Mechanism of fatigue failure in ultralong life regime

The fatigue fracture surfaces of specimens of heat treated hard steels which failed in the regime of N = 10(5) to 5 x 10(8) cycles, were investigated by optical microscopy and SEM. Specimens having a longer fatigue life had a particular morphology beside the inclusion at the fracture origin. The particular morphology looked optically dark and in the previous paper it was named the Optically Dark Area, ODA. The roughness inside ODA is larger than outside ODA. The relative size of the ODA to the size of the inclusion at the fracture origin increases with increase in fatigue life. Thus, the ODA is considered to have a crucial role in the mechanism of ultra long life fatigue failure. Direct evidences of existence of hydrogen at the inclusion at fracture origin are presented. It is presumed that the ODA is made by the cyclic stress coupled with the hydrogen which is trapped by the inclusion at the fracture origin. To verify the influence of hydrogen, specimens containing different levels of hydrogen were prepared by different heat treatments. The results obtained by fatigue tests of these specimens suggest that the hydrogen trapped by inclusions is a crucial factor which causes the ultra long fatigue failure of high strength steels. Aspects of the double S-N curve are also discussed in terms of experimental methods, specimen size and statistical distribution of inclusions sizes.