The Effects of Net-Shape Machining on the Performance of Al 2024-T3 Subjected to Axial Tension-Tension Fatigue Loads

Report No. ARL-TR-5277
Authors: Cyril Williams
Date/Pages: August 2010; 26 pages
Abstract: Surface texture and process defects resulting from net-shape machining of engineering materials are often ignored in the design analysis of machined components parts. In this investigation, the effects of net-shape machining on the fatigue life of 2024-T6 aluminum were studied. Specimens were prepared using Abrasive Water Jet (AWJ) machining and the surface texture resulting from machining was characterized using contact profilometry. Based on the results from the surface texture evaluation and axial tension-tension fatigue tests performed, it was found that the fatigue life of 2024-T6 aluminum is surface texture dependent. As the roughness increases, the fatigue strength of the 2024-T6 aluminum decreases. It was found that the notch depth of the machined surface plays an important role in both low and high cycle fatigue. However, the mechanisms involved at low cycle fatigue are not well understood.
Distribution: Approved for public release
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Last Update / Reviewed: August 1, 2010