Effects of size on the strength and deformation mechanism in Zr-based metallic glasses

We report results of uniaxial compression tests on Zr₃₅Ti₃₀Co₆Be₂₉ metallic glass nano-pillars with diameters ranging from ∼1.6 μm to ∼100 nm. The tested pillars have nearly vertical sidewalls, with the tapering angle lower than ∼1° (diameter >200 nm) or ∼2° (diameter ∼100 nm), and with a flat pillar top to minimize the artifacts due to imperfect geometry. We report that highly-localized-to-homogeneous deformation mode change occurs at 100 nm diameter, without any change in the yield strength. We also find that yield strength depends on size only down to 800 nm, below which it remains at its maximum value of 2.6 GPa. Quantitative Weibull analysis suggests that the increase in strength cannot be solely attributed to the lower probability of having weak flaws in small samples - most likely there is an additional influence of the sample size on the plastic deformation mechanism.     

Behavior of surface flaws in reactor pressure vessels under thermal-shock loading conditions

A pressurized-water, nuclear-reactor pressure vessel can be subjected to a severe thermal shock in the event of a loss-of-coolant accident (LOCA). If at the time of the LOCA there is a crack-like defect on the inner surface of the vessel, the crack may propagate as a result of the thermal shock. This paper discusses the conditions necessary for crack propagation during a LOCA, the detailed behavior of the cracks under these specific conditions, and an experimental program designed to determine the validity of the method of analysis (linear-elastic fracture mechanics) used to predict the behavior of flaws under severe thermal-shock loading conditions. A detailed fracture-mechanics analysis of the LOCA thermal shock was performed to help establish the scope of the experimental program. The results of this analysis indicate that present-generation and future PWR vessels will not experience excessive crack propagation. This is also true of earlier PWR vessels, which contain rather high concentrations of copper and, thus, are more susceptible to radiation damage, provided a phenomenon referred to as warm prestressing is effective. Eventually, the experimental program will include investigations of all the major fracture-mechanics phenomena predicted to occur under adverse LOCA-ECC conditions. Two of the experiments conducted thus far were designed for the study of long axial flaws that would penetrate no more than 20 percent of the wall of thick-wall steel test cylinders (533-mm OD×146-mm wall×914-mm length). During one of these experiments, no fast fracture took place, as predicted using LEFM. In the other experiment crack initiation and arrest were expected and took place, with a total penetration of ～16 percent. The agreement between experimental results and the LEFM analysis was very good, indicating that the LEFM analysis is valid at least for shallow flaws in thick-wall steel cylinders subjected to severe thermal shock.     

Use of photoelasticity to determine orthotropicK I stress-intensity factor

A new experimental method of obtaining orthotropic stress-intensity factor,K _I , is presented. The orthotropic photoelasticity and orthotropic linear-elastic fracture-mechanics laws are combined. The combined set of equations is used along with half-fringe photoelasticity to determineK _I in a compact-tension specimen made of a transparent unidirectional fiberglass-epoxy material. The results are compared with finite-element-method solutions.     

Gigacycle fatigue behaviors of two SNCM439 steels with different tensile strengths

Gigacycle fatigue behaviors of two SNCM439 steels with different tensile strengthes were experimentally studied by rotating bending tests,to investigate the effects of the tensile strength obtained by different heat treatment processes on very high cycle fatigue failure mechanisms.The material with higher tensile strength of 1 710 MPa exhibited typical gigacycle fatigue failure characteristics,whereas one with lower tensile strength of 1 010 MPa showed only traditional fatigue limit during the tests and no gigacycle failure could be found even when the specimen ran up to more than 10 8 cycles.Metallographic and fractographic analysis were carried out by an optical microscope (OM) and scanning electron microscope (SEM).It showed two different crack initiation mechanisms that for the specimen with lower tensile strength the crack prefers surface initiation and for that with higher strength the crack initiates from subsurface inclusions revealed by a fish-eye like microstructure.     

Experimental investigation on the propagation of fatigue cracks emanating from sharp notches

The effect of notch geometry on the propagation of fatigue cracks emanating from sharp V-shaped notches is investigated by means of an experimental campaign performed on Al-7075-T651 specimens carrying notches with opening angles of 45°, 90°, and 135°. The samples were tested using a servohydraulic machine under different loading directions and at several loading levels. The crack deflection induced by the variation in loading direction was determined my measuring the kinking angle and by studying the crack propagation plane through fractographic analysis. A linear elastic fracture mechanics approach was adopted for the analysis of experimental results. Stress intensity factors were calculated using an appropriate weight function set up for studying inclined edge cracks emanating from sharp V-notches. The influence of K _II on the crack propagation was discussed on the basis of theoretical and semi empirical models.     

Estimation of strengths in large annealed glass panels

A new model of the Log-Normal form for predicting the cumulative probabilistic distribution of strength in annealed glass panels is presented in this paper. The proposed model, which is supported by experimental evidences, shares certain features that are common with predictions by the Weibull’s model. However, as the dimension of the panel is above a certain limit, the strength of glass as predicted by the new model is much less sensitive to any further increase in the panel dimension than strength predicted by the Weibull’s model. This has important implications to the engineering design and risk assessments of glass facades in the future. The proposed alternative model was derived from results obtained from Monte Carlo simulations of non-interacting Griffith flaws based on principles of fracture mechanics. As interactions between flaws have been neglected in the analyses presented in the paper, the proposed model is intended to be applicable to glazing panels which contain widely spaced flaws. Results from physical experimentation in support of the simulation model have been presented in the paper.     

Modeling dynamic brittle behavior of materials with circular flaws or pores

Compressive failure of brittle materials is driven primarily by crack growth from pre-existing flaws in the material. These flaws, such as grain boundaries, pores, preexisting cracks, inclusions and missing grains, are randomly spaced and have a range of possible shapes and sizes. The current work proposes a micromechanics-based model for compressive dynamic failure of brittle materials with circular pore flaws, which incorporates both the number density and the size distribution of flaws. Results show that the distribution of flaw sizes is very important, particularly at moderate strain rate, since analyses based solely on the mean flaw size overpredict strength. Therefore, in order to increase dynamic strength at low to moderate strain rates, it is most effective to control the presence of large flaws. At very high strain rates, however, crack growth is activated even in small flaws and therefore controlling the total number density rather than the size of the flaws is effective for increasing dynamic strength. Finally, the model shows that neglecting very small flaws in the pore population may not have significant effects on the results in many cases, suggesting that the model is a useful tool for identifying a minimum resolution required for experimental characterization of microstructure.     

Near threshold fatigue behaviour of flake graphite cast irons microstructures

This paper describes the influence of material toughness degradation, through reversed temper embrittlement (RTE) and mean stress on the near threshold fatigue crack growth characteristics of a CrMoV turbine bolting steel at ambient and elevated temperatures. It was established at ambient temperatures that strong effects of R-ratio and material condition (toughness) were observed on near threshold fatigue crack growth characteristics. At elevated temperatures it was shown that for the non-embrittled material that only under low R-ratio conditions did increased temperature increase the level of threshold stress intensity ΔK_th, by some 20%. In the case of embrittled material, increasing the temperature increased ΔK_th levels by around 30% and decreased near threshold growth rates by an order of magnitude at low to intermediate R-ratio levels.The effects of R-ratio on ΔK_th for all material and mechanical testing conditions could be simply expressed by the difference between ΔK_th at R = O and a constant B multiplied by R.Quantitative fractographic observations indicated that, generally, the incidence of intergranular failure prevalent in embrittled and non-embrittled steels exhibited a maximum at some specific ΔK level. Also in embrittled steels large effects of environmental assisted crack (EAC) growth were observed at near threshold fatigue crack growth rates. It was suggested that this was the result of the much reduced material cohesive strength which was caused by the presence of both impurity and hydrogen atoms.     

Photoelastic determination of stress-intensity factors

The increasing number of analytical and numerical solutions for the crack-tip stress-intensity factor has greatly widened the scope of application of linear elastic fracture-mechanics technology. Experimental verification of a particular solution by elastic stress analysis is often a necessary supplement to provide the criteria for proper application to actual design problems. In this paper, it is shown that the photoelastic technique can be used to obtain rather good estimates of the stress-intensity factor for various specimen geometries and loading conditions. Treated are the following cases: wedge-opening load specimen, several notched rotating-disk configurations, and a notched pressure vessel. A sharp crack is simulated by a relatively narrow notch terminating in a root radius of 0.010 in or less. Stress distributions along the section of symmetry ahead of the notch tip are obtained using three-dimensional frozen-stress photoelasticity. The results are used to determine the stress-intensity factor, cK _I , by three methods. Two of these are based on Irwin's expressions for the elastic stress field at the tip cf a crack, and the other is a result of Neuber's hyperbolic-notch analysis. Agreement, with available analytical solutions is good.     

Porosity dependence of strength in brittle solids

The effect of pore size and pore volume fraction on strength in brittle solids is evaluated. The analysis considers that the strength degradaton of a solid containing a large number of spherical pores is due to a strong effect of porosity on Young's modulus. Each pore is assumed to possess radial or annular flaws emanating from the pore surface whose lengths are considered to be independent of pore size. The effect of stress concentration induced by the presence of the pore is included in the equation for strength through the Young's modulus dependence of porosity originally developed using the concept of crack opening displacement. It is shown that the strength of a solid containing spherical pores is controlled by the pore size, pore volume fracton and the radial (or annular) crack size to pore size ratio. Predicted variation of strength with pore volume fraction is tested against experimental data for glass and polycrystalline alumina.     

Predicting variability in the dynamic failure strength of brittle materials considering pre-existing flaws

We perform two-dimensional dynamic fracture simulations of a specimen in biaxial tension, incorporating various distributions of pre-existing microcracks. The simulations consider the spatial distribution of flaws while modeling the discrete failure processes of crack interactions and coalescence, and predict the macroscopic variability in failure strength. The model quantitatively predicts the effect (on the dynamic failure strength) of different shapes of the flaw size distribution function, the random spatial distribution of flaws, and the random local resistance to crack growth (i.e. strength) associated with each flaw. The effect of changing material volumes on the variability in failure strengths is also examined in relation to the flaw size distribution. The effect of loading rate on the variability in failure strengths is presented in a form that will enable improved constitutive modeling using non-local formulations at the continuum scale.     

Zonal fracturing mechanism in deep crack-weakened rock masses

The mechanical behaviors of deep crack-weakened rock masses are different from those of shallow crack-weakened rock masses. The surrounding rock in shallow crack-weakened rock mass engineering is classified into loose zone, plastic zone and elastic zone, while the surrounding rock in deep crack-weakened rock mass engineering is classified into fractured zone and non-fractured zone, which occur alternatively. It is assumed that the deep rock masses contain one joint set, in which the probability density function describing the distribution of sizes is assumed to follow the Rayleigh distribution, and the probability density function describing the distribution of spacing is assumed to follow the Weibull distribution. On the basis of strength criterion of deep rock mass, the near-field stress redistribution around circular opening induced by excavation is determined. The strong interaction among cracks is investigated by using the dislocation model. The nucleation, growth, interaction and coalescence of cracks were analyzed based on the strain energy density factor theory. When cracks coalesce, failure of deep crack-weakened rock masses occurs, fractured zone is formed. Then, size and quantity of fractured zone and non-fractured zone are given out. The size and quantity of fractured zone increase with decreasing strength of rock mass. The size and quantity of fractured zone increase with increasing in situ stress. Zonal fracturing phenomenon occurs once value of in situ stress is larger than the unaxial compressive strength of rock masses. The size and quantity of fractured zone decrease with increasing λ when p₂ > p₁. The size and quantity of fractured zone increase with increasing λ when p₂ < p₁.     

Analyses of tensile deformation of nanocrystalline α-Fe2O3+fcc-Al composites using molecular dynamics simulations

The tensile deformation of nanocrystalline α-Fe₂O₃+fcc-Al composites at room temperature is analyzed using molecular dynamics (MD) simulations. The analyses focus on the effects of variations in grain size and phase volume fraction on strength. For comparison purposes, nanostructures of different phase volume fractions at each grain size are given the same grain morphologies and the same grain orientation distribution. Calculations show that the effects of the fraction of grain boundary (GB) atoms and the electrostatic forces between atoms on deformation are strongly correlated with the volume fractions of the Al and Fe₂O₃ phases. In the case of nanocrystalline Al where electrostatic forces are absent, dislocation emission initiates primarily from high-angle GBs. For the composites, dislocations emits from both low-angle and high-angle GBs due to the electrostatic effect of Al-Fe₂O₃ interfaces. The effect of the interfaces is stronger in structures with smaller average grain sizes primarily because of the higher fractions of atoms in interfaces at smaller grain sizes. At all grain sizes, the strength of the composite lies between those of the corresponding nanocrystalline Al and Fe₂O₃ structures. Inverse Hall-Petch (H-P) relations are observed for all structures analyzed due to the fact that GB sliding is the dominant deformation mechanism. The slopes of the inverse H-P relations are strongly influenced by the fraction of GB atoms, atoms associated with defects, and the volume fractions of the Al and Fe₂O₃ phases.     

Characterization of crack tip stresses in plane-strain fracture specimens having weld center crack

Fracture toughness of metals depends strongly on the state of stress near the crack tip. The existing standards (like R-6, SINTAP) are being modified to account for the influence of stress triaxiality in the flaw assessment procedures. These modifications are based on the ability of so-called ‘constraint parameters’ to describe near tip stresses. Crack tip stresses in homogeneous fracture specimens are successfully described in terms of two parameters like J–Q or J–T. For fracture specimens having a weld center crack, strength mismatch ratio between base and weld material and weld width are the additional variables, along with the magnitude of applied loading, type of loading, and geometry of specimen that affect the crack tip stresses. In this work, a novel three-parameter scheme was proposed to estimate the crack tip opening stress accounting for the above-mentioned variables. The first and second parameters represent the crack tip opening stress in a homogeneous fracture specimen under small-scale yielding and are well known. The third parameter accounts for the effect of constraint developed due to weld strength mismatch. It comprises of weld strength mismatch ratio (M, i.e. ratio of yield strength of weld material to that of base material), and a plastic interaction factor (I_p) that scales the size of the plastic zone with the width of the weld material. The plastic interaction factor represents the degree of influence of weld strength mismatch on crack tip constraint for a given mismatch ratio. The proposed scheme was validated with detailed FE analysis using the Modified Boundary Layer formulation.     

A strength reliability model by Markov process of unidirectional composites with fibers placed in hexagonal arrays

This paper proposes a strength reliability model based on a Markov process for unidirectional composites with fibers in a hexagonal array. The model assumes that a group of fiber breaking points, a so-called cluster, evolves with increased stress. The cluster evolution process branches because of various fiber-breakage paths. Load-sharing structure of intact fibers around clusters was estimated from geometric and mechanical local load-sharing rules. Composites fracture if a cluster achieves a critical size, so the model expresses a fracture criterion by setting an absorbing state. Next, the author constituted a state transition diagram concerning cluster evolutions of 1-fiber to 7-fiber breaks and analytically solved simultaneous differential equations obtained from the diagram. Results showed that, as critical cluster size increases, slope of the fracture probability distribution is given in a Weibull probability scale as follows: m_c=i×m_f (i, the number of broken fibers in a cluster; m_c and m_f, Weibull shape parameters for fracture probabilities of a critical cluster and fiber strength, respectively). This relation between m_c and m_f had been shown by Smith et al. [Proc. R. Soc. London, A 388 (1983) 353–391], but the present study demonstrated it analytically without any lower tail of the Weibull distribution used in that paper. In addition, the present model can be approximated by a one-state birth model.     

双均值逼近屈服准则解析含腐蚀缺陷管道爆破压力

通过对Tresca和TSS屈服边长和边心距的均值同时进行逼近,建立了一个线性屈服准则,称为双均值逼近屈服准则.该准则在π平面上是一个等边非等角的十二边形,位于Mises圆内部.利用该准则对受内压作用的管道进行塑性极限分析,导出了含腐蚀缺陷管道爆破压力的解析解.该解析解是管材屈强比(σY/σT)、原始管道厚径比(t0/D0)、抗拉强度σT以及缺陷深度比(d0/t0)的函数.对比表明,该解析解所预测爆破压力与已有模拟和实验数据吻合较好.影响参数的定量分析表明,爆破压力随着屈强比或原始管道厚径比的增大而增大,随着缺陷深度比的增加而减小.所建立的爆破压力解析解对于管道的选材、设计以及安全评估具有重要意义.     

Effect of grain size on slow fatigue crack propagation and plastic deformation near crack tip

Fatigue crack growth and its threshold are investigated at a stress ratio of 0.5 for the three-point bend specimen made of Austenitic stainless steel. The effect of grain size on the crack tip plastic deformation is investigated. The results show that the threshold value Δk_th increases linearly with the square root of grain size d and the growth rate is slower for materials with larger grain size. The plastic zone size and ratio for different grain sizes are different at the threshold. The maximum stress intensity factor is k_max and σ_ys is the yield strength. At the same time, the characteristics of the plastic deformation development is discontinuous and anti-symmetric as the growth rate is increased from 2·10^—8 to 10⁻⁷ mm/cycle.A dimensionless relation of the form for collating fatigue crack starting growth data is proposed in which Δk_th represents the stress intensity factor range at the threshold. Based on experimental results, this relation attains the value of 0.6 for a fatigue crack to start growth in the Austenitic stainless steel investigated in this work. Metallurgical examinations were also carried out to show a transgranular shear mode of cyclic cleavage and plastic shear.     

Determination of Bond Strengths in Non-woven Fabrics: a Combined Experimental and Computational Approach

Interfiber bonds are important structural components in non-woven fabrics. Bond fracture greatly affects the strength and damage progression in a fiber network structure. Here, we present a novel combined experimental and computational approach to extract bond strengths in non-wovens. In this method, a small specimen is imaged and the obtained 3D geometry of the network is directly modeled in a finite element framework. Bond properties are determined by matching finite element simulation predicted mechanical response to the experimental data. This method is demonstrated by applying it to six specimens of a commercial polypropylene non-woven. A four parameter bi-linear interface law is used with normal stiffness k, shear stiffness βk, separation at the start of damage d ₁, and separation at total loss of bond stiffness d ₂. The determined normal strength (kd ₁)and shear strength (βkd ₁) are (1.3 ± 0.3) × 10² MPa and (1.0 ± 0.2) × 10² MPa, respectively. To show that the obtained bond parameters can be applied to a new specimen, a cross validation is conducted whereby parameters are fit from five specimens and then evaluated on the sixth. Additional validation of the obtained bond strength parameters was conducted with larger size artificial network simulations and peel tests. The proposed method in this work carries the dual advantages of characterizing actual bonds in a non-woven and characterizing hundreds of bonds simultaneously. The method can be applied to a variety of non-woven fabrics that are bonded at fiber-fiber intersections.     

Electrorheologial properties of hematite/silicone oil suspensions under DC fields

Electrorheological (ER) fluids composed of α-Fe₂O₃ (hematite) particles suspended in silicone oil are studied in this work. The rheological response has been characterized as a function of field strength, shear rate and volume fraction. Rheological tests under DC electric fields elucidated the influence of the electric field strength, E, and volume fraction, ϕ, on the field-dependent yield stress, τ_y. It was found that this quantity scales with E and ϕ with a linear and parabolic dependence, respectively. The viscosities of electrified suspensions were found to increase by several orders of magnitude as compared to the unelectrified suspension at low shear rates, although at high-shear rates hydrodynamic effects become dominant and no effects of the electric field on the viscosity are observed. The work is completed with the analysis of microscopic observations of the structure acquired by the ER fluid upon application of a constant electric field. Electrohydrodynamic convection is found to be the origin of the ER response rather than the commonly admitted particle fibrillation. This fact can provide an explanation to the relationship between yield stress and electric field strength as well as the pattern of periodic structures observed in the measurement geometries.