A method to predict fatigue crack initiation in metals using dislocation dynamics
Abstract A theory is proposed to predict the initiation of fatigue cracks using cyclic dislocation dynamics (DD) simulations. The evolution of dislocation networks in a grain is simulated over several cycles. It is shown that the dislocation density and the energy stored in the dislocation networks increase with the number of cycles. The results of the DD simulations are used to construct an energy balance expression for crack initiation. A hypothetical crack is inserted into the grain, and the Gibbs energy consisting of the energy of the dislocation structure, the surface energy of the hypothetical crack, and the reduction in continuum energy is evaluated. Once the Gibbs energy attains a maximum, the dislocation structure becomes unstable, and it becomes energetically more favorable to form a real crack. The proposed method is applied to oxygen-free high conductivity copper, and the results are compared against experiments. Finally, it is shown how the method can be amended to account for environmental effects.