Predicting corner crack fatigue propagation from cold worked holes

We predict the fatigue propagation of corner cracks from cold worked holes using three dimensional finite element models. The models account for the through thickness variation in residual stress left after cold working. The predictions are compared to experimental results in aluminum 2024-T351 and 7075-T651. The models show the evolution of P-shaped crack fronts similar to those observed in experiments. Predictions based on the initial residual stress field left after cold working were nonconservative, predicting either slower than experimental crack growth or crack growth that arrests. Predictions based on an estimate of the stable relaxed residual stress field near the hole were conservative, and predicted 5–10 times greater life than the current Department of Defense reduced initial flaw size approach.