The effect of the location of stage-I fatigue crack across the persistent slip band on its growth rate – A 3D dislocation dynamics study

Abstract

A 3D dislocation dynamics study to ascertain the probable path of stage-I fatigue crack propagation across the persistent slip band (PSB) in austenitic stainless steel is presented. Cyclic plasticity and the resulting crack tip slip displacement (CTSD) are evaluated for cracks of varying length introduced at PSB-center and at two PSB-matrix interfaces. CTSD attains high value at either of the two interfaces irrespective of the proximity of crack front to the grain boundary. Further, a difference in microcrack propagation rate is also observed among the two interfaces. The present results assert microcrack propagation preferrentially along one of the two PSB-matrix interfaces rather than at the PSB-center. A pre-existing PSB dislocation structure localises the cyclic slip for crack lengths up to approximately half of the grain depth for an applied strain range of 2 × 10^?4.     

Crack–grain boundary interactions in zinc bicrystals

In polycrystalline materials that fail by transgranular cleavage, it is known that crystallographic misorientation of preferred fracture planes across grain boundaries can provide crack growth resistance; despite this, the micromechanisms associated with crack transmission across grain boundaries and their role in determining the overall fracture resistance are not well understood. Recent studies on diverse structural materials such as steels, aluminum alloys and intermetallics have shown a correlation between fracture resistance and the twist component of grain misorientation. However, the lack of control over the degree and type of misorientation in experimental studies, combined with a dearth of analytical and computational investigations that fully account for the three-dimensional nature of the problem, have precluded a systematic analysis of this phenomenon. In this study, this phenomenon was investigated through in situ crack propagation experiments across grain boundaries of controlled twist misorientation in zinc bicrystals. Extrinsic toughening mechanisms that activate upon crack stagnation at the grain boundary deter further crack propagation. The mechanical response and crack growth behavior were observed to be dependent on the twist angle, and several accommodation mechanisms such as twinning, strain localization and slip band blocking contribute to fracture resistance by competing with crack propagation. Three-dimensional finite element analyses incorporating crystal plasticity were performed on a stagnant crack at the grain boundary that provide insight into crack-tip stress and strain fields in the second grain. These analyses qualitatively capture the overall trends in mechanical response as well as strain localization around stagnant crack-tips.     

基于准连续介质方法模拟纳米多晶体Ni中裂纹的扩展

通过准连续介质方法模拟了纳米多晶体Ni中裂纹的扩展过程.模拟结果显示:裂纹尖端的应力场可以导致晶界分解、层错和变形孪晶的形成等塑性形变,在距离裂纹尖端越远的位置,变形孪晶越少,在裂纹尖端附近相同距离处,层错要远多于变形孪晶.这反映了局部应力的变化以及广义平面层错能对变形孪晶的影响.计算了裂纹尖端附近区域原子级局部静水应力的分布.计算结果表明:裂纹前端晶界处容易产生细微空洞,这些空洞附近为张应力集中区,并可能促使裂纹沿着晶界扩展.模拟结果定性地反映了纳米多晶体Ni中的裂纹扩展过程,并与相关实验结果符合得很好     

Effect of microstructure on fracture in age hardenable Al alloys

ABSTRACT

In the present study, the fracture behaviour of AA6016 alloy was investigated during bending deformation. Wrap-bend tests were conducted and the material was subjected to different bend angles to study crack propagation. The average grain size of the as-received material is approximately 45?μm. The aspect ratio of the grains was changed from 0.53 to 0.40 during bending. The presence of deformation bands was observed during bending in both tensile and compressive regions of the sample. No orientation correlation was observed between the deformation band and its corresponding parent grain. The Schmid factor inside the deformation bands was higher than that of the parent grain, which indicates that the deformation bands accommodate strain during bending. The crystallographic texture evolved significantly during bending deformation. The strength of cube texture component decreases with increasing bend angle and new texture components formed during bending. These new texture components favour either single slip or duplex slip. A mixture of intra-granular and inter-granular fracture occurs during bending. It is observed that inter-granular crack propagation is predominantly favoured along high-angle boundaries, and grain boundary de-cohesion occurs in regions where the misorientation angle is greater than 40°. The formation of deformation-induced coincidence lattice site (CSL) boundaries is also observed during bending and it is shown that the volume fraction of CSL boundaries of Σ3 type increases with increasing bend angle. The current study shows that the formation of deformation-induced CSL boundaries of Σ3 type in AA6016 alloy can improve its inherent resistance to crack propagation during bending.     

晶体相场法研究应力状态及晶体取向对微裂纹尖端扩展行为的影响

采用晶体相场模拟研究了单向拉伸作用下初始应力状态、晶体取向角度对单晶材料内部微裂纹尖端扩展行为的影响, 以(111)晶面上的预制中心裂纹为研究对象探讨了微裂纹尖端扩展行为的纳观机理, 结果表明: 微裂纹的扩展行为主要发生在<011>(111)滑移系上, 扩展行为与扩展方向与材料所处的初始应力状态及晶体取向紧密相关. 预拉伸应力状态将首先诱发微裂纹尖端生成滑移位错, 进而导致晶面解理而实现微裂纹尖端沿[011]晶向扩展, 扩展到一定程度后由于位错塞积, 应力集中, 使裂纹扩展方向沿另一滑移方向[101], 并形成锯齿形边缘; 预剪切应力状态下, 微裂纹尖端首先在[101]晶向解理扩展, 并诱发位错产生, 形成空洞聚集型长大的二次裂纹, 形成了明显的剪切带; 预偏变形状态下微裂纹尖端则直接以晶面解理形式[101]在上进行扩展, 直至断裂失效; 微裂纹尖端扩展行为随晶体取向不同而不同, 较小的取向角度会在裂纹尖端形成滑移位错, 诱发空位而形成二次裂纹, 而较大的取向角下的裂纹尖端则以直接解理扩展为主, 扩展方向与拉伸方向几近垂直.     

Quantifying the grain boundary resistance against slip transfer by experimental combination of geometric and stress approach using stage-I-fatigue cracks

In recent studies, many groups have investigated the interaction of dislocations and grain boundaries by bi-crystals and micro-specimen experiments. Partially, these experiments were combined with supplementary simulations by discrete dislocation dynamics, but quantitative data for the grain boundary resistance against slip transfer is still missing. In this feasibility study with first results, we use stage-I-fatigue cracks as highly localised sources for dislocations with well-known Burgers vectors to study the interaction between dislocations in the plastic zone in front of the crack tip and selected grain boundaries. The stress concentration at the grain boundary is calculated with the dislocation-free zone model of fracture using the dislocation density distribution in the plastic zone from slip trace height profile measurements by atomic force microscopy. The grain boundary resistance values calculated from common geometric models are compared to the local stress distribution at the grain boundaries. Hence, it is possible to quantify the grain boundary resistance and to combine geometric and stress approach for grain boundary resistance against slip transfer to a self-contained concept. As a result, the prediction of the grain boundary resistance effect based on a critical stress concept is possible with knowledge of the geometric parameters of the grain boundary only, namely the orientations of both participating grains and the orientation of the grain boundary plane.     

Grain boundary cracking in fatigued bicrystals

Compact tension (CT) shaped copper bicrystals containing the 3(111), 9(221), 41(338) or random [110] tilt boundaries either perpendicular or parallel to the tensile axis (TA) were tested to examine the effect of grain boundary (GB) structure on fatigue crack initiation and propagation. With both types of bicrystals, the GB resistance to intergranular cracking increases with the decrease in the value. The effect of air on fatigue crack propagation is found to be of primary importance. It is shown that the GB is not necessarily a preferential site for crack propagation in vacuum. A crack introduced intergranularly in air may assume a stransgranular mode of growth in vacuum. The initial GB structure greatly affects the susceptibility of GBs to corrosion in air and this determines their resistance to crack growth. The relative importance of slip band cracking as compared to GB cracking in vacuum is examined. The dominant mechanism of fracture is seen to be determined by two factors: the GB structure in the non-equilibrium state and the geometry of slip with respect to GB orientation.     

Atomic scale investigation of grain boundary structure role on intergranular deformation in aluminium

The role that grain boundary (GB) structure plays on the directional asymmetry of an intergranular crack (i.e. cleavage behaviour is favoured along one direction, while ductile behaviour along the other direction of the interface) was investigated using atomistic simulations for aluminium 〈1 1 0〉 symmetric tilt GBs. Middle-tension (M(T)) and Mode-I crack propagation specimens were used to evaluate the predictive capability of the Rice criterion. The stress–strain response of the GBs for the M(T) specimens highlighted the importance of the GB structure. The observed crack tip behaviour for certain GBs (Σ9 (2 2 1), Σ11 (3 3 2) and Σ33 (4 4 1)) with the M(T) specimen displayed an absence of directional asymmetry which is in disagreement with the Rice criterion. Moreover, in these GBs with the M(T) specimen, the dislocation emission from a GB source at a finite distance ahead of the crack tip was observed rather than from the crack tip, as suggested by the Rice criterion. In an attempt to understand discrepancy between the theoretical predictions and atomistic observations, the effect of boundary conditions (M(T), Mode-I and the edge crack) on the crack tip events was examined and it was concluded that the incipient plastic events observed were strongly influenced by the boundary conditions (i.e. activation of dislocation sources along the GB, in contrast to dislocation nucleation directly from the crack tip). In summary, these findings provide new insights into crack growth behaviour along GB interfaces and provide a physical basis for examining the role of the GB character on incipient event ahead of a crack tip and interface properties, as an input to higher scale models.     

Formation and propagation of cracks during cyclic deformation

Summary Starting from observation of the geometric features of formation and propagation of cracks in cycled single crystals of copper a model was developed for fatigue cracking. The only and experimentally well established assumption of the model is that the slip during cyclic deformation tends to be coarse. By the cooperation of stress concentrations at the slip steps and the hardening of slip planes activated locally two slip systems (with different slip planes and Burgers vectors) are activated alternatively so that a crack develops from the slip step. It propagates without monotonically increasing the hardening at the crack tip. The coarse slip produces sharp slip steps at the surface for crack formation and prohibits crack blunting during propagation. In contrast to other models the one described can show how the irreversible process of crack formation and propagation can take place despite completely symmetrical push-pull stresses. The whole crack is formed merely by the motion of dislocations present in the material so that but comparatively small stresses are needed. As, moreover, no thermally activated processes are necessary, fatigue at 4·2°K can be explained too. The strong dependence of fatigue on the state of the surface can also be accounted for since the cracks form at the surface steps. Materials which tend to coarse slip even in unidirectional tests are expected to fatigue easily. This is corroborated experimentally. Finally, many details of crack geometry can be explained in terms of the model.Published in Z. f. Metallkunde58 (1967), 780.     

Stage-I fatigue crack studies in order to validate the dislocation-free zone model of fracture for bulk materials

Stage-I fatigue cracks are commonly described by the model of Bilby, Cottrell and Swinden (BCS model). However, since several experimental investigations have shown a dislocation-free zone (DFZ) in front of crack-tips, it is necessary to validate the new DFZ model and to examine the deviations to the BCS model. Therefore, the dislocation density distribution is derived from height profiles of slip lines in front of stage-I fatigue cracks in CMSX4® single crystals measured by contact-mode atomic force microscopy. This is possible, because the cracks are initiated at notches milled by focused ion beam technique directly on slip planes with a high Schmid factor. Consequently, the directions of the Burgers vectors are well known; it is possible to calculate the dislocation density distributions from the height profiles. The measured distributions are compared to the calculated distribution function of the DFZ model proposed by Chang et al. The additionally measured microscopic friction stress of the dislocations is then used to calculate the influence of grain boundaries on the dislocation density distribution in front of stage-I cracks. The calculation is done by the extended DFZ model of Shiue et al. and compared with the measured distribution function in polycrystalline specimens. Finally, the crack-tip sliding displacement as a measure for the crack propagation rate is compared for the DFZ model and the BCS model with the experimentally revealed values. The important result: the often used BCS model does not reflect the experimental measurements. On the contrary, the DFZ model reflects the measurements at stage-I cracks qualitatively and quantitatively.     

Stimulation and Suppression of Grain Boundary Sliding by Intragranular Slip in Zinc Bicrystals

The influence of intragranular slip on grain boundary sliding is studied in originally compatible zinc bicrystals with symmetric tilt boundary. The experiment is designed to separate different effects of intragranular slip on the boundary sliding and establish their mechanisms. Grain boundary sliding with and without development of intragranular slip is observed. The rate of sliding accompanied by slip is more than five times of that without slip. A good correlation between the boundary sliding and intragranular slip prior to slide hardening is established. Slide hardening followed by the negative sliding near one end of the boundary and strain hardening in the boundary vicinity, are observed at the last stages of deformation. For the case of formation of slip induced glissile grain boundary dislocations of opposite signs the possibility of their contribution to total grain boundary sliding, is analyzed. The effect of the increase in the rate of sliding is explained in terms of the accommodation of sliding by slip and appearance of additional glissile grain boundary dislocations of one sign due to strain incompatibility. Contribution of these different dislocation mechanisms to the increase in the sliding rate is determined for the stage of deformation preceding slide hardening. It is supposed that the effect of slide hardening and negative sliding as well as boundary curving is created by non-smooth boundary and small degree of incompatibility caused by straining.     

Study into laser heating of Ti---14Al---21Nb alloy to improve properties

Ti---14Al---21Nb alloy may find a potential application in advanced structures. On the other hand, incompatible atomic configurations at the grain boundaries render the grain boundary regions weak, which, in turn, provides possible crack development and propagation along these boundaries, i.e. due to room temperature slip behaviour of intermetallic alloys, nucleation and propagation of cracks become the mode of deformation. Considerable research has been carried out to solve the poor ductility of intermetallic alloy knowing the fact that altering the crystal structure and reducing slip distance by creating a small grain size structure may be one way of solving the problem. Consequently, laser heating at pulses 1 μs can provide a cooling rate of the order of 10⁶ K/s, which, in turn, makes it possible to change the metallurgical structure of the alloy to a desired structure. In the present study, a theoretical model based on Fourier analysis is carried out to predict the cooling rate after the laser pulse irradiation. An experiment is carried out to measure the cooling rate. The study is extended to include experimental investigation into metallurgical changes due to laser pulse.     

Low cycle fatigue cracking of Al 20wt% Zn multicrystals

Low cycle fatigue data are reported for multicrystalline specimens (i.e. polycrystals with a few large grains in the gauge section) of age-hardened AlZn alloy with elliptical G. P. zones. Experiments were carried out at constant strain amplitude, room temperature and frequency 2 Hz. The discussion focused on the role and relative importance of grain boundaries, extrusions and coarse slip bands for crack nucleation and propagation. Precipitation free zones bordering the grain boundaries are the most favoured sites of crack nucleation and early crack growth. The prevailing mechanism of the initial stage of transcrystalline cracking is alternating slip or shear. The large cracks with an extended plastic zone tend to follow the extrusions which are formed at the crack tip after sufficients number of cycles.The authors wish to thank Dr. P. Luká of Institute of Physical Metallurgy, Brno, for valuable comments on this work and to Mr. T. Páv, Nuclear Research Institute, e, for conducting the fatigue tests.     

Crack propagation as a free boundary problem

A sharp interface model of crack propagation as a phase transition process is discussed. We develop a multipole expansion technique to solve this free boundary problem numerically. We obtain steady state solutions with a self-consistently selected propagation velocity and shape of the crack, provided that elastodynamic effects are taken into account. Also, we find a saturation of the steady state crack velocity below the Rayleigh speed, tip blunting with increasing driving force, and a tip splitting instability above a critical driving force.     

Using transmission Kikuchi diffraction to study intergranular stress corrosion cracking in type 316 stainless steels

Transmission Kikuchi diffraction (TKD), also known as transmission-electron backscatter diffraction (t-EBSD) is a novel method for orientation mapping of electron transparent transmission electron microscopy specimen in the scanning electron microscope and has been utilized for stress corrosion cracking characterization of type 316 stainless steels. The main advantage of TKD is a significantly higher spatial resolution compared to the conventional EBSD due to the smaller interaction volume of the incident beam with the specimen.Two 316 stainless steel specimen, tested for stress corrosion cracking in hydrogenated and oxygenated pressurized water reactor chemistry, were characterized via TKD. The results include inverse pole figure (IPFZ) maps, image quality maps and misorientation maps, all acquired in very short time (<60 min) and with remarkable spatial resolution (up to 5 nm step size possible). They have been used in order to determine the location of the open crack with respect to the grain boundary, deformation bands, twinning and slip. Furthermore, TKD has been used to measure the grain boundary misorientation and establish a gauge for quantifying plastic deformation at the crack tip and other regions in the surrounding matrix. Both grain boundary migration and slip transfer have been detected as well.     

Atomic simulations of influence of twinning on crack propagation of Al

Molecular dynamics simulation was performed to investigate the influence of twin boundary(TB) spacing on crack propagation of Al.This study reveals the orientation of initial crack may affect the mechanism of crack growth obviously.TB strengthens Al when the crack orientation is parallel with TB because of the hinderance of TB to the emission of the dislocations.The results indicate that there is an optimal TB spacing for mechanical properties of the Al,exhibiting reverse HP(Hall-Petch) and HP effect when the TB spacing is near the critical TB spacing.Furthermore,we find that there is a yield strength hardening effect in nanotwinned Al when the crack orientation is perpendicular to the TB,and the Young’s modulus is smaller in the nanotwinned Al than that of twin free Al.The studies also demonstrate that this distinctive deformation behavior is related to nucleation of dislocations and the repulsive force of TB to the dislocations and crack propagation,as well as the distance between the crack tip and the TB.     

Elastic interaction of a dislocation array with a phase boundary

The equilibrium configuration of an array of dislocations in parallel equidistant slip planes under an external shear stress near a welded boundary between two isotropic half-spaces having different elastic constants is computed. For large external stress, the dislocations are arranged into an arc concave when seen from the boundary. It is concluded that such an arc is formed at the tip of a twin or of a martensitic plate near a phase boundary. The tensile stress across the boundary due to an edge dislocation array is discussed in connection with the formation of an interfacial crack.     

Transformation of Slip Dislocations in Σ3 Grain Boundary

Grain boundary processes during plastic deformation of bicrystals were studied by TEM. Two methods were used. In situ straining in the electron microscope followed by post mortem examination and post mortem observation of specimens previously deformed by in situ synchrotron radiation X-ray topography. Two mechanisms governing slip propagation across a coherent twin boundary in a Fe-Si alloy bicrystal were identified. The first mechanism is a dissociation of a slip dislocation with the Burgers vector lying parallel to the boundary into three equal grain boundary dislocations. The second mechanism is a decomposition of a slip dislocation with Burgers vector inclined to the boundary into a dislocation mobile in the other grain and two screw grain boundary dislocations.     

Analytical estimation of dislocation distribution at the tip of arrested cracks

Computer simulation technique is used for studying the plastic flow at the tip of an arrested crack in lithium fluoride crystals. Two stages of the dislocation structure formation at the tip of a crack are analyzed: the formation of slip lines at the instant of crack arresting, and their evolution after sample unloading and partial healing of the crack. The size and the number of dislocations in a slip line are determined as functions of the loading force at the instant of crack arresting and on frictional stresses. It is shown that, during sample unloading and healing, some dislocations emerge at the plane of the crack under the action of mutual repulsion and image forces, so that the dislocation density attains its maximum value at a distance from the crack tip. A finite region free of dislocations exists in the immediate vicinity of the crack tip.     

Influence of grain boundary sliding on fracture toughness of nanocrystalline ceramics

A theoretical model is proposed describing a new physical microscopic mechanism of increased fracture toughness of nanocrystalline ceramics. According to this model, when a ceramic with a microcrack is deformed, intensive grain boundary sliding occurs near the crack tip under certain conditions. This sliding is accompanied by the formation of an array of disclination dipoles (rotational defects) producing elastic stresses. These stresses partially compensate the high local stresses concentrated near the microcrack tip and thereby hamper the microcrack growth. The proposed model is used to theoretically estimate the increase in the critical microcrack length (the length above which the catastrophic growth of microcracks occurs) caused by the formation of disclination dipoles during grain boundary sliding in nanoceramics. The increase in the critical microcrack length is a quantitative characteristic of the increased fracture toughness of nanoceramics.