Real-time Measurement of Ultrasonic Waves at Bolted Joints under Fatigue Testing

The real-time measurement of the surface acoustic wave (SAW) was carried out during the fatigue testing of the bolted joints of aluminum alloy plates with a frequency of 0.001 Hz. SAW distributions in the bolted region were compared with those obtained by the synchronized measurement, in which the ultrasonic wave was generated in synchronization with a loading cycle in the fatigue testing with a frequency of 10 Hz. At different numbers of fatigue cycles, the intensity of the reflection from the fatigue crack obtained by the real-time measurement was in good agreement with that obtained by the synchronized measurement. In the real-time measurement, the reflection intensity and profile changed with the stress level in a loading cycle, which were in good agreement with those obtained by the synchronized SAW measurement. From these results, it was confirmed that the SAW distributions obtained by the synchronized measurement is coincident with ones obtained by the real-time measurement in one loading cycle, and is not influenced by the measurement conditions.     

Surface acoustic wave measurements of small fatigue cracks initiated from a surface cavity

A model for the low frequency scattering of a surface acoustic wave by a surface cylindrical cavity with two corner cracks is presented. It is applied to determine the depth of the small fatigue cracks initiated from a pit-type surface flaw. The general scattering formalism based on the elastodynamic reciprocity principle is employed. The effect of the cylindrical cavity on the surface wave reflection from cracks is considered using an approximate stress intensity factor for the corner cracks. In situ surface acoustic wave measurements have been performed during fatigue tests for an Al 2024-T3 sample. The surface wave signal was acquired continuously at different cyclic load levels. The model is verified by comparing calculated reflection signals and spectra with those from experiments. The depths of fully and partially open cracks are determined from the predicted and the measured surface wave reflections. The surface wave reflection is observed to be sensitive to crack closure.     

基于电磁声激励Lamb波的裂纹深度检测

本文采用电磁声传感器接收单一S₀模态激励,测量Lamb波在板中不同深度的槽形裂纹处的反射与透射,用于对已知扩展长度的表面裂纹进行深度测量。然后分析了Lamb波模态的频散与波动特性,由超声Lamb波的波结构,近似计算了S₀模态入射到裂纹时的反射系数。计算结果与实验结果一致。结果表明,Lamb波在有限长裂纹处的反射系数可采用二维模型中的反射系数求解公式近似求解。采用电磁超声传感器接收单一S₀模态激励,重复测量稳定性高,适用于Lamb波反射系数的测量。Lamb波的反射系数与裂纹深度有很好的对应关系,可用于板表面已知长度裂纹的深度测量。     

基于裂纹闭合效应的高载迟滞预测模型修正

裂纹闭合效应通常是导致I 型裂纹扩展在高载作用下发生迟滞效应的主要因素之一．本文采用汽车薄板QSTE340TM 材料，针对不同应力比，高载比条件下疲劳裂纹扩展行为进行了实验研究．论文通过断面分析，针对各参数对裂纹闭合效应的具体影响进行了分析讨论，认为裂纹作用区域随裂纹扩展而动态变化，从而提出了一种对有效应力强度因子幅的修正方法．通过在原有模型中引入幂函数形式的动态变量α，表征裂纹闭合效应的作用比例随裂纹长度的动态变化，取得了较好的效果．     

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.     

A reexamination of plasticity-induced crack closure in fatigue crack propagation

The crack closure concept is often used to consider the R-ratio and overload effects on fatigue crack growth. The presumption is that when the crack is closed, the external load produces negligible fatigue damage in the cracked component. The current investigation provides a reassessment of the frequently used concept with an emphasis on the plasticity-induced crack closure. A center cracked specimen made of 1070 steel was investigated. The specimen was subjected to plane-stress mode I loading. An elastic–plastic stress analysis was conducted for the cracked specimens using the finite element method. By applying the commonly used one-node-per-cycle debonding scheme for the crack closure simulations, it was shown that the predicted crack opening load did not stabilize when the extended crack was less than four times of the plastic zone size. The predicted opening load was strongly influenced by the plasticity model used. When the elastic–perfectly plastic (EPP) stress–strain relationship was used together with the kinematic hardening plasticity theory, the predicted crack opening load was found to be critically dependent on the element size of the finite element mesh model. For R = 0, the predicted crack opening load was greatly reduced when the finite element size became very fine. The kinematic hardening rule with the bilinear (BL) stress–strain relationship predicted crack closure with less dependence on the element size. When a recently developed cyclic plasticity model was used, the element size effect on the predicted crack opening level was insignificant. While crack closure may occur, it was demonstrated that cyclic plasticity persisted in the material near the crack tip. The cyclic plasticity was reduced but not negligible when the crack was closed. The traditional approaches may have overestimated the effect of crack closure in fatigue crack growth predictions.     

Experimental studies on the effect of overload on fatigue crack growth

The fatigue crack growth behavior resulting from a single overload is investigated. In order to clarify the mechanism of overload on fatigue crack growth, the processes of crack closure and opening and their stress levels are monitored by strain gages placed on the back surface of specimens, and the fracture surface morphologies are examined by the microfractography. Experimental results may be used to explain quantitatively the mechanisms of retardation and delayed retardation after a single overload.     

白云岩受压声学特性及其在裂缝研究中的应用

通过实验手段研究了白云岩在三轴和单轴加载过程中的声波波速、幅度、频谱特性的变化特征. 结果发现:(1)白云岩在受压变形过程中,声波波速的变化较好地反映了岩石内部裂缝的闭合、产生、扩展和贯穿等变化. 总体而言,横波波速比纵波能更好地预测裂缝的产生,而纵波对裂缝的非稳定发展或贯穿有较敏感的反映. (2)随着轴压的增大,纵、横波波形的末端都有散射波的出现,且横波波形末端的"鱼尾"状散射波信号更为明显(此时应力点为极限强度的60%左右),预示着岩石内部裂缝的产生和稳定扩展. (3)频谱曲线也很好地反映了岩石内部结构变形情况. 随着岩石受力的增大,频谱曲线上的振幅都呈现增大趋势,标志着岩石的压实阶段;当频谱曲线上低频段较高频段活跃时,标志着裂缝的产生;更有甚者,低频还会取代高频成为主频. (4)在岩石受压裂缝闭合阶段,首波振幅和频谱主振幅都呈现上升趋势;而在裂缝不稳定扩展阶段,主振幅表现出比首波振幅低的上升趋势;振幅曲线达到峰值后都存在一突降拐点,预示着岩石的贯通破坏. 研究对于地层岩石的动态长期监测和工程岩体的稳定性评价都具有重要的理论参考价值.      

裂纹闭合和循环塑性预应变及循环载荷压缩部分对裂纹扩展速率的影响

本文针对三种国产材料 Ｌｙ１１ｃｚ、 Ｌｙ１２ｃｚ 铝合金和 １８ Ｍｎ Ｈ Ｐ钢,通过实验初步考察了循环塑性预应变和循环载荷压缩部分对疲劳裂纹扩展的影响;采用电测法,测定了两种铝合金材料疲劳裂纹扩展的张开应力和有效应力强度因子幅值比 Ｕ。结果表明：（１）材料循环塑性预应变和循环载荷压缩部分,都使疲劳裂纹扩展速率提高;（２）常幅载荷下,在疲劳裂纹稳定扩展阶段,有效应力强度因子幅值比 Ｕ 与应力比 Ｒ 有关,与裂纹长度ａ 无关,并依赖于材料的力学性能。     

A new photoelastic model for studying fatigue crack closure

The photoelastic analysis of crack tip stress intensity factors has been historically developed for use on sharp notches in brittle materials that idealize the cracked structure. This approach, while useful, is not applicable to cases where residual effects of fatigue crack development (e.g., plasticity, surface roughness) affect the applied stress intensity range. A photoelastic model of these fatigue processes has been developed using polycarbonate, which is sufficiently ductile to allow the growth of a fatigue crack. The resultant stress field has been modeled mathematically using the stress potential function approach of Muskhelishvili to predict the stresses near a loaded but closed crack in an elastic body. The model was fitted to full-field photoelastic data using a combination of a generic algorithm and the downhill simplex method. The technique offers a significant advance in the ability to characterize the behavior of fatigue cracks with plasticity-induced closure, and hence to gain new insights into the associated mechanisms.     

DETERMINATION OF CRACK SURFACE DISPLACEMENTS FOR A RADIAL CRACK EMANATING FROM A SEMI-CIRCULAR NOTCH USING WEIGHT FUNCTION METHOD

A radial crack emanating from a semi-circular notch is of significant engineering importance. Accurate determination of key fracture mechanics parameters is essential for damage tolerance design and fatigue crack growth life predictions. The purpose of this paper is to provide an efficient and accurate closed-form weight function approach to the calculation of crack surface displacements for a radial crack emanating from a semi-circular notch in a semi-infinite plate.Results are presented for two load conditions: remote applied stress and uniform stress segment applied to crack surfaces. Based on a correction of stress intensity factor ratio, highly accurate analytical equations of crack surface displacements under the two load conditions are developed by fitting the data obtained with the weight function method. It is demonstrated that the WuCarlsson closed-form weight functions are very efficient, accurate and easy-to-use for calculating crack surface displacements for arbitrary load conditions. The method will facilitate fatigue crack closure and other fracture mechanics analyses where accurate crack surface displacements are required.     

降载勾线法在高强钢疲劳断裂试验中的应用

制作高强钢特征试件,在压、弯应力共同作用下进行疲劳断裂试验;结合疲劳辉纹产生机理,采用降载勾线法在试件断面制造出“海滩状花纹”;利用CAD软件描绘断面形貌并测量裂纹长度,用Newman-Raju理论进一步研究表面裂纹扩展的规律,并与试验值比较.结果表明降载勾线法可以解决高强度钢表面裂纹不易测量及断面难以观测到疲劳辉纹的问题;采用Newman-Raju公式模拟压弯组合应力下表面裂纹扩展形貌是合适的,但由此计算的疲劳寿命偏于保守.另外,当压弯应力比值较小时,计算扩展形貌时压应力可以忽略,而计算疲劳寿命时压应力不可忽略.     

Fatigue crack growth through residual stress fields—theoretical and experimental studies on thick-walled cylinders

Experiments are described which determined the effects of various residual stress distributions on the growth rate of fatigue cracks. For each stress distribution, the contribution (K_RS) to the net stress intensity at the crack tip is determined, and a comparison is then made with the behaviour predicted using a fracture mechanics approach based on a weight function analysis and a simple crack closure model. The example studied is a thickwalled pressure vessel containing a longitudinal crack which grows radially from the inner surface; fatigue cracks were grown under laboratory conditions in ring test specimens. sectioned from vessels which had been cold-expanded by different amounts to increase their pressure limits, and so contained various complex residual stress distributions. The experiments provide direct evidence that the effects of residual stress (and by extension, thermal stress) on the crack tip stress intensity may be modelled conveniently using weight function techniques, and can be incorporated satisfactorily in fatigue crack growth analyses.     

随机超载对疲劳裂纹扩展迟滞效应的模拟

考虑超载的迟滞效应,对随机超载作用下的疲劳裂纹扩展进行了模拟计算．载荷谱为在基本恒幅循环载荷基础上加入一以泊松流发生的随机超载序列,超载的大小为均匀分布．采用裂纹闭合模型考虑超载的迟滞效应,认为裂纹张开应力在超载引起的塑性区内按线性规律衰减．循环续循环模拟计算出裂纹从初始长度一直到疲劳破坏的扩展曲线．据此,计算了各种超载发生强度和大小下的疲劳裂纹扩展寿命的平均值与标准差。     

Mixed-mode stress intensity factors and critical angles of cracks in bolted joints by weight function method

Summary   Mechanical joints, such as bolted or riveted joints, are widely used in structural components. Reliable determination of stress intensity factors for cracks in bolted joints is required to evaluate their safety and fatigue life. The weight function method is an efficient technique to calculate stress intensity factors for various loading conditions by the stress analysis of an uncracked model. In this paper, the mixed-mode stress intensity factors for cracks in bolted joints are analyzed by the weight function method, and coefficients included in the weight function are determined by finite element analysis for reference loadings. The critical angle at which mode I stress intensity factor becomes maximum is determined, and the effects of the amount of clearance and crack length on the critical angle are investigated. Received 28 February 2001; accepted for publication 22 June 2001 RID=" ID=" The authors are grateful for the support provided by a grant from the Korea Science & Engineering Foundation (KOSEF) and Safety and Structural Integrity Research Center at the Sungkyunkwan University.     

Cracks’ closure in 3-D fracture dynamics: the effect of relative location of two coplanar cracks

In this paper, the problem of two equal coplanar cracks with allowance for the crack faces contact interaction was investigated. The problem of the cracks located in homogeneous, isotropic, and linearly elastic solid subjected to normally incident tension–compression wave is solved by the boundary integral equations method. The influence of the distance between two cracks on the stress intensity factors (opening mode and transverse shear mode) is studied for a range of wave numbers. The results are compared with those obtained neglecting cracks’ closure.     

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.     

On the circumferential strain factor criterion of mixed mode brittle fracture

In this paper, the criteria of mixed mode brittle fracture are carefully examined. It has been shown that, the circumferential strain factor criterion is rational and safe.With the exception of opening mode, mixed mode plane strain fracture of comparatively ductile materials(metals), in general, does not follow the theory of linear elastic fracture mechanics.Like the stress intensity factor that which is concerned is playing an important role in pure opening mode crack problems. We believe that, in mixed mode crack problems, the circumferential strain factor will become a parameter to determine the rate of fatigue crack propagation per cycle, and of stress corrosion cracking per unit time.First published in Nanking Aeronautical Institute Report of Science and Technology, No. 680, Jan., 1980 (in Chinese).     

A model for predicting the retardation effect following a single overload

Many engineering components are subjected to variable amplitude loading history. It is well known that retardation in fatigue crack growth occurs due to application of single overloads in a constant amplitude loading block. Many models have been proposed to capture this counter intuitive phenomenon which has resulted in improved understanding of retardation effect following tensile overloads and consequently resulting in better life prediction models. The proposed study is focused on to evaluation of retardation in fatigue life due to application of a single overload. A model for prediction of crack growth and crack growth rate following single overloads is presented. Several modifications to Wheeler’s growth idea are proposed, which incorporate a consideration for effective stress intensity factor, based on Elber’s concept of crack closure, relationship between overload ratio and the Wheeler’s exponent, and fatigue growth rate calculations. The results presented here show that plastic zone interaction following overload and the consideration of crack closure explain retardation effect following a single overload. Correlation between analysis and experimental data obtained from several sources in literature show that the scheme, is robust and provides an insight into the nonlinear aspect of crack growth results. The model has been tested for 2024-T3 aluminum alloy and 6061-T6 aluminum alloy and thorough calibrations performed, established the fidelity of the program.     

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。