Fatigue crack initiation and propagation in ferrous powder metallurgy alloys

Many of the targeted applications for powder metallurgy materials, particularly in the automotive industry, undergo cyclic loading. It is, therefore, essential to examine the fatigue mechanisms in these materials. The mechanisms of fatigue crack initiation and propagation in ferrous powder metallurgy components have been investigated. The fatigue mechanisms are controlled primarily by the inherent porosity present in these materials. Since most, if not all, fatigue cracks initiate and propagate at the specimen surface, surface replication was used to determine the role of surface porosity in relation to fatigue behavior. Surface replication provides detailed information on both initiation sites, and propagation path of fatigue cracks. The effect of microstructural features such as pore size, mean pore spacing, as well as the heterogeneous microstructure on crack deflection was examined and is discussed. Fracture surfaces were examined to elucidate a mechanistic understanding of fatigue processes in these materials.