Quantification of fatigue damage accumulation using non-linear ultrasound measurements

This article attempts to relate ultrasonic second harmonic generation to dislocation structures in fatigued materials. By focusing on the fact that asymmetric dislocation motion is required to generate the second harmonic, a theoretical derivation of the non-linearity parameter (ratio of the amplitude of second harmonic to square of the amplitude of the fundamental) from dislocation pile-ups is presented. In order to verify the theory, harmonic generation was measured along a failed fatigue sample of DA718, a nickel base superalloy that exhibits planar slip, and consequently dislocation pile-ups. TEM studies along the length of the failed fatigue sample revealed a banded dislocation structure, composed of pile-ups near the fracture zone and a sparse dislocation network closer to the grip region. The non-linearity parameter was found to increase by between 90% and 140% from the grip region to the fracture zone and this correlated well with the calculations based on theoretical expressions derived here.