Fatigue specimens of a Ti-6Al-4V alloy containing internal artificial defects with controlled and reproducible size and shape have been produced. These defects systematically led to the initiation of a fatigue crack which propagation has been monitored in situ by synchrotron X-ray tomography during R=0.1 uniaxial fatigue tests at 20 Hz. The crack growth curves of the internal cracks have been obtained for 6 samples. Ex situ fatigue tests have been performed on samples submitted to a supplementary heat treatment or containing a defect put into contact with air. The results obtained tend to support the fact that internal fatigue cracks grow from the notch in a vacuum environment. On the fracture surfaces of samples containing an artificial defect not connected to air, two regions have been observed. They correspond to the Rough Area and the Fish Eye regions observed for internal cracks initiated from natural defects. The transition between those two regions takes place when the plastic radius size is equivalent to the grain size.

Very high cycle fatigue fracture is often associated with internal crack propagation and one major problem to study the initiation and the propagation of this internal crack is to detect its initiation and quantify its propagation rate. The objective of the present work is to develop an experimental methodology to follow the initiation and propagation of the internal crack. The experimental technique presented here is based on temperature field measurement on the specimen surface during an ultrasonic fatigue test using infrared thermography. Indeed, plasticity in the reverse cyclic plastic zone near the crack front generates heat sources due to the dissipation of plastic energy rate and thus an increase of the temperature which propagates through the specimen thanks to heat conduction. By considering the heat source located in the reverse cyclic plastic zone and the geometry of the crack obtained by tomographic observations, finite element simulation of the heat transfer problem enables us to establish a relationship between the internal crack growth and the temperature field evolution on the specimen surface. The results obtained for a cast aluminum alloy are presented and analyzed.

This work presents a new ultrasonic fatigue testing device for studying the initiation and propagation mechanisms of internal microstructurally short fatigue cracks using in situ synchrotron tomography. Its principle is described as well as the method used for automatically detecting crack initiation and its subsequent growth. To promote internal crack initiation, specimens containing internal casting defects were tested between the high cycle and very high cycle fatigue regimes (10(7)-10(9) cycles). Preliminary results show the ability of this new device to initiate an internal microstructurally short crack in a reasonable testing time and monitor its growth.

Fatigue specimens designed with controlled internal defects were obtained by diffusion bonding of Ti-6Al-4V sheets containing femtosecond laser drilled notches. Crack initiation from the internal defect occurred systematically. The cracks were characterised by in situ synchrotron X-ray tomography. Propagation rates are lower than those of surface cracks of comparable sizes in the same material and fall between experimental data obtained for fatigue cracks propagating in air and in vacuum.