Numerical Analysis of Curvilinear Fatigue Crack Growth and Plastic Zone Evolution in Haynes 230 Superalloy Under Variable Stress Ratios

This paper presents a high-fidelity numerical simulation of curvilinear fatigue crack growth (FCG) through a modified Compact Tension (CT) specimen made of Haynes 230 nickel-based superalloy. The specimen’s design, featuring three extra holes, was intentionally chosen to induce mixed-mode loading and complex, non-linear crack paths. Crucially, this configuration allows for a thorough examination of how the specimen’s geometry, restraints, or minor manufacturing discrepancies affect the localized stress state. Experimental data corresponding to three different initial crack patterns were utilized to validate the numerical model implemented within the ANSYS simulation environment. The comparison demonstrated that the present simulated crack trajectory was significantly closer to the experimental results than those obtained from earlier numerical simulations using ZFEM-TERF and FRANC3D. Furthermore, the current study critically examined the validity of Linear Elastic Fracture Mechanics (LEFM) by analyzing the evolution of the Cyclic Plastic Zone (CPZ) size for two distinct stress ratio values: R = 0.5 and R = −1. The findings confirm the full satisfaction of the Small-Scale Yielding (SSY) criterion throughout the crack growth history for the positive stress ratio (R = 0.5). Conversely, the negative stress ratio (R = −1) caused a significant violation of the SSY assumption in the later stages of propagation. This highlights how the applicability of LEFM is largely dependent on the loading regime and underscores the necessity of employing Elastic–Plastic Fracture Mechanics (EPFM) for fully reversed cycles. This research establishes a well-founded and valuable protocol for predicting Fatigue Crack Growth (FCG) in complex superalloy components.