Effect of residual stresses induced by cold expansion on the crack growth in 6082 aluminum alloy

Fatigue crack growth from an expanded hole is simulated. Expansion and its degree influence are studied using a numerical analysis. Stress intensity factors are determined and used to estimate the fatigue life. Residual stress field is evaluated using a nonlinear analysis. These stresses are superposed with the applied stresses field in order to estimate crack growth with a linear 3-D model.Experimental test are conducted under constant loading. Results of this investigation indicate expansion and its degree are benefit on fatigue life. A good agreement was observed between the FEM analysis and the experimental result.

► Fatigue crack growth from an expanded hole is simulated.
► The influence of expansion and its degree is studied using a numerical analysis.
► Analysis allows determination of SIF, used to evaluate the fatigue life.
► Residual stress field is determined using a nonlinear analysis.
► Stresses are superposed with the applied stresses in order to evaluate crack growth.