The crack growth rate development with increased crack size could be observed in Fig.19. As seen
in Fig.17b) there is a clear difference in morphology for the fracture surfaces within and outside the
fish-eye. Similarly, the crack growth rate evolution has a slightly different character, Fig.19. While
in the fish-eye with increasing crack size the growth rate increases insignificantly, outside the
fish-eye the growth rate evolution follows Paris power law. Fatigue crack growth within and
outside the fish-eye could be described as small and large crack growth, respectively.
Crack growth rate, m/cyc.
1E-06
"Fish-eye"
Outside "fish-eye"
1E-07
1E-08
1E-09
1
10
100
Stress intensity, MPam

Figure 19. The relationship between stress intensity and crack growth rate for small internal (fish-eye) and
larger cracks during VHCF of an AISI H11 steel.
21
3.2.2 Fatigue crack formation from stringer type inclusion

From the fracture surfaces it could be observed that a fatigue crack tends to initiate in the widest
section of an inclusion stringer and then grow as a circular crack in the manner shown in Fig.20.
This type of crack growth could be explained by the fact that for an elliptical crack the stress
intensity has a peak at the ends of the short axis [47], which is W in Fig.20.
Inclusion stringer
Fatigue crack front
L
Figure 20. Schematic illustration of a VHCF crack initiating from an elongated microstructural defect.
The fatigue cracks might initiate in different sections of an elongated defect but the dominant crack
develops in a place where the stress intensity is the highest, which is usually the widest section of the
stringer. Here multiple micro-cracks might initiate from the cavity of the stringer and later coalesce
creating small steps on the fracture surface, Fig.21.
Figure 21. Fatigue crack initiates in the central part of the elongated a) slag inclusion and b) void, where stress
intensity for the created crack is expected to be the highest.
22
The majority of the fatigue initiating defects described in this study has width to length, W/L, ratio
below 0.3. For such defects the difference in length would produce negligible changes in stress
intensity of the crack initiated in the critical section of the stringer. This makes the width of the
stringer type defect the most important dimension, which would contribute to the initial crack
formation and growth. In this way, for example, only a small part of the elongated defect in Fig.21b)
actively participated in the early fatigue crack development. This reasoning is in line with the results
reported by Makino in [47] where he concludes that the initial crack growth occurs only in the
middle part of an elliptical defect and that the VHCF properties are largely defined by that part.
3.3 Rough Area formation

Many researchers have reported the existence on the fracture surface of a particularly rough area
formed next to the fatigue initiating defect. Together with the defect it was called optically dark
area (ODA) by Murakami et al. [26,27], granular bright facet by Shiozawa et al. [28] and fine
granular area by Sakai et al. [29]. In this study the ODA definition is used as shown in Fig.22.
Figure 22. Rough area formation around the fatigue initiating defects in specimens produced from a) hotwork and b) cold-work tool steels which failed after 1.04 108 and 1.11 109 load cycles respectively.
Schematically the VHCF crack formation within the fish-eye could be represented as in Fig.23,
where the size definitions for the ODA and Rough Area are shown. For the sake of clarity in this
study it is worth underlining that the difference between the ODA and the Rough Area is that ODA
consists of both - the defect or part of it and the Rough Area. In case of stringer-type defect the
Rough Area is usually formed on one side of the defects, Fig.22a), but sometimes it forms to
different extent on both sides, Fig.22b).
23
Figure 23. Schematic representation of a fish-eye failure with the ODA feature.
The mechanisms of fatigue crack propagation within this area are not clear. However, as shown in
Paper II and discussed in [25,27], the VHCF life is almost exclusively spent by the time the crack
reaches the ODA border. This means that a very slow mechanism, with crack growth rates well
below one inter-atomic distance per load cycle, is controlling fatigue crack development within the
ODA. Due to limited cohesion of the slag inclusions to the matrix, they could be treated as cavities
of the same dimensions. Hear two main crack evolution scenario are possible. The first one is that
fatigue crack initiates from the defect cavity at an early stage in relation to the total VHCF life and
most of the life is consumed propagating the crack to the ODA boarder. Alternatively, it might
require the largest part of the total fatigue life to initiate the crack from the defect cavity and then
propagate it to the ODA border and further to final failure. For the author the former scenario
appears more probable and the following are evidence to support it:
First of all, in Paper IV it has been shown that the Rough Area was only found in failed specimens
with fatigue lives above 107 load cycles. Moreover, while the ODA size is approximately the same
for all specimens, the size of the Rough Area increases with increasing fatigue life, Fig.24. This
indicates that most of the fatigue life is spent to form the Rough Area. Furuya et al. have also
observed [49] that the Rough Area was formed only in specimens with fatigue lives above 107 load
cycles, while other researchers found it in the specimens with fatigue life above 10 6 load cycles
[3,30,50]. In all these works the size of Rough Area increased with longer fatigue lives.
24
L rough / L oda
0,8
0,6
Batch-1
Batch-2
0,4
0,2
0
1E+06
1E+07
1E+08
1E+09
1E+10
Numbrer of cycles to failure

Figure 24. The relationship between the Rough Area size and the respective fatigue life in specimens
produced from a hot-work tool steel.
Secondly, in Paper IV the Rough Area was found in specimens that survived more than 109 load
cycles and which then were run to failure at high stresses and short fatigue lives. Because the
extensive Rough Area could not possibly be formed during the short fatigue life at high stresses, it is
fair to conclude that it was created during initial VHCF testing which was interrupted without
failure. If that testing was allowed to continue, the Rough Area would extend to the ODA size
followed by relatively fast crack growth and final failure.
Finally, It should be pointed out here that the stress concentration, Kt , caused by the geometry of
the inclusion cavity is the main driving force for the early fatigue crack formation. For the perfect
circle Kt 3 but in reality slag inclusions with rather sharp edges form cavities that deviate from
circular, resulting in much higher Kt . An example of a slag inclusion producing imprint in the matrix
that would result in the Kt factor much higher than three is shown in Fig.25. It could be concluded
from Fig.25b) that two fatigue cracks initiated in places where sharp inclusion edges cut into the
surrounding matrix creating favourable cavity geometry for high Kt . A step on the fracture surface
suggests that those two cracks eventually coalesced to form a single crack front. This observation is
an indication of the fact that even at this micro-scale the geometry of the cavity influences the initial
crack development.
25
Figure 25. a) Slag inclusion stringer consisting of grains with sharp edges; b) higher magnification of image a)
showing fatigue crack origin in places where Kt is the highest.
Another evidence of a fatigue crack initiating from an inclusion cavity in that place where stress
concentration is the highest is shown in Fig.26. From the fracture surface, Fig.26a), it could be
observed that the initial crack growth, represented by the Rough Area, did not occur in the widest
section of the elongated defect. After analysing the second half of the defect cavity, Fig.26b), it
becomes evident that in the widest section of the defect a large spherical inclusion produced rather
smooth cavity with relatively large radius and, therefore, having small stress concentration factor Kt .
On the other hand, in the place where the Rough Area started to form, due to shallowness of the
cavity its critical radius was small, resulting in high Kt .
Figure 26. Two halves: a) and b) of a hot-work tool steel specimen that failed after 1.30109 load cycles,
revealing Rough Area formation from a slag inclusion.
26
The fatigue researches seem to agree that it is relatively easy to initiate a micro-crack from the defect
cavity but more difficult to propagate it [5,51]. Therefore, it is common to regard slag inclusions as
pre-existing cracks of the same dimensions. As carbides have much better cohesion to the matrix
compared to the slag inclusions, the fatigue crack is often created by carbide cracking in two parts.
Under the condition of constant amplitude testing there appears to be no reason why this cracking
would occur late in the fatigue life and not in the beginning. Therefore, if a carbide leads to the
VHCF failure it is not unreasonable to consider this carbide as pre-existing crack of the same size,
which resulted in fatigue failure.
3.3.1 Rough Area border

As mentioned earlier the Rough Area is only found in specimens with fatigue life above 10 7 load
cycles and its size increases with increasing fatigue life. It could be said that the Rough Area is a
fracture surface feature that is unique for VHCF. Therefore, the Rough Area border, or the ODA
border shown in Fig.23, marks the crack size which triggers the transition from crack growth
mechanisms specific for VHCF to crack growth mechanisms found in HCF. The appropriate
parameter to characterize a crack under the conditions of cyclic loading is a stress intensity factor
range
. In Paper IV the
was calculated for all specimens with very long life using crack of
ODA size. The results show that for almost all the specimens the stress intensity range
at
the ODA border is between 3 and 4 MPam, Fig.27. This is also valid for specimens which had load
history prior to testing. The load history consisted of fatigue testing without failure up to at least 10 9
load cycles. The threshold stress intensity range for crack propagation
for steels lies
approximately at the same level, which suggests that the ODA boarder marks the material specific
transition from the below threshold crack propagation within the ODA to the above threshold crack
growth outside the ODA. Similar results have been obtained in [3,30,50].
27
KODA , MPam
5
4
3
2
1
Batch-1
Batch-2
Load history
1E+06
1E+07
1E+08
1E+09
1E+10
Number of cycles to failure.

Figure 27. Stress intensity range at the ODA border in specimens with and without load history
prior to fatigue testing.
In [49] Furuya et al. concluded that the ODA size rather than the defect size is the key factor
limiting the VHCF properties. They found that the ODA size is smaller in the specimens that had
higher fatigue strength at 109 load cycles. It was suggested that suppression of the ODA size is
important to improve the VHCF properties. In the opinion of this thesis author, the ODA size is a
mere consequence of a fatigue crack reaching the size representative of the
and, therefore,
changing the crack growth mechanism, which is reflected by difference in the fracture surface
appearance. It is not surprising then that the ODA size at 109 load cycles was smaller in specimens
that failed at higher stresses because for shorter cracks higher stress levels are required to reach
value. This is in line with one of the conclusions made in [49] saying that the ODA size is
independent of the type of fatigue initiating defect.
3.3.2 Stress intensity factor range at fatigue initiating defects

As described in Paper V, the material volume subjected to approximately the same maximum stress
during VHCF testing is measured in tens of mm3, Fig.4. Fatigue failures sometimes occur at local
stresses that are significantly lower than the maximum stresses in the specimen, which means that
the material volume within which fatigue failure can initiate is some hundreds of mm3. In such large
volume there are thousands of slag inclusions and other microstructural defects that are commonly
found in steels. Which one of these defects causes fatigue failure depends on the combination of
different factors.
28
In the VHCF domain it would be fair to assume that most microstructural defects in steels become
cracks of approximately the same dimensions relatively soon in the fatigue life. Which of this cracks
would have enough driving force to propagate depends on two main parameters: the crack (defect)
size and the magnitude of cyclic stress acting on the defect. A suitable parameter to measure this
driving force is a stress intensity factor range
. In other words, the magnitude of stress intensity
factor at the defect,
, defines the rate at which the crack would grow to form the Rough
Area. Because in giga-cycle range fatigue life is almost entirely spent to propagate the crack within
the Rough Area, than there should be traceable relation between the
and the
corresponding fatigue life. As seen in Fig.28, lower values of
result in longer VHCF life.
Similar trend is observed in [3,50].
4
Kdefect , MPam
2
Batch-1
sp.4
sp.10
1
sp.11
Batch-2
0
1E+06
1E+07
1E+08
1E+09
1E+10
Number of cycles to failure

Figure 28. Stress intensity range for a crack of a size equal to the fatigue initiating defect, plotted against the
corresponding fatigue life. In sp.4, sp.10 and sp.11 one end of elongated fatigue initiating defect reached
specimen surface.
For the material in Fig.28 the necessary

value to result in fatigue life of 109 load cycles is
around 2.3 MPam. As to sp.4, sp.10 and sp.11, these are the specimens with one end of the
elongated defect reaching to the surface, which enabled air penetration to the crack nucleation site.
This environmental effect could be held responsible for reducing the
needed to result in
the same fatigue life.
While
defines the rate of mechanism responsible for Rough Area formation, for different
materials the same value of
might result in different rates of crack growth within the
Rough Area. The higher value of
is needed to result in fatigue life of 109 load cycles, the
more resistant is the microstructure to the mechanisms responsible for Rough Area creation. Fig.29
29
presents the relation between

and the corresponding fatigue life for two different types of
tool steels: a) hot-work AISI H13 with martensitic microstructur and hardness of 455 HV; b) a
special purpose high carbon cold-work tool steel with martensitic microstructur and hardness of 814
HV. The estimated fatigue strength at 109 load cycles when tested with load ratio R=0.1 is 34524
MPa and 42426 MPa in stress amplitude for materials a) and b) respectively. The average size of
fatigue initiating inclusions is 17 m in diameter for material a) and 14 m for material b).
Figure 29. The relation between VHCF life and stress intensity range at the fatigue initiating defect for: a) an
AISI H13 hot-work tool steel and b) medium alloyed high strength cold-work tool steel.
The average
at 109 load cycles is approximately the same for the two materials, meaning
that the fatigue strength at 109 load cycles is expected to be comparable given that the defects of the
same size are present. On the other hand,
at 108 load cycles in material b) is higher than in
material a), which implies that the expected fatigue strength of material b) at 108 load cycles would be
significantly higher than fatigue strength of material a). In other word, the steeper the trend line as in
Fig.29, the greater is the materials fatigue strength deterioration in the giga-cycle range. This
reasoning is in line with VHCF results described in [1,52], where it is observed that high strength
steels generally have much greater difference in fatigue strength at 106 and 109 cycles, compared to
more ductile lower strength steels.
The conclusion that could be drawn from the above discussion is that in the giga-cycle regime
higher hardness does not necessarily translates into better fatigue strength. It is not unlikely that the
fatigue strength of material a) at 1010 load cycles would be higher than the corresponding fatigue
strength of material b). The reasons for this type of behaviour might become easier to explain when
possible mechanisms of Rough Area formation are explored in the next section. At this point there
is no definite answer as to which microstructural properties produce the highest resistance to Rough
30
Area formation. Moreover, as implied by Fig.29 the microstructural features that are beneficial for
fatigue strength at one fatigue life might be detrimental at another. For example, the large carbide
content in material b) contributes to fatigue strength at high stresses and relatively short lives.
Whereas, as discussed below, at low stresses and very long lives, a slow process of carbide decohesion might contribute to Rough Area creation and lower fatigue strength.
3.3.3 Mechanisms of Rough Area formation

It could be seen from Fig.22,25,26 that the morphology of the Rough Area is distinctly different
from the remaining fracture surface within the fish-eye, which implies different crack growth
mechanisms. In the example shown in Fig.30, the Rough Area was formed only on one side of an
elongated inclusion stringer and its morphology, Fig.30b), is compared to the fracture surface on the
other side of the defect, Fig.30c), which was created after the Rough Area has been formed.
Figure 30. Fracture surface of a hot-work tool steel specimen that failed after 6.92108 load cycles, revealing
differences in morphology for the Rough Area (b) and the rest of the fish-eye (c).
31
Even though it has been shown in Paper II and IV that the VHCF life is almost entirely spent to
propagate fatigue crack from the size of microstructural defect to the ODA border, the mechanisms
of such a slow growth remain unclear. Fig.30b) reveal very complex and deflected crack growth path,
which is in line with extremely low (in average much lower than one interatomic distance per load
cycle) crack growth rate expected during the Rough Area formation. As an average prior austenitic
grain size for this material is between 10 and 15 m, it could be seen from Fig.30b) that there is a
considerable crack front deflection within the same grain.
In fatigue, crack deflection often takes place if a crack reaches some kind of an obstacle and tries to
overcome it by changing its path direction. For small crack growth in HCF such obstacles could be
grain boundaries. In order to overcome them, due to different crystallographic orientations in
neighbouring grains, the crack needs to deflect which might require additional driving force. In
VHCF during Rough Area formation multiple crack deflections take place within the same prioraustenitic grain, which leads to conclusion that grain boundaries are not responsible for major crack
retardation and the resulting very long fatigue life.
Taking into account that the average crack growth rate within the Rough Area is significantly lower
than one interatomic distance per load cycle, while considering impossibility of crack propagation by
a step smaller than one lattice distance, there is a significant number of load cycles between crack
advances. Judging from the Rough Area size of a few m and long fatigue life consumed for its
formation, this number of non-propagating load cycles could be estimated in tens of thousands load
cycles. During such periods of crack stagnation a slow process of weakening the crack tip
surrounding microstructure takes place. This process is driven by cyclic stresses and results in local
damage accumulation, which eventually leads to small crack advancement. Then a new period of
local damage accumulation begins. At the end, after multiple crack advancements, the fatigue crack
reaches the ODA size. At that point it has stress intensity factor range equal to
, so the crack
has enough driving force to propagate by a small distance with each load cycle. It remains to be
explained as to why crack stagnation persists over so many load cycles and what causes eventual
crack advances in such a zigzag-like pattern.
One of the most sited explanations of the mechanisms responsible for the Rough Area formation is
the theory of hydrogen assisted crack growth developed by Murakami et al. [26,27]. According to the
authors, the crack growth within the ODA is enabled by synergistic effect of cycle stresses and
hydrogen that is trapped by the inclusion. It is argued that without hydrogen the crack equal to the
size of the inclusion would be non-propagating. The destructive effect of hydrogen helps the crack
growing to a critical size (ODA size) when it is big enough to propagate entirely due to the applied
stress. It is hypothesized that the reason for fatigue failure in the very long life regime is that the
mechanical fatigue threshold for a small crack emanating from a non-metallic inclusion is reduced by
an environmental effect associated with hydrogen trapped at the inclusion. Although the combined
mechanism of cyclic stress and hydrogen is not clear, the possible effect may be related to enhancing
the mobility of screw and edge dislocations and reducing internal friction by hydrogen.
32
Although in this thesis there is no direct evidence in support of hydrogen assisted growth theory, it
is difficult to deny the destructive role of hydrogen on fatigue properties in steels. It has been
reported that the concentration of hydrogen at slag inclusions in steels is much higher than in the
matrix. In addition, it is known that presence of hydrogen in steels reduces strength as it makes the
fatigue crack propagation easier [44,53]. Li et al. demonstrates in [44] that in a spring steel with
hydrogen content of 0.2, 0.6 and 2.5 p.p.m. the fatigue strength at 109 load cycles constitutes
71318, 70316 and 49824 MPa respectively. At the same time the Rough Area is formed in
specimen with different hydrogen content. Therefore, while presence of hydrogen might enhance
the rate of Rough Area formation, the Rough Area might still form without hydrogen even though
higher stresses would be required. Consequently, it could be argued that hydrogen is more a
contributing factor rather than the primary reason for the crack growth within the Rough Area.
Shiozawa et al. developed another commonly cited theory of Rough Area formation using VHCF
test results of high carbon chromium bearing steel [30]. According to the authors the Rough Area is
formed as a result of slow process of carbide de-cohesion from the matrix in the vicinity of crack
initiating defect, Fig.31a). This results in the formation of micro cracks which grow and eventually
coalesce with each other forming the Rough Area, Fig.31b). The micro-cracks propagate along the
boundaries between the matrix and the carbides. Therefore, the roughness generated at the fracture
surface corresponds to the carbides size. Having grown to the ODA size the crack continues to
propagate as an ordinary crack with little dependence on the microstructure forming the remainder
of the fish-eye, Fig.31c). It was concluded that the greater roughness of the ODA compared with
the surrounding area is formed by the holes from which the carbides have been peeled off and by
the carbides themselves that stick out from the matrix.
Figure 31. Schematic illustration of carbide de-cohesion model for Rough Area formation in steels [30].
33
While the described model might work as a reasonable explanation of the Rough Area formation in
steels with large volume fraction of carbides, it is difficult to apply this theory to steels where carbide
volume is not as substantial. Moreover, even though the fatigue crack might follow the interface
between the large carbides and the matrix, the original mechanism of Rough Area formation is the
one which causes carbides de-cohesion.
In authors opinion the mechanism by which the fatigue crack advancement within the Rough Area
occurs is related to small scale deformation induced vacancy creation. As shown earlier, the stress
intensity range for the crack in question is below the threshold value
. Therefore, no extensive
plastic zone at the crack tip would be expected. Nevertheless, a small scale dislocation interaction
would take place. As described in [54], the annihilation of edge dislocation causes excessive vacancy
concentration which provides a driving force for vacancy diffusion in the direction of the free
surface. In case of internal crack this free surface would be the crack itself. Moreover, the easiest
way for vacancies to diffuse would be within the most stressed volume, namely crack tip region.
During the crack stagnation period, which lasts for thousands of load cycles, the concentration of
vacancies in the crack tip region becomes relatively high. This weakens the microstructure and
makes it possible for a crack to propagate by a small distance. This process could be accelerated by
the presence of hydrogen. According to Nagumo et al. [55], the primary deteriorating effect of
hydrogen is attributed to the stabilization and promotion of vacancy agglomeration. They found that
the deformation-induced vacancy concentration is enhanced in the presence of hydrogen. The
discussed above de-cohesion of carbides is by nature a process of gradual vacancy accumulation on
the carbide-matrix interface.
Due to random nature of vacancy concentration in the crack tip region, the crack path would have
no predictable pattern which could be traced down to the microstructural features in the material.
This kind of picture is observed in Fig.30b). Moreover, considering that thousands of load cycles are
spent to propagate a crack by one interatomic distance within the ODA, the proposed mechanism
appears reasonable in terms of crack growth rates as well as vacancy generation and diffusion rates.
In addition, as described in [54] the vacancies produced during cyclic loading are responsible for
swelling of the material, which produces micro-protrusions and extrusions on the surface during
HCF. Assuming that in the VHCF vacancy assisted crack growth is responsible for Rough Area
formation, the low rate vacancy generation might result in nano-scale protrusion formation on the
free surface where fatigue crack initiated. Fig.32 shows the interface of the fatigue initiating slag
inclusion and the matrix with some free space between them. Here the protrusion-resembling
asperities are found in the region of fatigue crack initiation. While their origin is unknown, the
protrusion shape appears thermodynamically unfavourable to be formed during solidification of the
inclusion cavity, which gives reason to suggest that they were created during early cyclic loading.
34
Figure 32. a), b), c) nano-size protrusions that are observed at the interface between steel matrix and fatigue
initiating inclusion in the region of fatigue crack initiation; d) asperity formation on the otherwise smooth
surface of the inclusion cavity in the proximity of the crack initiation site.
3.4 Fatigue initiating potential of a defect

One of the common questions asked with respect to VHCF is why at very long lives fatigue failure
most often initiate from the bulk of the material. To a large extend the answer lies in the
mechanisms of fatigue crack formation at low stresses. As the stresses are not sufficiently high to
induce plastic deformation in the material, the local stress raisers such as microstructural defects
become the only locations where stresses are high enough to cause any kind of irreversible
deformation activity. Even though the rate of this, without exaggeration, nano-scale activity is
extremely slow, given sufficiently high number of load cycles, it still leads to final failure.
35
There is no doubt that such stress raising defects could be present on the material surface. In case of
ultrasonic fatigue testing, the surface defects in the hour-glass section of the specimen are minimised
by polishing and their fatigue potential is lowered by introduction of surface compressive stresses by
machining operation. In practice the components subjected to VHCF undergo different surface
treatment to eliminate surface crack initiation. It is not surprising then why at low stresses and long
lives fatigue failures in steels initiate from microstructural defects.
From the magnitude of microstructural defects in a tested material, only one with highest fatigue
initiating potential will lead to fatigue failure. As discussed earlier, a possible way of estimating this
potential is to calculate stress intensity factor range for the crack of the defect size,
. For
9
the tested material in Fig.28 no failure before 10 load cycles is expected to be initiated from the
internal defect with
< 2 MPm . The higher
value is, the greater a potential
the defect has to initiate fatigue failure.
Fig.33 presents the fatigue results for an AISI H13 hot-work tool steel tested at different stress
levels (Paper A). It appears that with decreased stress the size of fatigue initiating defects increases,
Fig.33a). This observation could be explained by considering that at low stresses only the largest
defects within the tested volume have the
value large enough to initiate fatigue failures,
whereas, at higher stresses even smaller defects have sufficient driving force for the crack formation
and growth. It is fair to assume that in a specimen that is tested at high stresses large defects (such as
in series 1E+09, Fig.33a) also exist. A reasonable question would be why at high stresses fatigue
failure does not originate from those defects?
In authors opinion, the initial crack growth occurs simultaneously from all the defects in the
microstructure that have sufficiently high
value. If, at relatively high stresses, for a few
microstructural defects this value is above
, then fatigue cracks could grow at various rates
from all of them. However, only one crack becomes dominant and eventually causes final failure,
leaving possible other cracks hidden in the bulk. The dominant is likely to become a crack that first
reaches specimen surface, as from that point its growth rate would increase significantly. Therefore,
at high stresses near surface defects become critical, even though the largest defects might be
present deeper in the bulk. Similarly, at low stresses when
<
, the cracks develop
within the Rough Area from different defects simultaneously. That crack which first reaches the
ODA size and, therefore, has the stress intensity range representative of
starts propagating at
much faster rates resulting in final failure. Once again numerous Rough Area cracks are left
unnoticed in the microstructure.
36
Figure 33. Fatigue initiating defects in three test series produced from AISI H13 tool steel and tested at 10
Hz (1E+05, 2E+06) and 20 kHz (1E+09).
The described scenarios are in agreement with the trend observed in Fig.33b), namely that with
decreasing stresses the fatigue initiating defects tend to be located further from the specimen
surface. At high stresses most of the fatigue life is consumed propagating a fatigue crack. Among the
competing microstructural defects, the one which is located closer to the surface has a greater
chance to cause final failure due to shorter propagating distances. On the other hand, the defects
that are capable to cause fatigue failure at low stresses are much less frequent, and they are more
likely to be found in the larger volume than the one close to the surface.
An ultrasonic fatigue test is usually interrupted automatically when a fatigue crack in the specimen
becomes so large that the resonance vibrations are no longer possible. The hour-glass section of a
specimen for which ultrasonic testing was stopped at 9.79108 load cycles due to large internal crack
is shown in Fig.34a). It appears as if two cracks approached the surface almost at the same time but
were hindered from further growth as testing was interrupted. If crack branching is excluded, then
those cracks had different microstructural defects as their origins. After breaking the specimen with
high tensile stresses a fish-eye fracture was revealed, Fig.34b).
37
Figure 34. a) hour-glass section of a fatigue specimen after 9.79108 load cycles showing the internal cracks
reaching the specimen surface; b) fracture surface of the specimen in a) after
it has been broken by a tensile load.
The majority of fatigue initiating defects in Fig.33a) were slag inclusions of stringer type, but some
failures originated from carbides. The results indicate that carbides as crack origins are more
probable at higher stresses. This could be explained by the fact that due to good cohesion between
carbides and the matrix, they are not readily viewed as pre-existing defects. However, at high stresses
carbide cracking might occur which results in fatigue crack formation. Long life fatigue failures of an
AISI D2 cold-work tool steel are reported by Sohar et al. in [56], where the authors observed that
carbides which acted as crack origins were fractured rather than de-cohered.
Summary
Very High Cycle Fatigue could be defined as a progressive structural damage of materials under
repeated loading with more than 107 load cycles. The attention to this phenomenon has been
growing since 80th when it was observed that for some materials fatigue limit at 106 107 load cycles
does not exist. Instead, fatigue failures continue to occur at 108 and 109 load cycles at stress levels
that are bellow the conventionally safe fatigue limit.
This finding promoted the development of the modern ultrasonic resonance fatigue testing
equipment, which allows economical and efficient testing in the giga-cycle range. It utilizes the use
of piezo-electric components, which transform high frequency electric signal into sinusoidal
vibrations of the same frequency. Those vibrations are then amplified to achieve the desirable
fatigue stresses in the specimen. One of the most common equipment modifications is a 20 kHz
38
ultrasonic testing system that allows application of constant amplitude tensile fatigue stresses. Such
system was used to generate fatigue results described in this thesis.
Due to excellent fatigue properties of many tool steels, they become the material of choice for many
demanding applications with very long fatigue lives. In this study a few hot-work and cold-work tool
steels have been tested with reference fatigue life of 109 load cycles. The experiments were
performed using the hour-glass type specimens with 6 mm diameter of the smallest cross-section
and the hour-glass radius of 31 mm. They were extracted from the steel billets in the transverse
direction representing the worst case for fatigue properties. The critical specimen section was
ground and polished to prevent surface crack initiation.
The results presented in this thesis show that fatigue strength in tool steels decreases with increased
number of load cycles. For instance, in case of AISI H13 hot-work tool steel the difference in
fatigue strength at 2106 and 109 load cycles is almost 20 %. In contrast to LCF where fatigue cracks
initiate from the surface, in giga-cycles regime microstructural defects in the material become fatigue
crack origins. In tool steels to such defects belong slag inclusions, large carbides or their
segregations, possible pores in the material, etc. In the overwhelming majority of fatigue
experiments described in this study, the VHCF failures initiated from the stringer type slag
inclusions consisting mainly of a mixture of aluminium oxides, calcium oxides and calcium sulfides.
Fatigue crack initiations from carbides were rare and more frequent at higher stresses.
A fracture surface formed as a result of VHCF crack growth is characterized by presence of the socalled fish-eye. It is a relatively flat circular feature that is formed during low rate (in the range of
20 nm/cyc.) internal crack propagation. At the fish-eye border a change of crack growth
mechanism takes place and then the crack propagates at an increasing rate until final failure occurs.
At closer inspection of the VHCF fracture surface a Rough Area formed around the fatigue
initiating defect could be observed. Its size is comparable to that of the defect. Moreover, in relation
to the defect the Rough Area size increases with longer fatigue life. Furthermore, the Rough Area is
only found in failed specimens with fatigue lives above 107 load cycles.
In has been shown that in the giga-cycle regime more than 99 % of the total fatigue life is consumed
to propagate the fatigue crack from the size of the defect to the Rough Area border. When the
fatigue crack has grown to the Rough Area border, it has a stress intensity factor range,
,
representative of the threshold for crack propagation
. Consequently, the crack growth within
the Rough Area occurs at the below threshold
range. Here the estimated average crack growth
rate is much lower than one inter-atomic distance per load cycle.
The exact mechanism of fatigue crack development within the Rough Area is unknown. Many
researchers believe that crack growth in that region is accomplished by synergistic effect of cyclic
stresses and the hydrogen that is trapped at microstructural defects. It has also been shown that the
Rough Area could be formed by carbide de-cohesion from the matrix in the region surrounding the
fatigue initiating defect. Such de-cohesion results in the network of small cracks, which eventually
39
coalesce and form the Rough Area around the defect. Despite evidence in support of the described
mechanisms, they do not seem to offer a single solution for the original mechanism of Rough Area
creation in different steel microstructures, as Rough Area might form in steels with no large carbides
and very little hydrogen content. Further research in this direction is required.
Ultrasonic fatigue testing has proved to be a unique tool to evaluate fatigue strength of a material in
the very long live regime. In addition, it provides an excellent opportunity to assess material
cleanness with respect to the largest microstructural defects present in the tested volume. Due to
their rare occurrence, such defects are practically undetectable by the conventional defect evaluation
techniques like Optical Microscopy. Furthermore, ultrasonic fatigue testing is a relatively flexible
method as it could be adjusted to provide a variety of stress conditions and test environments.
Ultrasonic specimen design could be manipulated to suit the main objective of VHCF testing and
reflect closely the desired stress conditions.
At the same time, fatigue strength estimated using ultrasonic resonance equipment for a certain
number of load cycles should be used with caution. As demonstrated in the thesis the actual
ultrasonic stresses acting at the fatigue initiating defects could be by over 20 % lower than the
nominal stresses due to material damping effect and stress gradient in the specimen. Therefore, if
fatigue strength calculations are based on nominal stresses, the strength is likely to be overestimated.
In addition, the obtained VHCF strength would decrease with increase in material volume subjected
to critical stresses. As a result the fatigue strength estimated using ultrasonic specimens with small
critically stressed volume would be higher than that of the component with much larger critical
volume. Finally, during ultrasonic testing excessive specimen heating due to internal friction occurs.
Therefore, efficient specimen cooling and accurate temperature control are needed to be able to use
the generated fatigue data for design of components subjected to the VHCF.
The technological development in many areas of engineering is driven towards ever higher speeds
and longer service lives. With such tendency the interest in VHCF research is expected to be even
greater in the future. Thus the accelerated fatigue testing would remain a valuable source of fatigue
data in giga-cycle regime. Even though ultrasonic testing would further extend to include new
materials, the research in VHCF properties of high performance steels is likely to be one of the
dominant directions in this field.
Conclusions
This thesis describes different aspects of Very High Cycle Fatigue phenomenon in tool steels. The
discussion is largely focused around the microstructural fatigue initiating defects; the specialities of
crack formation and growth at low stresses and very long lives; and various factors that should be
40
considered when using ultrasonic fatigue testing technique. The following main conclusions could
be drawn from the study:
No fatigue limit was observed for the tested tool steels at 106 107 load cycles. Instead, the
so called fish-eye fatigue failures occurred at progressively decreasing stress levels as
fatigue lives increased to as many as 5109 load cycles.
Slag inclusions were found to be the main type of VHCF initiating defects. Moreover, they
were much larger than the inclusions that could be found using conventional defect
detection techniques. This shows that apart its main purpose, ultrasonic fatigue testing is also
an excellent tool for material purity analysis. Large carbides were also identified as possible
VHCF initiating defects. However, they were more likely to cause failure at fatigue lives
below 107 load cycles.
It has been demonstrated that the VHCF life is almost exclusively spent during extremely
slow initial crack growth process, which leads to the Rough Area formation on the fracture
surface around the fatigue initiating defect. The Rough Area size was found to increase with
longer fatigue lives.
The stress intensity factor range at the Rough Area border,

, is representative of the
threshold value for fatigue crack propagation,
, meaning that fatigue crack propagation
within the Rough Area occurs in the below threshold regime. In addition the VHCF life was
found to increase with lower value of stress intensity factor at fatigue initiating defect,
.
The actual stresses at fatigue initiating defects could be by around 20 % lower than the
nominal used for ultrasonic testing, if material damping and stress gradient in the specimen
are accounted for.
The choice of specimen design is an important step in ultrasonic testing, which among other
would define the stress gradient in the specimen; material volume subjected to critical
stresses; maximum stress with minimum displacement amplitude; the degree of heat
generation in the specimen.
41
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45

of tool steels
An increasing number of engineering components are expected to have fatigue life

in the range of 107 - 1010 load cycles. Some examples of such components are found
in airplanes, automobiles and high speed trains. For many materials fatigue failures
have lately been reported to occur well after 107 load cycles, namely in the Very High
Cycle Fatigue (VHCF) range. This finding contradicts the established concept of
a fatigue limit, which postulates that having sustained around 107 load cycles the
material is capable of enduring an infinite number of cycles provided that the service
conditions are unchanged. With the development of modern ultrasonic fatigue testing
equipment it became possible to experimentally establish VHCF behaviour of various
materials. For many of them the existence of the fatigue limit at 107 load cycles has
been proved wrong and their fatigue strength continues to decrease with increasing
number of load cycles.
High performance steels is an important group of materials used for the components
subjected to VHCF. This study explores the VHCF phenomenon using experimental
data generated by ultrasonic fatigue testing of selected tool steels. The overall aim
is to gain knowledge of VHCF behaviour of some common tool steel grades, while
establishing a fundamental understanding of mechanisms for crack development in
the very long life regime. The study demonstrates that VHCF cracks in tested steels
initiate from microstructural defects like slag inclusions, large carbides or voids. It is
established that VHCF life is almost exclusively spent during crack formation at below
threshold stress intensity values which results in a unique for VHCF morphology on
the fracture surface.
Significant attention is devoted in the thesis to the ultrasonic fatigue testing technique,
i.e. the validity and applicability of its results. FEM is employed to give an additional
perspective to the study. It was used to calculate local stresses at fatigue initiating
defects; examine the effect of material damping on ultrasonic stresses; and to evaluate
various specimen geometries with respect to resulting stress gradient and maximum
stressed material volume.

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Faculty of Technology and Science

Very high cycle fatigue

Very high cycle fatigue

Karlstad University Studies

Vitaliy Kazymyrovych. Very high cycle fatigue of tool steels

List of enclosed papers

Evaluation of the giga-cycle fatigue strength, crack initiation and

The significance of crack initiation stage in very high cycle

Local stresses and material damping in very high cycle fatigue.

Initial crack growth in very high cycle fatigue of a hot-work

Stress verification and specimen design for ultrasonic

Assessment of strength and inclusions of tool steels in very high

Very high cycle fatigue of high performance steels.

Very high cycle fatigue of engineering materials.

Authors contribution to the papers

Major part of planning, experimental work, evaluation and writing.

Major part of planning, experimental work, evaluation and writing.

Major part of planning, experimental work, evaluation and writing.

Major part of planning, experimental work, evaluation and writing.

Major part of planning, experimental work, evaluation and writing.

2. ULTRASONIC FATIGUE TESTING ................................................................................. 5

3. VHCF OF HIGH PERFORMANCE STEELS .................................................................. 12

Number of load cycles

predicted fatigue limit, MPa

2. Ultrasonic fatigue testing

Conventional (100 Hz)

testing technique. He introduced piezo-electric transducers that transformed 20 kHz electrical

Figure 2. Ultrasonic fatigue test system and stress-displacement field [1].

2.2 Specimens used for ultrasonic testing

Figure 3. Specimens used for VHCF testing described in this thesis.

Material volume, mm3

2.3 Local stresses at fatigue initiating defects

2.4 Effect of material damping in ultrasonic testing

Stress amplitude, MPa

FEM (no damping)

Distance along the specimen, mm

3. VHCF of high performance steels

Stress amplitude, MPa

3.1 Fatigue initiating defects

Figure 14. Pores in a cold-work tool steel causing VHCF failure.

3.2 Stages of VHCF crack development

3.2.1 Crack growth rate

Crack growth rate, m/cyc.

Stress intensity, MPam

3.2.2 Fatigue crack formation from stringer type inclusion

Fatigue crack front

3.3 Rough Area formation

Numbrer of cycles to failure

3.3.1 Rough Area border

Number of cycles to failure.

3.3.2 Stress intensity factor range at fatigue initiating defects

Number of cycles to failure

For the material in Fig.28 the necessary

presents the relation between

3.3.3 Mechanisms of Rough Area formation

3.4 Fatigue initiating potential of a defect

The stress intensity factor range at the Rough Area border,

Very high cycle fatigue

An increasing number of engineering components are expected to have fatigue life