A plastic flow-induced fracture theory for fatigue crack growth is pre
sented. A new formulae for the fatigue stress intensity threshold and
the fatigue crack growth rate law are derived by applying the principl
e of energy conservation in considering the fatigue crack growth proce
ss in the presence of local plastic flow ahead of the crack-tip. The p
resent theory predicts not only the fatigue crack growth rate being ju
st proportional to the rate of creation of dislocation at the crack-ti
p, but also the fatigue stress intensity threshold, which can be deter
mined according to the applied fatigue stress amplitude and the charac
teristic size of microstructural fracture process ahead of the crack-t
ip, and can account for the fatigue crack growth characteristics at bo
th low and high levels of applied fatigue stress intensity amplitude.
All the results are universal and agree with the existing empirical re
sults and experimental observations.