Microstructurally small fatigue crack (MSFC) formation includes stages of incubation, nucleation and microstructurally small propagation. In AA 7075-T651, the fracture of Al 7 Cu 2 Fe constituent particles is the major incubation source. In experiments, it has been observed that only a small percentage of these Fe-bearing particles crack in a highly stressed volume. The work presented here addresses the identification of the particles prone to cracking and the prediction of particle cracking frequency, given a distribution of particles and crystallographic texture in such a volume. Three-dimensional elasto-viscoplastic finite element analyses are performed to develop a response surface for the tensile stress in the particle as a function of the strain level surrounding the particle, parent grain orientation and particle aspect ratio. A technique for estimating particle strength from fracture toughness, particle size and intrinsic flaw size is developed. Particle cracking is then determined by comparing particle stress and strength. The frequency of particle cracking is then predicted from sampling measured distributions of grain orientation, particle aspect ratio and size. Good agreement is found between the predicted frequency of particle cracking and two preliminary validation experiments. An estimate of particle cracking frequency is important for simulating the next

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The von Neumann – Mullins relation has been extended to higher dimensions by MacPherson and Srolovitz. Their exact solution relates the rate of volume change of an individual grain in a 3-dimensional isotropic polycrystal to its mean width and total length of triple lines (assuming isotropic boundaries). The objective of this study is to verify that grains in a moving finite element grain growth model obey this law. Algorithms have been developed in order to calculate mean width of individual grains in digital microstructures for which the grain structure is discretized with both volumetric and surface meshes. Theoretical rate predictions were obtained from the measured mean widths and triple line lengths. Good agreement was found between growth rates measured in the simulations and the predictions of MacPherson – Srolovitz theory for the cases of an isolated shrinking sphere, individual grains in a digitally generated coarse polycrystal, and individual grains in a microstructure reconstructed from serial sectioning of stabilized cubic zirconia. Departures from this relationship appeared to be related to the grain shape.

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