Edge dislocations generated from a microcrack under initial residual stress of non-uniform distribution

Crystal nucleation gives rise to inhomogeneity in the crystal lattice. The prevailing stresses and strains caused by non-uniform cooling can create microcracks with residual stresses locked-in at the end segments. These stresses can have a non-uniform distribution where the amplitude can increase or decrease from the microcrack tip which is highly strained to generate edge dislocations under in-plane shear. A dual scale microdislocation crack model is considered by focusing attention near the microcrack tip singularity such that more than 10 orders of magnitude in lineal dimension can be covered from the atomic to the microscopic scale. The concept of a scale multiplier is employed to connect the microscopic and atomic scale results. Discontinuity at the cross-scaling location is necessitated by dividing the full range of the non-equilibrium process into two regions within which equilibrium mechanics can be used. When needed, additional mesoregions can be added to reduce the transient discontinuities.Solved in closed form is the solution for the generation of edge dislocations due to non-uniform residual stress distributions at the end segment of the microcrack tip which will henceforth be referred to simply as the “tip”. Three different Cases I, II and III will be considered where the residual stress will possess a peak at the different locations. Case I for the furthest away from the tip, Case II for the peak nearest to the tip and Case III for the peak in the middle of the residual stress segment. Compared are the scale multiplier α whose maximum value being one corresponding to no discontinuity at cross-scaling. Hence, small α corresponds to large discontinuity. For Cases I, II and III, αs are found, respectively as 0.17, 0.43 and 0.28. The largest discontinuity occurred at α = 0.17 when the peak of the residual stress is farthest away from the microcrack tip. The largest number of edge dislocations or imperfections are also generated for Case I. The precise location of the residual stress peak is related to the magnitude and the segment length of the residual stress. These findings are manifestation of the variety of non-homogeneities that can arise in a metal alloy during crystal formation, not to mention the prevailing conditions at the grain boundaries. The idea is not to account for the details per se but to test the sensitivities of the microscopic and atomic parameters involved. To this end, the energy density function for the dual scale model will be determined and discussed in connection with what has been emphasized.     

Fatigue crack growth of cable steel wires in a suspension bridge: Multiscaling and mesoscopic fracture mechanics

Intrinsically, fatigue failure problem is a typical multiscale problem because a fatigue failure process deals with the fatigue crack growth from microscale to macroscale that passes two different scales. Both the microscopic and macroscopic effects in geometry and material property would affect the fatigue behaviors of structural components. Classical continuum mechanics has inability to treat such a multiscale problem since it excludes the scale effect from the beginning by introducing the continuity and homogeneity assumptions which blot out the discontinuity and inhomogeneity of materials at the microscopic scale. The main obstacle here is the link between the microscopic and macroscopic scale. It has to divide a continuous fatigue process into two parts which are analyzed respectively by different approaches. The first is so called as the fatigue crack initiation period and the second as the fatigue crack propagation period. Now the problem can be solved by application of the mesoscopic fracture mechanics theories developed in the recent years which focus on the link between different scales such as nano-, micro- and macro-scale.On the physical background of the problem, a restraining stress zone that can describe the material damaging process from micro to macro is then introduced and a macro/micro dual scale edge crack model is thus established. The expression of the macro/micro dual scale strain energy density factor is obtained which serves as a governing quantity for the fatigue crack growth. A multiscaling formulation for the fatigue crack growth is systematically developed. This is a main contribution to the fundamental theories for fatigue problem in this work. There prevail three basic parameters μ^∗, σ^∗ and d^∗ in the proposed approach. They can take both the microscopic and macroscopic factors in geometry and material property into account. Note that μ^∗, σ^∗ and d^∗ stand respectively for the ratio of microscopic to macroscopic shear modulus, the ratio of restraining stress to applied stress and the ratio of microvoid size ahead of crack tip to the characteristic length of material microstructure.To illustrate the proposed multiscale approach, Hangzhou Jiangdong Bridge is selected to perform the numerical computations. The bridge locates at Hangzhou, the capital of Zhejiang Province of China. It is a self-anchored suspension bridge on the Qiantang River. The cables are made of 109 parallel steel wires in the diameter of 7 mm. Cable forces are calculated by finite element method in the service period with and without traffic load. Two parameters α and β are introduced to account for the additional tightening and loosening effects of cables in two different ways. The fatigue crack growth rate coefficient C₀ is determined from the fatigue experimental result. It can be concluded from numerical results that the size of initial microscopic defects is a dominant factor for the fatigue life of steel wires. In general, the tightening effect of cables would decrease the fatigue life while the loosening effect would impede the fatigue crack growth. However, the result can be reversed in some particular conditions. Moreover, the different evolution modes of three basic parameters μ^∗, σ^∗ and d^∗ actually have the different influences on the fatigue crack growth behavior of steel wires. Finally the methodology developed in this work can apply to all cracking-induced failure problems of polycrystal materials, not only fatigue, but also creep rupture and cracking under both static and dynamic load and so on.