Pseudo plane stress mode II crack growth in plastic materials

The near tip field of mode II crack that grows in thin bodies with power hardening or perfectly plastic behavior is analyzed. It is shown that for power hardening behavior, the pseudo plane stress field possesses the logarithm singularity, i.e. σ (ln r)²/(n−1), (ln r)^{2n/(n − 1)}, where r is the distance from the crack tip, n the hardening exponent is σⁿ. When n → ∞ the solution reduced to that for the perfectly plastic case.     

Fatigue and fretting fatigue of ion-nitrided 34CrNiMo6 steel

This work is concerned with the surface treatment (ion nitriding) of fretting fatigue and fatigue resistance of 34CrNiMo6. Tests are made on a servo-hydraulic machine under tension for both treated and non-treated specimens. The test parameters involve the applied displacements δ±80–±170 μm; fretting pressure σ_n=1000–1400 MPa; fatigue stress amplitude σ_a=380–680 MPa and stress ratio R=−1. The ion nitriding process improves both fatigue and fretting fatigue lives. Subsurface crack initiation from internal discontinuities was found for ion-nitrided specimens.     

Near tip field for pseudo Mode II crack growth: Power law hardening material

The asymptotic behavior of stress and strain near the tip of a Mode II crack growing in power law hardening material is analyzed by assuming that the crack grows straight ahead even though tests show otherwise. The results show that the stress and strain possess the singularities of (ln r)^2/(n−1) and (ln r)^2n/(n−1) respectively. The distance from the crack tip is r, and n is the hardening exponent, i.e. σⁿ. The amplitudes of the stress and strain near the crack tip are determined by the asymptotic analysis.     

A comparative study of crack propagation models for PMMA and PVC

An analysis of examining the validity of a unified approach proposed earlier by the authors for the fatigue crack propagation (FCP) of engineering materials to include PMMA and PVC is described. The proposed formulation has been shown capable of characterizing a diversified range of materials with a master FCP diagram and expressed as da/dN = A(ΔG)^m/(G_c − G_max).An experimental program is undertaken to measure fatigue growth rate with the standard compact tension specimen. The FCP results are for the first instance analysed for each material using the unified formulation. The validity of the formulation for producing a master FCP diagram is verified when the fatigue crack growth rates of the materials are successfully characterized in one master diagram, yielding an excellent coefficient of correlation of 0.993. No such success is attained using a number of conventional FCP laws considered most acceptable to characterize polymeric materials.     

Effect of material nonhomogeneities on the HRR dominance

This work studies the asymptotic stress and displacement fields near the tip of a stationary crack in an elastic–plastic nonhomogeneous material with the emphasis on the effect of material nonhomogeneities on the dominance of the crack tip field. While the HRR singular field still prevails near the crack tip if the material properties are continuous and piecewise continuously differentiable, a simple asymptotic analysis shows that the size of the HRR dominance zone decreases with increasing magnitude of material property gradients. The HRR field dominates at points that satisfy |α⁻¹ ∂α/∂x_δ|1/r, |α⁻¹ ∂²α/(∂x_δ ∂x_γ)|1/r², |n⁻¹ ∂n/∂x_δ|1/[r|ln(r/A)|] and |n⁻¹ ∂²n/(∂x_δ ∂x_γ)|1/[r²|ln(r/A)|], in addition to other general requirements for asymptotic solutions, where α is a material property in the Ramberg–Osgood model, n is the strain hardening exponent, r is the distance from the crack tip, x_δ are Cartesian coordinates, and A is a length parameter. For linear hardening materials, the crack tip field dominates at points that satisfy |E_tan⁻¹ ∂E_tan/∂x_δ|1/r, |E_tan⁻¹ ∂²E_tan/(∂x_δ ∂x_γ)|1/r², |E⁻¹ ∂E/∂x_δ|1/r, and |E⁻¹ ∂²E/(∂x_δ ∂x_γ)|1/r², where E_tan is the tangent modulus and E is Young’s modulus.     

Strain strengthening effects in Witwatersrand quartzite

A series of uniaxial compression specimens were tested over a range of applied ram displacement rates of 8.9 × 10⁻⁴ to 8.9 mm/sec to elucidate the effects of loading rate on the uniaxial compressive fracture stress of Witwatersrand quartzite. It was demonstrated that even within standard loading rate ranges, considerable scatter in the fracture strength (under uniaxial compression) existed in this particular quartzite rock. Nevertheless, a definite trend of increasing fracture resistance with increasing monotonic loading rate was evident inasmuch that increasing the loading rate (strain rate) by four orders of magnitude increase the fracture strength by almost 2.8 times. Prior fatigue loading also produced a significant strain strengthening as the uniaxial compressive fracture stress tended to increase in a sigmoidal fashion with increasing number of fatigue cycles prior to testing. Indeed, the fracture strength of quartzite was almost doubled in value after 10⁻ cycles. Plane strain fracture toughness tests utilising three point bend specimens were conducted and an average of K_lc = 1.7 MPa√m was realized. In both the uniaxial compression tests and the fracture toughness tests, failure occurred by crack extension predominantly by a transgranular flat cleavage-like mode through pure quartzite (silica) regions. However, crack extension was also observed to occur in an intergranular “ductile-like” mode through areas associated with inclusions prevalent in the quartzite.     

Fatigue life prediction of out-of-plane gusset welded joints using strain energy density factor approach

Fatigue growth behavior of out-of-plane gusset welded joints is studied using the strain energy density factor approach. Fatigue tests on two types of specimens with curvatures of ρ = 0 and ρ = 30 were performed in order to estimate fatigue strength under tension. Fatigue crack growth analysis is carried out to show the effects of initial crack shape, initial crack length and stress ratio. Fatigue crack growth parameters were obtained from crack growth curves assuming constant crack shapes. The results of analysis for the assumed crack shapes agreed well with the experimental data. Fatigue propagation life of the ρ = 30 specimen was larger than that of the ρ = 0 specimen.     

Effect of stress ratio and specimen thickness on fatigue crack growth of CK45 steel

Presented are the effect of stress ratio and thickness on the fatigue crack growth rate of CK45 steel according to DIN 17200. Test results are obtained for constant amplitude load in tension with three stress ratios of R=0, 0.2 and 0.4 and three specimen thicknesses of B=6, 12 and 24 mm. Microgauge crack opening values were used to calculate ΔK_eff values from which the da/dN − ΔK_eff curves are obtained. Crack closure can be applied to explain the influence of mean stress and specimen thickness on the fatigue crack growth rate in the second regime of the two-parameter crack growth rate relation. An empirical model is chosen for calculating the normalized load ratio parameter U as a function of R, B and ΔK and, for correlating the test data.     

Influence of load amplitude and uniaxial tensile properties on fatigue crack growth

The rate at which energy is accumulated within a unit volume of material in fatigue is assumed to depend not only on load-time history but also on the specimen size and geometry in addition to material type. A threshold level for the hysteresis strain energy density function accumulated in the material is used for predicting macrocrack growth. This is accomplished by application of the incremental theory of plasticity for each increment of crack growth. The accumulated hysteresis strain energy density factor ΔS to crack growth increment Δa ratio is found to be constant for fixed specimen size and loading, i.e., . Results are obtained for the cylindrical bar specimens with a penny-shaped defect at the center subjected to a constant amplitude and frequency loading. The resistance curves in the ΔS versus Δa plot are parallel lines as specimen size is altered. This information provides a rational means for predicting the influence of specimen size on fatigue lifetime.The results are also compared with those found for geometrically similar plate specimens with line cracks. Cylinder bar specimens of the same material are found to sustain more load cycles prior to catastrophic failure.     

Softening behaviour and correction of the fracture energy

The area under the load–displacement softening curve gives the total external work on the test specimen and not the fracture energy. The fracture energy follows from half this area that is equal to the critical strain energy release rate at the first crack increment. For wood this is correctly applied for mode II. For mode I however, as for other materials, the total area is wrongly regarded, a factor 2 is too high. In some applications, based on crack increment cycles, the error is even a multiple of this factor 2. On the other hand, the measurements at softening may show an apparent decrease of the specific fracture energy that can be explained by a small crack joining mechanism when the ultimate state of the ligament of the test specimen is reached. Post fracture behaviour is thus not comparable with the behaviour of macro crack initiation.It is further shown, by the kinetics of the process, that the irreversible work of an ultimate loading cycle is proportional to the activation energy of the fracture process and not to the driving force of the process. This explains why the crack velocity decreases with the increase of this irreversible work and increases with the stress intensity increase.The fracture energy is a function of the Griffith strength and is thus related to the effective width of the test specimen and not to the ligament length. This also has to be corrected. Based on the derivation of the softening curve, the reported fracture toughness of 720 kN m^−1.5 of double-edge notched tests is corrected to 330 kN m^−1.5 and the value of 467 kN m^−1.5, based on the fracture energy, of the compact tension tests, is also corrected to the right value of 330 kN m^−1.5. A revision of published mode I data, based on the fracture energy obtained by the area of the softening curve, is thus necessary.     

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.     

Enhancement of fracture toughness of steel with defects by warm-prestressing

The technique of warm-prestressing to improve the resistance of structural steel with defects against low temperature fracture has received considerable attention. It is found that warm-prestressing can improve the fracture toughness and change the COD or δ_c, especially the crack tip plastic opening δ_p.The experimental results obtained from three-point bending tests of 42Mn2 steel specimens at −60°C and −20°C are analyzed. Experiments are also made on the bursting of pressure vessels manufactured from #20 steel. The results indicate that warm-prestressing at room temperature increased the bursting pressure at −40°C for d/t = 0.2 to 0.4, where d is the depth of surface crack and t the vessel thickness.     

Application of differential-integral equation to elliptical crack problem under shear load

Stress intensity factors for an elliptical crack under shear loading are investigated. The differential-integral equation is applied to solve the problem. It is found that, if the integrated function takes the form of (1 − (x/a)² − (y/b)²)^1/2 x^m yⁿ, a and b being the major and minor axis of the ellipse, the relevant differential-integral equation can be evaluated. Using this property, the boundary value problems are solved for the shear loading in the form of power function. Finally, results are presented for twelve particular example problems.     

Grain boundary oxidation and fatigue crack growth at elevated temperatures

Fatigue crack growth rate at elevated temperatures can be accelerated by grain boundary oxidation. Grain boundary oxidation kinetics and statistical distribution of grain boundary oxide penetration depth were studied.At a constant ΔK-level and at a constant test temperature, fatigue crack growth rate, da/dN, is a function of cyclic frequency, ν. A fatigue crack growth model of intermittent micro-ruptures of grain boundary oxide is constructed. The model is consustent with the experimental observations that, in the low frequency region, da/dN is inversely proportional to ν, and fatigue crack growth is intergranular.     

The behavior of cracked cross-ply composite laminates under shear loading

An interlaminar-shear-stress analysis developed earlier by Tsai et al. (1990, Micro-cracking-Induced Damage in Composites) for a [φ_m/θ_n], bi-directional composite laminate is used to solve the case of a cross-ply [0_m/90_n]_x laminate with the 90° layer only or both layers cracked under pure shear loading. Strains, forces and laminate shear modulus reduction due to matrix cracking were obtained. Experimental results for shear modulus as a function of crack densities were obtained by a simple shear test and they agree very well with the theoretical prediction.     

Limitations of growth regimes for cracks initiated in smooth fatigue specimens

The stages of the growth of small cracks initiating at natural flaws in smooth specimens subjected to fatigue loading are characterized and the dominant propagation mechanisms and corresponding fracture paths are described. Characteristic crack lengths are introduced to assess the transition between the regimes of microstructurally small cracks, physically small cracks and long cracks. A log Δσ-log a-diagram is used to derive estimates of these crack lengths. It is shown that simple formulate can be found which relate these characteristic crack lengths to mechanical and material parameters that can be measured using standard fracture mechanics specimens and fatigue tests.     

Spin tests to determine brittle fracture under plane strain

The feasibility of using cyclic thermal stress or hydrostatic pressure to generate a fatigue crack in a large test-rotor blank is demonstrated. Test rotors, having test notches with fatigue-crack terminations, were spun to fracture to determine optimum test-notch design. It was found that, for the other test-notch dimensions held, it was necessary to extend the fatigue crack a minimum of 0.1 in. from the machined portion of the test notch to obtain a most effectively notched test rotor. In another series of tests, the influence of temperature on brittle-fracture strength of a Cr-Mo-V steel under plane strain was evaluated. It was found that, although there is a significant increase in fracture strength with increasing temperature, no knee in the curve is apparent in the vicinity of the conventionally measured transition temperatures ofNDT andT ₅₀. Also, design against brittle fracture is still required at temperatures aboveNDT andT ₅₀.Paper was presented at 1968 SESA Spring Meeting held in Albany, N. Y., on May 7–10.     

Influence of mean stress on the fatigue crack growth characreristics of CrlMo steel tube at elevated temperature

The fatigue crack growth characteristics of CrlMo steel have been investigated at 861 K over the R-ratio range 0.1–0.7 utilising a dwell time of 10 min. at maximum load. All tests were conducted under load control in a laboratory air environment. It was established that the R-ratio significantly affected the fatigue crack extension behaviour inasmuch that with increasing R-ratio, the critical ΔK level for the onset of creep fatigue interactive growth, ΔK^IG, decreased from 20 to 7 MPa√m and the threshold stress intensity, ΔK_th, decreased from 9 to about 3 MPa√m. At intermediate ΔK levels, i.e. between ΔK_th and ΔK^IG, the fatigue crack extension rates, for all R-ratio values, resided on or slightly below the CTOD line, which represents the upper bound for contrnuum controlled fatigue crack growth. Creep fatigue interactive growth was typified by crack extension rates that reside above the CTOD line with a ΔK^IG dependence; the attainment of some critical creep condition or crack linkage condition which causes the abrupt change in crack extension behaviour at ΔK^IG; and crack extension occurs almost exclusively in an intergranular manner. The R-ratio and ΔK^IG followed a linear relation. A literature review concerning the effect of temperature on the threshold fatigue crack growth characteristics of low alloy ferritic steels demonstrated powerful effects of temperature; the magnitude of these effects, however, were dependent upon the testing temperature regime and R-ratio level. The effect of R-ratio on ΔK_th was greatest at temperatures >400°C, significant at ambient temperatures and least in the temperature range 90°C to <300°C. The relationship between temperature and ΔK_th, at a given R-ratio, exhibited a through and a minimum ΔK_th value was observed in the temperature range 200–250°C. The magnitude of the temperature effects on ΔK_th decreased with increasing R-ratio. Such effects of temperature and R-ratio on ΔK_th was reasonably explained in terms of crack closure effects. Finally, the present elevated temperature fatigue crack growth data exhibited massive crack extension enhancement values when compared to ambient near-threshold fatigue crack growth data for CrlMo steel. Such large enhancement values were the combined effects of temperature (environment) and frequency.     

Ultrasonic evaluation of fatigue crack growth of high strength steel at ambient temperature and below

By means of an ultrasonic testing device, the crack length in compact tension specimens is monitored. Four ultrasonic probes are used to cover the region of crack extension by transmission waves. The echo of the crack is amplified during fatigue crack propagation. By a knowledge of the initial crack length after precracking and the critical crack length, the alteration of the ultrasonic echo provides the information for determining the intermediate crack length which can be used to calculate the stress intensity range ΔK with respect to the elapsed cycles and the crack growth rate, da/dN.     

Prediction of mixed-mode fracture based on an elasto–plastic energy balance criterion

The maximum energy release rate criterion, i.e., G _max criterion, is commonly used for crack propagation analysis. This fracture criterion is based on the elastic macroscopic strength of materials. In the present investigation, however, the G _max criterion has been modified in order to accommodate the consideration of plastic strain energy. This modified criterion is extended to study the fatigue crack growth characteristics of mixed-mode cracks. To predict crack propagation due to fatigue loads, a new elasto–plastic energy model is presented. This new model includes the effects of material properties such as strain hardening exponent n, yield strength σ _y , and fracture toughness and stress intensity factor ranges. The results obtained are compared with those obtained using the commonly employed crack growth law and the experimental data.