Prediction of Fatigue Crack Growth in Vacuum-Brazed Titanium Alloy

The assessment of fatigue is a crucial concern in welded components and structures. This study investigates the fatigue properties and models for predicting fatigue crack growth in Ti-6Al-4V titanium alloy when processed by vacuum brazing with TiCuNi filler. Fatigue properties and the impact of the stress ratio were determined through constant amplitude fatigue tests. By utilizing the results obtained from variable amplitude fatigue tests, various prediction models for fatigue crack growth were examined: modifications for load interaction, residual stress, and crack closure. The results indicate that the microstructures in the brazed zone consist of numerous fine, elongated needle-like Widmanstätten structures. In terms of cycle counting methods, the rainflow method outperforms the simple-range method. In the stable crack growth rate region, fatigue crack growth rate increases with the rise in stress ratio in a manner similar to high-strength steels. The Paris model without any modification obtains good predictions. For models modified with crack closure, the Elber model yields slightly better prediction results than the Schijve model. Among fatigue crack growth prediction models, the Willenborg model with residual stress modification produces the best results. Fracture surfaces within fatigued specimens’ brazed zones exhibit ductile failure characteristics, where fatigue striations and secondary cracks were observed.