Strain-induced passivity breakdown in corrosion crack initiation

Corrosion crack nucleation and growth are modelled as a moving boundary problem. The model incorporates three physical processes––dissolution, passivation and straining––into a continuum mechanical framework. The dissolution triggers surface advance; the passivation restrains the access of the environment to bare metal; the deformation causes for passivity breakdown. Plane cracks nucleating from surface pits in an elastic–plastic material body under fatigue load are considered. The problem is solved using a FEM program and a moving boundary tracking procedure. The model simulates how cracks form and grow in a single continuous course. The geometry of the developed cracks is found independent of the initial pit size. Plasticity is found to influence the curvature at the tip of the nucleated corrosion cracks. The most important evolution length parameter, the width of the corrosion crack, is found to depend on the size constraints of the tracking procedure. It is concluded that the model is deficient for determining all length scales observed in reality. Physical processes to be considered in an advanced model are proposed and discussed.     

Effect of elastic constants on crack channeling in a thin film bonded to an orthotropic substrate

A channeling crack confined in an orthotropic film bonded to an orthotropic substrate under a steady-state condition is investigated. The problem is formulated based on a modified Stroh formalism and an orthotropy rescaling technique, in order to determine the necessary material parameters required to describe the steady-state energy release rate. A closed form of the energy release rate is obtained with the exception of the normalized energy release rate for the transformed bimaterial structure that consists of the orthotropic film and isotropic substrate. The normalized energy release rates for the transformed problem are shown to depend on only four material parameters and are numerically calculated using finite element analyses. The periodic channels in the film layer of the bimaterial structure are also considered. The steady-state energy release rates for the periodic channeling cracks are obtained as a function of the ratio of the film thickness to the crack spacing for various combinations of the material parameters.     

表面裂纹疲劳扩展的数值模拟(Ⅱ)

根据Paris疲劳裂纹扩展规律,对拉伸和纯弯曲疲劳载荷下表面裂纹扩展进行了数值模拟。数值模型中,用三次样条函数曲线拟合裂纹尖端,在裂纹扩展增量计算中考虑了裂纹闭合影响。裂纹形状演化的模拟结果与Newman和Raju经验公式预测结果进行了比较,表明了所采用的数值模拟方法的实用性。研究发现,裂纹闭合对疲劳裂纹扩展过程中的裂纹形状演化以及裂纹尖端的应力强度因子(SIF)分布都有明显影响。同裂纹形状演化一样,疲劳裂纹扩展过程中裂纹尖端的SIF分布表现出明显的特征。最后,建议了一个简单函数来统一描述表面裂纹尖端的SIF分布。     

Evolving crack patterns in thin films with the extended finite element method

This paper develops the extended finite element method (XFEM) to evolve patterns of multiple cracks, in a brittle thin film bonded to an elastic substrate, with a relatively coarse mesh, and without remeshing during evolution. A shear lag model describes the deformation in three dimensions with approximate field equations in two-dimensions. The film is susceptible to subcritical cracking, obeying a kinetic law that relates the velocity of each crack to its energy release rate. At a given time, the XFEM solves the field equations and calculates the energy release rate of every crack. For a small time step, each crack is extended in the direction of maximal hoop stress, and by a length set by the kinetic law. To confirm the accuracy of the XFEM, we compare our simulation to the exiting solutions for several simple crack patterns, such as a single crack and a set of parallel cracks. We then simulate the evolution of multiple cracks, initially in a small region of the film but of different lengths, showing curved crack propagation and crack tip shielding. Starting with multiple small cracks throughout the film, the XFEM can generate the well-known mud crack pattern.     

Environmentally assisted initiation and growth of multiple surface cracks

The initial stages of stress corrosion on an amorphous polymer is investigated. This is done by exposing stressed specimens of polycarbonate to an acetone and water solution. The surface develops two distinct features of degradation that appear on different length scales when subjected to tensile stress. Small pits form on the surface and make it rough. These pits are in the order of micrometers, and are found to be randomly distributed. They occur even without load and seem to slightly increase in number with increasing stress. In the millimeter domain, visible to the bare eye, surface cracks are formed transverse to the direction of loading. The occurrence of cracks is seen to have a positive stress threshold value, exceeding which, a linear increase of number of cracks with stress is found. The manners in which the cracks grow and coalesce on the surface are examined. It is seen that they do not meet crack tip to crack tip. Instead, they avoid each other initially and coalesce crack tip to crack side. The results are discussed in the light of mechanical considerations. A stress analysis for a few configurations of meeting cracks supports the experimental observations. With assumptions of stress corrosion crack growth and coalescence, a simulation of cracks growing from randomly distributed initiation sites is performed. Similar crack patterns as obtained in the experiments are found.     

基于局域分析的疲劳短裂纹群体演化随机模型

采用局域裂纹数密度描述金属材料中不同局部区域的疲劳短裂纹群体损伤的发展情况通过考虑在不同局域存在的材料性质的随机涨落及局部损伤对损伤总量发展的影响，建立了局域裂纹数密度演化随机方程对方程数值求解从而模拟了材料的疲劳短裂纹损伤过程结果显示出主裂纹出现的随机性，并讨论了裂纹总数与最大裂纹尺度在统计意义上的演化特征     

An interacting micro-crack damage model for failure of brittle materials under compression

A model is developed for brittle failure under compressive loading with an explicit accounting of micro-crack interactions. The model incorporates a pre-existing flaw distribution in the material. The macroscopic inelastic deformation is assumed to be due to the nucleation and growth of tensile “wing” micro-cracks associated with frictional sliding on these flaws. Interactions among the cracks are modeled by means of a crack-matrix-effective-medium approach in which each crack experiences a stress field different from that acting on isolated cracks. This yields an effective stress intensity factor at the crack tips which is utilized in the formulation of the crack growth dynamics. Load-induced damage in the material is defined in terms of a scalar crack density parameter, the evolution of which is a function of the existing flaw distribution and the crack growth dynamics. This methodology is applied for the case of uniaxial compression under constant strain rate loading. The model provides a natural prediction of a peak stress (defined as the compressive strength of the material) and also of a transition strain rate, beyond which the compressive strength increases dramatically with the imposed strain rate. The influences of the crack growth dynamics, the initial flaw distribution, and the imposed strain rate on the constitutive response and the damage evolution are studied. It is shown that different characteristics of the flaw distribution are dominant at different imposed strain rates: at low rates the spread of the distribution is critical, while at high strain rates the total flaw density is critical.     

The mode III cracks originating from the edge of a circular hole in a piezoelectric solid

A mode III fracture problem of edge cracks originating from a circular hole in an infinite piezoelectric solid is studied based on complex variable method combined with the method of conformal mapping. Explicit and exact expressions for the complex potentials, field intensity factors and energy release rates are presented under the assumption that the surface of the cracks and hole is electrically impermeable. Numerical analysis is then conducted to discuss the influences of crack length and applied mechanical/electric loads on the field intensity factors and energy release rate for one and two edge cracks, respectively. It is found that for the case of a single edge crack, the field intensity factors are greater than those of double edge cracks, and moreover the electric loads can either promote or retard crack growth, depending on the magnitude and direction of the applied electric loads.     

含广布腐蚀坑结构寿命评估方法

为了定量评估含广布腐蚀损伤老龄化飞机结构的剩余强度, 采用等效裂纹方法将腐蚀坑沿垂 直于外界最大主应力方向进行投影处理, 使其转化为具有相同寿命的等效初始表面裂纹, 然 后采用参数化有限元方法,求解等效裂纹前沿的应力强度因子、裂纹扩展方向和裂纹扩展增量, 建立并应用应力强度因子变化历程, 采用循环接循环的损伤累积方法对含广布等效表面裂纹 在疲劳载荷作用下的寿命进行了预测. 预测结果为复杂环境中含广布腐蚀坑的飞机结构寿命 预测提供了参考.     

On a general concept for the analysis of crack growth and material damage

For finite strain dynamics a variational model of crack evolution is formulated within the generalized oriented continuum methodology. In this approach position- and direction-dependent deformation and strain measures are used to describe the (macro)motion of the body with defects, which may evolve relative to the moving body. The inelastic behaviour of continua with evolving defects is represented by phenomenological equations including the transversal crack evolution. A strain-induced crack propagation criterion is defined by the difference between the strain energy release rate and the rate of the surface energy of the crack. A possible nucleation of microcracks in terms of the average drag coefficient of the crack configuration is proposed. Based on the crack growth criterion presented in this paper, the kinking of cracks is investigated using variational concepts. A constitutive damage model of Kachanov's type accounting for the crack density is derived in terms of the free energy functional and a dissipation potential.     

Edge cracks in plastically deforming surface grains

A selection of surface crack problems is presented to provide insights into Stage I and early Stage II fatigue crack growth. Edge cracks at 45^o and 90^o to the surface are considered for cracks growing in single crystals. Both single crystal slip and conventional plasticity are employed as constitutive models. Edge cracks at 45^o to the surface are considered that either (i) kink in the direction perpendicular to the surface, or (ii) approach a grain boundary across which only elastic deformations occur.     

Monitoring short fatigue cracks with miniature strain gages

An experimental technique to monitor the length and the opening level of a short fatigue crack is presented. It is based on the progressive decrease with crack length of the response of miniature strain gages installed on the surface near the crack plane. A first gage installed close to the crack plane can monitor cracks from 10 μm in depth to half a millimeter where the response saturates. Other gages at larger distances from the crack plane are less sensitive but can monitor longer cracks. The response is measured so that it is independent of strain-gage calibration, Young's modulus and Poisson's ratio. The paper first presents the basic principles and possibilities of the technique as well as a finite-element analysis performed on automatic welded joints with straight-fronted cracks for which the technique has been developed. The results give a correlation between gage response, crack length and gage location and the conditions of replacement of a gage reaching saturation. The practical exploitation of the technique has required further work to derive a continuous calibration of the gage response that includes corrections to account for the gage finite dimensions and the crack-plane inclination. This calibration is shown to give crack lengths that compare well with fractographic marks and typical results that have been obtained on short crack growth at the weld toe are presented. In particular, the resolution of the technique is put into evidence with results on the initial growth of a 0.1 mm nonpropagating crack. The paper finally points out the distinctive features that appear in current works to adapt the technique to the growth of semi-elliptical cracks of low and high aspect ratio.     

Experimental and theoretical study on numerical density evolution of short fatigue cracks

Fatigue testing was performed using a kind of triangular shaped specimen to obtain the characteristics of numerical density evolution for short cracks at the primary stage of fatigue damage. The material concerned is a structural alloy steel. The experimental results show that the numerical density of short cracks reaches the maximum value when crack length is slightly less than the average grain diameter, indicating grain boundary is the main barrier for short crack extension. Based on the experimental observations and related theory, the expressions for growth velocity and nucleation rate of short cracks have been proposed. With the solution to phase space conservation equation, the theoretical results of numerical density evolution for short cracks were obtained, which were in agreement with our experimental measurements. The project supported by the National Natural Science Foundation of China and the Chinese Academy of Sciences.     

拉压循环载荷下正交异性钢桥面板肋-面板焊缝裂纹扩展分析

采用四步法计算了考虑循环载荷中压应力影响的正交异性钢桥面板的肋-面板焊缝表面裂纹扩展。第一步是基于正交异性钢桥面板的疲劳分析模型,计算肋-面板焊缝处的应力,第二步是通过肋-面板焊缝的三维局部模型,用Schwartz-Neumann交替法计算焊缝表面裂纹的应力强度因子分布,第三步是用二维断裂力学模型和增量塑性损伤模型,计算循环载荷中的压应力对裂纹扩展的影响,第四步是用第二步中的三维裂纹分析结果和第三步中的二维断裂力学模型得到的裂纹扩展公式,计算钢桥面板的肋-面板焊缝表面裂纹扩展。计算结果表明,对应于正交异性钢桥面板肋-面板焊缝处的循环应力,本文所用模型的裂纹尖端反向塑性区导致裂纹扩展率增加50%以上。研究结果为正交异性钢桥面板肋-面板焊缝裂纹的疲劳寿命分析提供了研究基础。     

缺口试样疲劳短裂纹行为研究

采用复型方法对中碳结构钢单边钝缺口试样的非穿透和穿透疲劳短裂纹的演化过程进行了研究。结果表明：试样的疲劳破坏主要是由形成于缺口根部的表面短裂纹扩展引起的；形成穿透裂纹以前的短裂纹形成和扩展过程占试样疲劳寿命的７０％以上；线弹性断裂力学不适合于描述表面裂纹和穿透裂纹早期阶段的扩展特性；某些条件下，裂纹初始几何形状的影响是导致穿透裂纹早期扩展出现奇异特性的主要原因。     

On dissolution driven crack growth

The formation and growth of a crack in a body subjected to stress driven material dissolution is studied. The rate of material dissolution is proportional to strain energy and curvature of the body surface. The formation of a crack from a plane surface is preceded by an evolving surface roughness. The continued dissolution enhances roughness amplitude resulting in pit formation. As the pit grows deeper into the material, it assumes the shape of a crack. The sharpness of the crack reaches its maximum during this transition from a pit to a crack. As the crack grows, a self-similar state is gradually assumed. During this phase characteristic lengths of the crack shape scale with the crack length. In line with this the crack progressively becomes blunt. The widest part of the crack when unloaded is in the vicinity of the crack tip. A consequence of the model is that no criterion is needed for crack growth. Neither is a criterion needed for determination of the crack path. It also follows that the crack growth rate is almost independent of the remote load. Further, spontaneous crack branching is anticipated. A motivation for this is given.     

Flow Around a Crack in a Porous Matrix and Related Problems

The equations governing plane steady-state flow in heterogeneous porous body containing cracks are presented first. Then, a general transformation lemma is presented which allows extending a particular solution obtained for a given flow problem to another configuration with different geometry, behaviour and boundary conditions. An existing potential solution in terms of discharges along the cracks, established by Liolios and Exadaktylos (J Solids Struct 43:3960–3982, 2006) for non-intersecting cracks in isotropic matrix, is extended to intersecting cracks in anisotropic matrix. The basic problem of a single straight crack in an infinite body submitted to a pressure gradient at infinity is then investigated and a closed-form solution is presented for the case of void cracks (infinite conductivity), as well as a semi-analytical solution for the case of cracks with Poiseuille type conductivity. These solutions, derived first for an isotropic matrix, are then extended to anisotropic matrices using the general transformation lemma. Finally, using the solution obtained for a single crack, a closed-form estimation of the effective permeability of micro-cracked porous materials with weak crack density is derived from a self-consistent upscaling scheme.     

STUDY ON THE SURFACE CRACK GROWTH BEHAVIOR IN 14MnNbq BRIDGE STEEL

Three-dimensional crack closure correction methods are investigated in this paper.The fatigue crack growth tests of surface cracks in 14MnNbq steel for bridge plate subjected to tensile and bending loadings are systematically conducted.The experimentally measured fatigue crack growth rates of surface cracks are compared with those of through-thickness cracks in detail.It is found that the crack growth rates of surface cracks are lower than those of through-thickness cracks.In order to correct their differences in fatigue crack growth rates, a dimensionless crack closure correction model is proposed.Although this correction model is determined only by the experimental data of surface cracks under tensile loading with a constant ratio R=0.05, it can correlate the surface crack growth rates with reasonable accuracy under tensile and bending loadings with various stress ratios ranging from 0 to 0.5.Furthermore, predictions of fatigue life and crack aspect ratio for surface cracks are discussed, and the predicted results are also compared with those obtained from other prediction approaches.Comparison results show that the proposed crack closure correction model gives better prediction of fatigue life than other models.     

Coupled modeling of damage growth and permeability variation in brittle rocks

This paper presents a coupled model for anisotropic damage and permeability evolution by using a micro–macro approach. The damage state is represented by a second order tensor. The evolution of damage is determined from a crack propagation criterion. The free enthalpy function of cracked material is obtained by using micromechanical considerations. It is assumed that cracks exhibit normal aperture which is coupled with the crack growth due to asperities of crack faces. By using Darcy’s law for macroscopic fluid flow and assuming laminar flow in microcracks, the overall permeability of the RVE is obtained by a volume averaging procedure taking into account crack aperture in each orientation.     

On delamination growth from channel cracks in thin-film coatings

Interfacial fracture (delamination) originating from channel or tunnel cracks is a common failure mode in layered structures. While this subject has been addressed extensively, little is known on the actual process of fracture. It is this aspect which is of concern here. The evolution of delamination damage is followed in situ using an all-transparent system designed to reduce material variability and thermal stresses. The specimen is composed of two glass plates glued onto a polycarbonate slab by a RT epoxy resin. With a proper control of the glass surface, stable delamination growth from a single channel crack occurs. This growth evolves smoothly from the tip of the channel crack, although the delamination area is generally irregular and non-symmetric. The fracture resistance varies greatly between nominally identical samples, attesting to a great sensitivity to such irregularity as well as to bonding surface conditions. The effect of system variables on delamination growth is evaluated using a 2D FEA. The analysis predicts general trends observed in the tests, and it indicates means for an optimal design against premature failure. Finally, the merit of evaluating fracture toughness of ultra-thin films using the channel cracking approach is discussed.