Use of atomic force microscopy for characterizing damage evolution during fatigue

A study of the development of surface fatigue damage in PH 13-8 Mo stainless steel and copper by atomic force microscopy (AFM) was performed. AFM observations allow highly automated, quantitative characterization of surface deformation with a resolution of 5 nm or better, which is ideal for understanding fatigue damage evolution. A secondary objective was to establish a correlation between fatigue life exhausted and impedance spectroscopy.; Strain controlled fatigue tests were conducted both in high and low cycle fatigue regimes, and interruptions of the fatigue tests allowed characterizing the evolution of the surface upset at various life-fractions. In the low strain amplitude tests on stainless steel (Δϵ_pl/2 = 0.0026%), surface damage occurred in the shape of narrow streaks at the interface between martensite laths where reverted austenite was present. The streaks eventually coalesced to form crack nuclei. In high strain amplitude tests (Δϵ _pl/2 = 0.049%), fatigue surface damage was essentially dominated by the formation of extrusions. In copper, both low (Δϵ_pl/2 = 0.061%) and high (Δϵ_pl/2 = 0.134%) strain amplitude tests showed the formation of slip bands (mainly extrusions) across entire grains. Protrusions were present only in copper specimens tested at the high strain amplitude. Crack nucleation in the low strain amplitude tests occurred in both materials at the interface between a region that sustained a high level of deformation and one with little evidence of surface upset. This commonality between these two materials that are otherwise very dissimilar in nature suggests a universal scheme for location of fatigue crack nucleation sites during HCF.; A procedure was developed in this study to quantitatively characterize the amount of irreversible surface strain. The proposed formalism is applicable to any material, independently of the type of surface damage, and leads to a criterion for crack nucleation based on physical evidence of surface damage.; A correlation between fatigue damage and impedance spectroscopy measurements was shown in copper, in particular during the primary cyclic hardening stage. The measurements were however less sensitive to the development of surface upset that occurred beyond that stage.