Fatigue crack propagation within Al-Cu-Mg single crystals based on crystal plasticity and XFEM combined with cohesive zone model

[Display omitted] •Deformation behavior during fatigue stage II conforms to the mixed law of elastic and plastic mechanics.•The simulation combines crystal plasticity, extended finite element method and cohesive zone model.•Grain orientation plays a predominated role in affecting fatigue crack propagation of Al-Cu-Mg alloy.•Goss orientation has the strongest ability in improving the fatigue resistance of Al-Cu-Mg single crystal. A method combining crystal plasticity (CP), the eXtended Finite Element Method (XFEM), and cohesive zone model (CZM) with traction separation law is developed for an Al-Cu-Mg alloy to predict the effect of grain orientation on fatigue crack propagation (FCP) during stage ΙΙ within a single crystal. The simulation results show that of all the orientations, Goss grain possesses the largest fatigue crack deflection, then followed by Cube orientation. Comparatively, Brass, Copper, S and Random grains have relatively small crack deflection angles. Besides, it is found that Goss grain with the largest fatigue crack deflection possesses the lowest FCP rate as compared with other orientations. The results of simulations are consistent with previous experimental observations. This indicates that this coupled CP XFEM CZM simulation method is capable of well predicting the effect of grain orientation on FCP during fatigue stage ΙΙ of Al-Cu-Mg single crystal.