Short cracks initiated in Al 6013-T6 with the focused ion beam (FIB)-technology

The fatigue crack growth behaviour of short corner cracks in the Aluminium alloy Al 6013-T6 was investigated. The aim was to determine the crack growth rates of small corner cracks at a stress ratio of R = 0.1, R = 0.7 and R = 0.8 and to find a possible way to predict these crack growth rates from fatigue crack growth curves determined for long cracks. Corner cracks were introduced into short crack specimens, similar to M(T) – specimens, at one side of a hole (Ø = 4.8 mm) by cyclic compression (R = 20). The precracks were smaller than 100 μm (notch + precrack). A completely new method was used to cut very small notches (10–50 μm) into the specimens with a focussed ion beam. The results of the fatigue crack growth tests with short corner cracks were compared with the long fatigue crack growth test data. The short cracks grew at ΔK-values below the threshold for long cracks at the same stress ratio. They also grew faster than long cracks at the same ΔK-values and the same stress ratios. A model was created on the basis of constant Kmax-tests with long cracks that gives a good and conservative estimation of the short crack growth rates.