Review and evaluation of the double-torsion technique for fracture toughness and fatigue testing of brittle materials

This paper reviews the double-torsion (DT) test as an experimental technique for the measurement of fracture toughness and slow-crack-growth behavior in brittle materials based on the authors' experiences and an evaluation of current literature. The DT technique has numerous advantages due primarily to the fact that the stress intensity is independent of crack length, at least for the central half of the specimen. Although the technique was first proposed about 20 years ago, and has been used extensively since then, there are a number of important unresolved questions concerning the methodology. To date there has been no standardization of test procedure or specimen geometry. A review of specimen geometries in use indicates that the proportions that are most commonly employed (based on the literature and experience) are width:W, length: 3W, thickness:W/6–W/15. Grooves on both the top and the bottom surfaces have been used to guide the crack, however it has been found that ungrooved, but very accurately aligned, specimens give the best results. Theoretical thickness-correction factors which account for both relatively thick specimens (with respect to width) and the effect of the size of the loading points, have been considered. The effect of crack-front profile on measured values of crack velocity and stress intensity is contentious. Althogh the stress intensity,K, varies along the crack front, the front merely translates axially. For the presentation of crackvelocity stress-intensity (V-K) data, the consensus seems to be that the only rational velocity to use is that based on the crack's intersection with the tensile surface. Despite some of the shortcomings mentioned above, the DT technique is widely accepted and gaining in popularity. It is particularly useful under cyclic fatigue conditions for investigating the effect of a change in a single parameter on crack-growth rate, using the very effective and elegant ‘changeover’ method.     

CTOD试验焊缝表面开缺口试样裂纹前沿平直度研究

对于裂纹尖端张开位移(CTOD)试验,焊缝试样中预制疲劳裂纹前沿平直度直接影响了试样制备的合格率,是试验的关键难题之一．试验中常对试样进行预处理以提高裂纹前沿平直度,但由此也使试验结果与实际情况产生一定差异．本文深入研究规范BS7448: Part2中对焊缝试样取样方向的规定,对表面开缺口试样裂纹尖端焊接残余应力进行分析,运用大型有限元软件ANSYS模拟90mm厚钢板焊接过程,求解了横向残余应力沿板厚方向及焊缝方向的分布规律,研究出横向残余应力分布是影响焊缝试样预制裂纹前沿平直度的主要原因,并通过试验进行验证．试验结果表明,表面开缺口试样可不经过局部韧带压缩等预处理而得到合格的裂纹前沿平直度,试验不改变原焊缝残余应力,可测得更加接近焊缝实际情况的CTOD韧度值,给CTOD试验中合理选取焊缝试样取样方向提供了新思路．     

Investigation on 3D fatigue crack propagation in surface-cracked specimens

In the present work the fatigue crack growth in AISI304 specimens is investigated experimentally. In 3D finite element analysis the virtual crack closure technique is applied to calculate distributions and variations of the stress intensity factor along the surface crack front. It is confirmed that the stress intensity factor along the surface crack front varies non-uniformly with crack growth. Crack growth rate is proportional to the stress intensity factor distribution in the 3D cracked specimen. The fatigue crack growth in surface cracked specimens can be described by the Forman model identified in conventional compact tension specimens. For crack growth in the free specimen surface the arc length seems more suitable to quantify crack progress. Geometry and loading configuration of the surface cracked specimen seem to not affect the fatigue crack growth substantially.     

动、静裂纹作用偏置效应的动焦散冲击实验

为了研究冲击荷载作用下脆性材料中运动裂纹与静止裂纹的相互作用,选取动态载荷下断裂行为与岩石材料类似且本身光学特性较好的有机玻璃（PMMA）作为实验材料,试件尺寸为220 mm×50 mm×5 mm,采用激光切割制作长度5 mm的预制裂纹和长度10 mm的静止裂纹,预制裂纹位于试件的底部边缘中心,静止裂纹的中心位于试件水平轴线。将静止裂纹偏置距离作为单一变量,采用数字激光动态焦散实验系统对含不同缺陷的PMMA进行三点弯曲实验,并结合几何分形理论研究不同偏置距离下运动裂纹的分形规律。实验结果表明:存在预制裂纹与静止裂纹的临界偏置距离（6 mm）,该条件下裂纹轨迹对应的分形维数值最大,裂纹轨迹的规则程度最低,裂纹破坏形态最复杂。当预制裂纹与静止裂纹的偏置距离在0～6 mm时,裂纹Ⅰ起裂后垂直向上扩展一段距离,与静止裂纹交汇,并停滞一段时间后发生二次起裂,直至贯穿试件,偏置距离和交汇点竖向坐标值呈近似线性函数关系。偏置距离的存在不会影响裂纹Ⅰ的起裂时间和应力强度因子,但会显著减小裂纹Ⅱ的动态应力强度因子,且停滞时长随偏置距离的增大而逐渐缩短。当偏置距离大于临界偏置距离时,运动裂纹不再与静止裂纹交汇而是呈拱状向试件上边缘扩展直至贯穿,裂纹的起偏时间、起偏位置也会出现明显的滞后现象。     

CTOA and crack-tunneling measurements in thin sheet 2024-T3 aluminum alloy

The stable tearing behavior of 2.3-mm thick sheets of 2024-T3 aluminum alloy was experimentally investigated for middle crack tension specimens having initial flaws that were: (a) flat fatigue cracks (low fatigue stress) and (b) 45-deg through-thickness slant cracks (high fatigue stress). The critical CTOA values during stable tearing were measured by two independent methods, optical microscopy and digital-image correlation. Results from the two methods agree well.The CTOA measurements and observations of the fracture surfaces have shown that the initial stable tearing behavior of low and high fatigue stress tests is significantly different. The cracks in the low fatigue stress tests underwent a transition from flat-to-slant crack growth, during which the CTOA values were high and significant crack tunneling occurred. After crack growth equal to about the thickness (a>B), CTOA reached a constant value of 6 deg and after crack growth equal to about twice the thickness (a>2B), crack tunneling stabilized. The cracks in the high fatigue stress tests reach the same constant CTOA value after crack growth equal to about the thickness, but produced only slightly higher CTOA values during initial crack growth. The amount of tunneling in the high fatigue stress tests was about the same as that in the low fatigue stress tests after the flat-to-slant transition.This study indicates that stress history has an influence on the initial portion of the stable tearing behavior. The initial high CTOA values, in the low fatigue crack tests, coincided with large three-dimensional crack front shape changes due to a variation in the through-thickness crack-tip constraint. The measured CTOA reached a constant value of 6 deg for crack growth of about the specimen thickness. This coincided with the onset of 45-deg slant crack growth and a stabilized, slightly tunneled (about 20 percent of the thickness) crack-front shape. For crack growth on the 45-deg slant, the crack front and local field variables are still highly three dimensional.     

Intergranular strain evolution near fatigue crack tips in polycrystalline metals

The deformation field near a steady fatigue crack includes a plastic zone in front of the crack tip and a plastic wake behind it, and the magnitude, distribution, and history of the residual strain along the crack path depend on the stress multiaxiality, material properties, and history of stress intensity factor and crack growth rate. An in situ, full-field, non-destructive measurement of lattice strain (which relies on the intergranular interactions of the inhomogeneous deformation fields in neighboring grains) by neutron diffraction techniques has been performed for the fatigue test of a Ni-based superalloy compact tension specimen. These microscopic grain level measurements provided unprecedented information on the fatigue growth mechanisms. A two-scale model is developed to predict the lattice strain evolution near fatigue crack tips in polycrystalline materials. An irreversible, hysteretic cohesive interface model is adopted to simulate a steady fatigue crack, which allows us to generate the stress/strain distribution and history near the fatigue crack tip. The continuum deformation history is used as inputs for the micromechanical analysis of lattice strain evolution using the slip-based crystal plasticity model, thus making a mechanistic connection between macro- and micro-strains. Predictions from perfect grain-boundary simulations exhibit the same lattice strain distributions as in neutron diffraction measurements, except for discrepancies near the crack tip within about one-tenth of the plastic zone size. By considering the intergranular damage, which leads to vanishing intergranular strains as damage proceeds, we find a significantly improved agreement between predicted and measured lattice strains inside the fatigue process zone. Consequently, the intergranular damage near fatigue crack tip is concluded to be responsible for fatigue crack growth.     

Effect of specimen size and crack depth on 3D crack-front constraint for SENB specimens

Three-dimensional (3D) elastic–plastic finite element analyses (FEA) are performed to study constraint effect on the crack-front stress fields for single-edge notched bend (SENB) specimens. Both rectangular and square cross-section of the specimens with a deep crack of a/W=0.5 are considered to investigate the effect of specimen size. A square-cross-section specimen with a shallow crack of a/W=0.15 is also considered to examine the effect of crack depth. Stresses from FEA at the crack front on different planes of the specimen are compared with those determined by the J–A₂ three-term solution. Results show that in-plane stress fields can be characterized by the three-term solution throughout the thickness even in the region near the free surface. Cleavage fracture toughness data is compared to predict the effects of specimen size and crack depth on fracture behavior. It is found that the distributions of crack opening stress are nearly the same for the SENB specimens at the critical J which is consistent with the RKR model. Furthermore our results indicate that there is a distinct relationship between the crack-front constraint and the cleavage fracture toughness. By introducing the failure curves, the minimum fracture toughness and scatter band can be well captured using the J–A₂ approach.     

A two-parameter model to predict fatigue life of high-strength steels in a very high cycle fatigue regime

In this paper, ultrasonic(20 kHz) fatigue tests were performed on specimens of a high-strength steel in very high cycle fatigue(VHCF) regime. Experimental results showed that for most tested specimens failed in a VHCF regime, a fatigue crack originated from the interior of specimen with a fish-eye pattern, which contained a fine granular area(FGA) centered by an inclusion as the crack origin. Then,a two-parameter model is proposed to predict the fatigue life of high-strength steels with fish-eye mode failure in a VHCF regime, which takes into account the inclusion size and the FGA size. The model was verified by the data of present experiments and those in the literature. Furthermore, an analytic formula was obtained for estimating the equivalent crack growth rate within the FGA. The results also indicated that the stress intensity factor range at the front of the FGA varies within a small range, which is irrespective of stress amplitude and fatigue life.     

A delamination gage for carbon fiber composites

A graphite crack gage familiar to fracture testing of nonconductive polymeric materials has been adapted to measure delamination growth in carbon fiber composites. The gage consists of a continuous graphite film whose conductance changes linearly with respect to crack length. The development of an insulation technique so that the electrical film may be applied to carbon fiber composites is described. Further constraints on the gage design occur due to the narrow profiles of conventional delamination specimens. These limitations are reviewed in detail along with appropriate methods for manufacturing and calibration of the gage for delamination experiments. A simple shunt voltage measurement circuit is described along with a derivation of the relationship of crack length to voltage. Two example applications are provided: stable delamination growth in a conventional double cantilever beam (DCB) specimen and dynamic delamination growth in a single-edge-notched (SEN) strip. The electrical delamination length measurements from the DCB tests were found to compare well with the location of the delamination front determined by microscopy and radiography. These results give confidence in dynamic delamination results where growth rates exceeding 1000 m/s were measured. Sample evaluations of delamination toughness are made using the experimental data; compliance methods are used in the case of the DCB analysis, and dynamic finite element methods are used in the case of the SEN strip analysis.     

有限厚度板穿透裂纹前缘附近三维弹性应力场分析

通过三维有限元计算来研究有限宽度、有限厚度含有穿透裂纹板的裂纹前缘应力场，从中找出应力强度因子与板的厚度、裂纹长度之间的关系，同时还分析了裂尖的三维约束程度和三维约束区的大小。分析结果表明：应力强度因子沿厚度的分布是不均匀的，应力强度因子的最大值及其位置与厚度有关；有限厚度板中面应力强度因子(KI)m-p及最大应力强度因子(KI)max均大于平面应力或平面应变的应力强度因子。对有限厚度裂纹问题，按平面应力或平面应变来考虑是不安全的；板中面的应力强度因子(KI)m-p及最大应力强度因子(KI)max是厚度B／a的函数；板的中面离面约束系数Tx最大，自由面(z=B)Tx=0。沿厚度方向裂尖附近的离面约束系数Tx也是z／B和B／a的函数，随着厚度的增加离面约束系数Tx增大，离中面越近离面约束系数Tx越大。Tx随着x的增大急剧减小，三维约束影响区域大小大约为板厚的一半，且裂纹长度a／W对应力强度因子沿厚度变化规律及Tx影响区域大小影响较小。     

基于数字散斑相关方法测定Ⅰ型裂纹应力强度因子

提出了一种通过数字散斑相关方法测定金属材料Ⅰ型裂纹尖端位置和应力强度因子的实验方法.实验采用疲劳试验机对含Ⅰ型缺口的Cr12MoV钢试件预制裂纹,通过数字散斑相关方法测试试件在三点弯曲加载条件下裂纹的扩展过程及裂尖区域的位移场.将位移场数据代入裂尖位移场方程组,采用牛顿-拉普森方法求解含未知参量的裂尖非线性位移场方程组,计算裂尖位置和应力强度因子.实验结果表明,采用该方法可以准确地测定金属材料Ⅰ型裂纹应力强度因子、裂尖位置及裂纹扩展长度,解决了以往研究中因不能准确测定裂纹尖端位置,而无法准确计算Ⅰ型裂纹裂尖断裂参数的难题,揭示了金属材料裂纹扩展过程中应力强度因子演化特征.     

PZT-4紧凑拉伸试样的断裂分析

基于线性压电材料的复势理论,通过解析分析,导出了一种分析有限压电板裂纹问题的解析数值方法. 首先,计算了含中心裂纹有限板的断裂参数,与Woo和Wang的解析数值法(Int J Fract, 1993, 62: 203$\sim$218)相比较,表明该方法具有很高的精度和很好的计算效率. 随后,采用该方法和有限元法计算了PZT-4紧凑拉伸试样在绝缘裂纹面边界条件下断裂时的断裂参数,发现各断裂参数的临界值分散性很大,不能作为压电材料的单参数断裂准则. 进而,针对试样真实的裂隙形状,采用有限元法计算了裂隙尖端的应力、电位移场,比较了裂隙内介质的介电性能对裂隙尖端场的影响,计算了带微裂纹的真实裂隙模型的断裂参数并进行了理论分析.      

Three-dimensional effects in interfacial crack propagation

The paper describes the use of crack-opening interferometry for examining the variation in normal crack-opening displacements (NCOD) along the front of an interfacial crack in an edge-cracked bimaterial strip under biaxial loading. For the glass/epoxy combination considered here, the crack front was concave in the direction of crack growth, in contrast to previous observations with a glass/polyurethane/glass sandwich specimen and cracks in homogeneous materials. The NCOD were greatest in the interior of the specimen for all mode-mixes considered and the exponents in a power-law fit of NCOD versus distance from the crack front decreased towards the free surface. The exponents varied with mode-mix, suggesting that interfacial crack-front geometries could be similarly affected.     

Novel Method for Analyzing Crack Growth in Polymeric Microtensile Specimens by <Emphasis Type="Italic">In Situ</Emphasis> Atomic Force Microscopy

In this paper a micro tensile test which allows the determination and observation of the crack growth behaviour in thin polymer layers is presented. The setup consists of micromanipulators and piezo actuators for straining the sample while an atomic force microscope (AFM) is used for scanning the crack tip area with high lateral resolution. The stress in the specimen is determined by an optical microscope for observation of the deflection of a force sensing beam. The material under investigation is an amorphous and strongly entangled thermoplastic polyimide which can be patterned photolithographically and is spin cast to form layers of 3 μm thickness. The results show the potential of the setup to measure crack length, crack tip opening and nominal stress. The stress-crack length-diagram then allows to determine different stages during crack growth.     

类岩石材料中表面裂纹扩展模式的实验研究

采用粘贴式轴拉方法实现了类岩石材料的直接拉伸实验,通过在类岩石材料试件中预制表面裂纹研究了类岩石材料中表面裂纹的扩展模式.研究发现,粘贴式轴拉方法可以满足一般类岩石材料的直接拉伸实验;类岩石材料中表面裂纹首先从试件正面开始扩展;表面裂纹的存在极大地影响着材料的破坏模式,类岩石材料在试件的正面上会表现出明显的二维穿透性裂纹的扩展形态,但是受其影响裂纹在厚度方向扩展会发生偏转,从而使得试件背面的最终贯通方向没有与加载方向垂直,而是呈一倾角,并且和表面裂纹的倾角和深度有关.     

基于厚度法确定小冲杆试验能量转变温度

以A106管材钢为研究对象,进行了小冲杆断裂试验,获得断后试样的最小厚度;在对试样断裂后的变形分析中,建立了试样厚度减薄率与温度的关系,规避了低温试验中载荷和位移测量不准确导致小冲杆能量转变温度不确定的问题。结果表明:基于厚度法可以准确确定小冲杆断裂试验的能量转变温度;小冲杆断裂试验后,试样最薄厚度的减小率与温度曲线关系呈现S型,有上平台、转变区、下平台三个典型区域;根据厚度减薄率与温度曲线关系可以得到小冲杆的能量转变温度。采用厚度法得到的小冲杆断裂试验的转变温度与能量法获得的结果基本一致。     

平面应变下紧凑拉伸试样的动态断裂韧性的实验研究

材料的动态断裂韧性是衡量材料在动载荷作用下抵杭裂纹扩展能力的重要指标,以往的材料动态断裂韧性测试多采用三点弯曲试样,而针对紧凑拉伸试样的动态断裂韧性研究很少.本文将紧凑拉伸试样(即CT试样)简化成等效弹簧质量模型,得到了CT试样动态应力强度因子的近似表达式.对Hopkinson压杆装置进行了改进,利用改进后的实验装置进...     

Crack growth of through and part-through thickness cracks under cyclic loading

Stress intensity factor expressions corrected for crack front curvature are used to derive the corrosion fatigue growth data for through and part-through thickness cracks subjected to cyclic loading. Results are obtained by application of the boundary element method for solving three-dimensional crack problems. Different radius of curvature is assumed using the open literature cyclic crack growth parameters for air and sea water. As is to be expected, crack growth increased with decreasing crack front curvature and in sea water environment when compared with that in air.     

狭长缺口根部萌生的小裂纹扩展分析

根据伴随着小裂纹延展过程中不同力学参数相互作用的分析研究基础之上,我们就疲劳小裂纹的扩展特性进行了分析,根据不扩展裂纹性质对小裂纹的长度范围进行了讨论,探讨了狭长缺口根部萌生的小裂纹扩展速率, 并研究了不扩展裂纹形成机理,推演出不扩展裂纹长度计算方法,发展出一种预测小裂纹扩展行为的方法,借助这种方法可以实现裂纹萌生寿命的预测,与疲劳设计相结合可以进一步提高构件安全性与可靠性．不扩展小裂纹的长度可以通过计算定量得到,它与材料的疲劳极限、裂纹门槛值及缺口尺寸等参数紧密相关．以理论数据为依据,可以设计出针对一定材料及尺寸的试样,使其在一定荷载条件下不扩展裂纹长度达到宏观可观测的范围,进而降低小裂纹测量方面的技术难度,进一步验证不扩张裂纹形成机理．