Prediction of failure in weldments — Part II: Joint with initial notch and crack

This investigation is concerned with predicting failure initiation sites ina butt weld joint under bending. The nonuniform load transmission characteristics through the weld metal, heat-affected zone and base material resulting from alteration in their microstructure are reflected through the macroscopic yield strength parameter. Elastic-plastic stress and strain redistribution is obtained for each increment of load increase. Analyzed in detail are the contours of constant strain energy density for determining the local and global stationary values which are assumed to be related to failure and stability of the system. Failure is predicted to initiate in the heat affected zone at the site of maximum of the minimum local strain energy density function. This corresponds to the experimental observation where cracking starts from the side of the butt joint where local stretching is maximum.     

A field model interpretation of crack initiation and growth behavior in ferroelectric ceramics: change of poling direction and boundary condition

Strain energy density expressions are obtained from a field model that can qualitatively exhibit how the electrical and mechanical disturbances would affect the crack growth behavior in ferroelectric ceramics. Simplification is achieved by considering only three material constants to account for elastic, piezoelectric and dielectric effects. Cross interaction of electric field (or displacement) with mechanical stress (or strain) is identified with the piezoelectric effect; it occurs only when the pole is aligned normal to the crack. Switching of the pole axis by 90° and 180° is examined for possible connection with domain switching. Opposing crack growth behavior can be obtained when the specification of mechanical stress σ^∞ and electric field E^∞ or (σ^∞,E^∞) is replaced by strain ε^∞ and electric displacement D^∞ or (ε^∞,D^∞). Mixed conditions (σ^∞,D^∞) and (ε^∞,E^∞) are also considered. In general, crack growth is found to be larger when compared to that without the application of electric disturbances. This includes both the electric field and displacement. For the eight possible boundary conditions, crack growth retardation is identified only with (E_y^∞,σ_y^∞) for negative E_y^∞ and (D_y^∞,ε_y^∞) for positive D_y^∞ while the mechanical conditions σ_y^∞ or ε_y^∞ are not changed. Suitable combinations of the elastic, piezoelectric and dielectric material constants could also be made to suppress crack growth.     

Damage accumulation and crack growth in bilinear materials with softening: Application of strain energy density theory

A pseudo-elastic damage-accumulation model is developed by application of the strain energy density theory. The three-point bending specimen is analyzed to illustrate the crack growth characteristics according to a linear elastic softening constitutive law that is typical of concrete materials. Damage accumulation is accounted for by the decrease of elastic modulus and fracture toughness. Both of these effects are assessed by means of the strain energy density functions in the elements around a slowly moving crack. The rate of change of the strain energy density factor S with crack growth as expressed by the relation dS/da = constant is shown to describe the failure behavior of concrete. Results are obtained for different loading steps that yield different slopes of lines in an S versus a (crack length) plot. The lines rotate about the common intersect in an anti-clockwise direction as the load steps are increased. The intersect shifts upward according to increase in the specimen size. In this way, the combined interaction of material properties, load steps and specimen geometry and size are easily analyzed in terms of the failure mode or behavior that can change from the very brittle to the ductile involving stable crack growth. An upper limit on specimen or structural size is established beyond which stable crack growth ceases to occur and failure corresponds to unstable crack propagation or catastrophic fracture. The parameters that control the failure mode are the threshold values of the strain energy density function (dW/dV)_c and the strain energy density factor S_c.     

Non-self-similar crack growth in elastic-plastic finite thickness plate

This work is concerned with non-self-similar crack growth in medium strength metal plates while the loading step, plate thickness and material properties are altered. The three-dimensional elastic-plastic finite element stress analysis is combined with the strain energy density criterion for modeling the material damage process from crack initiation to final global instability including the intervening stage of slow crack growth. Both inelastic deformation and crack growth are accounted for each increment of loading such that the redistribution of stresses and strains are made for each new crack profile. Numerical results are obtained for the center cracked plate configuration under uniform extension with twenty-seven (27) different combinations of specimen thickness, loading step and material type. The fracture toughness S_c being related to K_1c for three different materials are predicted analytically from the corresponding uniaxial tensile test data. Effective strain energy density factor and half crack length are defined so that the results can be compared with their two-dimensional counterparts. Crack growth resistance curves (R-curves) are constructed by plotting as a function of . The condition is found to prevail during slow crack growth. Translation and/or rotation of the lines can yield results other than those calculated and serve a useful purpose for scaling component size and test time. The minimum thickness requirement for the ASTM valid K_1c test is also discussed in connection with predictions based on the strain energy density criterion. The corresponding K_1c for smaller specimens that exhibit moderate ductility and nonlinearity can also be obtained analytically. In such cases, the influence of loading step can be significant and should not be neglected. Notwithstanding the shortcomings of the theory of plasticity, the qualitative features of non-self-similar crack growth are predicted by the strain energy density criterion. Any refinements on the analytical modeling of the material damage process would only affect the results qualitatively, a subject that is left for future investigation.     

Tensile and compressive buckling of plates weakened by cracks

Plates are susceptible to buckling under compression when the thickness dimension becomes sufficiently small. Such mode of structure failure can prevail even if the plates were extended in tension. Wribkling of stretched thin sheets is a commonly observed phenomenon that leads to complex deflection patterns, particularly in regions close to crack-like imperfections. Predictions of the buckled displacement modes for plates weakened by cracks will be made on the basis of a theory formulated by application of variational calculus. Finite element method is used such that defects of other shapes can also be analyzed. Various buckled displacement modes of a center-cracked plate are determined and displayed graphically. The critical buckling loads are found to decrease with increasing crack size. Moreover, local wrinkling of the plate surface becomes less pronounced for the higher buckling modes. The method of solution applies equally well to plates that are initially curved.     

Multi-scale and multi-order singularity approach to non-equilibrium mechanics: Coupling of atomic-micro-macro damage

Offered in this work is the development of a macro/meso/micro model that covers the lineal scale of 10⁻¹¹ to 10⁰ by application of the volume energy density function. Boundary constraints and defect geometries are shown to play a role at the smaller scale in the same way as those at the macroscopic scale. Different orders of stress (or energy density) singularities are used to describe the defect geometry and prevailing constraint via the boundary conditions in a way similar to singularity adopted in classical fracture mechanics. Two classes of singularities have been identified in addition to classical one without violating the finiteness conditions of the local displacement and energy density. Still the connection of results from the different scales is no small task and is made possible by application of a scale multiplier. It is determined by considering the interactive effects of the parameters at the different scales from the atomic to the macroscopic. Unlike the classical boundary value problem approach, application of the scale multiplier has led to closed-form asymptotic multiscale solutions that otherwise would not have been made possible. The procedure is demonstrated for the anti-plane shear of a macro-micro-atomic model that accounts for imperfection at the different scales Published in Prikladnaya Mekhanika, Vol. 42, No. 1, pp. 3–22, January 2006.     

Scaling of size/time/temperature — Part 2: Progressive damage in uniaxial compressive specimen

This work is concerned with predicting the fatigue failure initiation of a wing/fuselage bolt assembly. Accounted for in the analysis are both the influence of energy dissipation and damage accumulation as the structure is subjected to repeated cyclic loading. Results involving the location and number of cycles to initiate a fatigue crack 10⁻² in. are obtained. They agreed both qualitatively and quantitatively with the experimental findings. Also discussed is the influence of pre-torque in the bolt which tends to decrease the number of cycles to fatique crack initiation. Fatigue life may be extended by altering the load path so as to decrease the accumulation of energy near the site of failure initiation. This can be accomplished without major modification of the design. The methodology that makes use of the strain energy density criterion can be used to optimize the fatigue strength of other structural sub-assemblies by appropriate combination of material and geometry for specified load conditions.     

Kinetics of microcrack blunting ahead of macrocrack approaching shear wave speed

The fracturing of glass and tearing of rubber both involve the separation of material but their crack growth behavior can be quite different, particularly with reference to the distance of separation of the adjacent planes of material and the speed at which they separate. Relatively speaking, the former and the latter are recognized, respectively, to be fast and slow under normal conditions. Moreover, the crack tip radius of curvature in glass can be very sharp while that in the rubber can be very blunt. These changes in the geometric features of the crack or defect, however, have not been incorporated into the modeling of running cracks because the mathematical treatment makes use of the Galilean transformation where the crack opening distance or the change in the radius of curvature of the crack does not enter into the solution. Change in crack speed is accounted for only via the modulus of elasticity and mass density. For this simple reason, many of the dynamic features of the running crack have remained unexplained although speculations are not lacking. To begin with, the process of energy dissipation due to separation is affected by the microstructure of the material that distinguishes polycrystalline from amorphous form. Energy extracted from macroscopic reaches of a solid will travel to the atomic or smaller regions at different speeds at a given instance. It is not clear how many of the succeeding size scales should be included within a given time interval for an accurate prediction of the macroscopic dynamic crack characteristics. The minimum requirement would therefore necessitate the simultaneous treatment of two scales at the same time. This means that the analysis should capture the change in the macroscopic and microscopic features of a defect as it propagates. The discussion for a dual scale model has been invoked only very recently for a stationary crack. The objective of this work is to extend this effort to a crack running at constant speed beyond that of Rayleigh wave. Developed is a dual scale moving crack model containing microscopic damage ahead of a macroscopic crack with a gradual transition. This transitory region is referred to as the mesoscopic zone where the tractions prevail on the damaged portion of the material ahead of the original crack known as the restraining stresses, the magnitude of which depends on the geometry, material and loading. This damaged or restraining zone is not assumed arbitrarily nor assumed to be intrinsically a constant in the cohesive stress approach; it is determined for each step of crack advancement. For the range of micronotch bluntness with 0 < β < 30° and 0.2 σ_∞/σ₀ 0.5, there prevails a nearly constant restraining zone size as the crack approaches the shear wave speed. Note that β is the half micronotch angle and the applied stress ratio is σ_∞/σ₀ with σ₀ being the maximum of the restraining stress. For σ_∞/σ₀ equal to or less than 0.5, the macrocrack opening displacement COD is nearly constant and starts to decrease more quickly as the crack approaches the shear wave speed. For the present dual scale model where the normalized crack speed v/c_s increases with decreasing with the one-half microcrack tip angle β. There prevails a limit of crack tip bluntness that corresponds to β 36° and v/c_s 0.15. That is a crack cannot be maintained at a constant speed if the bluntness is increased beyond this limiting value. Such a feature is manifestation of the dependency of the restraining stress on crack velocity and the applied stress or the energy pumped into the system to maintain the crack at a constant velocity. More specifically, the transitory character from macro to micro is being determined as part of the unknown solution. Using the energy density function dW/dV as the indicator, plots are made in terms of the macrodistance ahead of the original crack while the microdefect bluntness can vary depending on the tip geometry. Such a generality has not been considered previously. The macro-dW/dV behavior with distance remains as the inverse r relation yielding a perfect hyperbola for the homogeneous material. This behavior is the same as the stationary crack. The micro-dW/dV relations are expressed in terms of a single undetermined parameter. Its evaluation is beyond the scope of this investigation although the qualitative behavior is expected to be similar to that for the stationary crack. To reiterate, what has been achieved as an objective is a model that accounts for the thickness of a running crack since the surface of separation representing damage at the macroscopic and microscopic scale is different. The transitory behavior from micro to macro is described by the state of affairs in the mesoscopic zone.     

Initiation and growth characterization of corner cracks near circular hole

The finite element analysis of crack problems often incorporates the asymptotic character of the local solution into the formulation. Embedment of stress or strain singularities can impose serious restrictions on the outcome and inconsistencies in predicting crack and/or growth. These restrictions are discussed in connection with the problem of two diametrically opposite corner cracks near a circular hole subjected to remote uniform tension. Enforced in the numerical treatment is the 1/r character of the strain energy density function local to the corner crack border where r is the radial distance measured from the crack front. The tendency for the corner crack to become a through crack is predicted by assuming that each point of the crack border extends by an amount proportional to the strain energy density factor. The path would correspond to the loci of minimum strain energy density function. Numerical results are displayed graphically and discussed in connection with crack initiation and non-self-similar crack growth.     

基于箭形累积损伤的裂纹尖端力学:奇异性分级和多尺度分段

在适度的空间和时间尺度组合下,裂纹既可在几个月中蠕变几个纳米,也能在几秒钟内扩展10km.虽然裂纹的尖端没有实际的质量,但是它能通过激活周围的物质而处于高能量状态.依赖于材料的损伤方向,激活质量的减少和增加可发生在尺度转变之前或之后.每个尺度区的分段阈值被假定为与裂纹尖端速度的平方a~2和激活质量密度M的乘积有关:W=M_(↓↑)a_(↑↓)~2和D=M~(↓↑)a_(↑↓)~2.W和D分别被称为直接吸收和自耗散能量密度.正如下标/上标符号所示,激活的质量密度M_(↓↑)和M~(↓↑)与裂纹尖端速度a变化趋势相反,既可增加也可减少.a~2和M的互补效应隐含着常用于宇宙物理学建模的膨胀和/或收缩的物理过程.在用于尺度敏感的裂纹尖端的行为时,激活的质量密度有相同的解释.分段时的多尺度可以由…皮观、纳观、微观和宏观…组成.因此,形象地说,材料损伤过程可以通过裂纹扩展过程中非均匀的总体和局部能量的传递来模拟.疲劳裂纹扩展引起的材料损伤被用来阐释由大到小和由慢到快的尺度/时间序,热力学中的冷→热和有序→无序转换.这一过程正巧与宇宙演化的箭形方向相反,宇宙演化遵循小→大和快→慢,而热力学相反,遵循热→冷和无序→有序.为了表示由损伤萌生所造成的类裂缝型缺陷的不均匀性,提出了一个被称为裂纹尖端力学(crack tip mechanics,CTM)的新模式.涉及的范围是模拟原子列之间的界面裂纹或连续体中分叉的切口.假如需要的话,尺寸和时间的范围可以复盖从皮观到宏观甚至更大.虽然采用疲劳裂纹来说明CTM的基本原理,在宇宙物理学背景中与直接吸收和自耗散相关的膨胀和收缩的情况可以描述裂纹周围激活质量的行为,它们可看为能量的汇或源.奇异性被用来捕获能量的源或汇的特性,物理上,两者作为界面的一部分,从数学上看则是不连续的线的一部分.能量从一种形式变为另一种形式取决于能量吸收或耗散的箭形损伤时间,这之中牵涉到尺度分段和奇异性强度的联合应用.材料组分随时间的劣化是根据指定的设计寿命导出的,从而使材料的响应与加载率的时间历史匹配.2024-T3铝板的皮观/纳观/微观/宏观开裂模型用来说明什么地方可以增加结构的寿命部分.皮观/纳观/微观/宏观/结构系统的性能随时间劣化可以用9个尺度转变物理参数来描述:纳观/微观区有3个(μ_(na/mi)~*,σ_(na/mi)~*,d_(na/mi)~*),微观/宏观区有3个(μ_(mi/ma)~*,σ_(mi/ma)~*,d_(mi/ma)~*),皮观/纳观区有3个(μ_(pi/na)~*,σ_(pi/na)~*,d_(pi/na)~*).下标pi,na,mi,ma和struc分别表示皮观、纳观、微观、宏观和结构.只要知道两个相连的尺度敏感参数,在较低尺度的时间相关的局部物理参数就完成了分析连续体的形式论,虽然它们并不需要用实验来知道.更具体地说,根据皮观→纳观→微观→宏观分别有1.25/1.00/0.75/0.50的λ奇异性强度,皮观裂纹、纳观裂纹、微观裂纹和宏观裂纹的转变特征是从时间箭形的指定的寿命预期来确定的.附加的0.25强度的奇异性可用于结构元件.回想起来,λ=0.5相应于断裂力学中的应力分量与r~(0.5)成反比,r是与宏观裂纹尖端的距离.微观裂纹、纳观裂纹和皮观裂纹分别赋予r~(-0.75),r~(-1.0),r~(-1.25)的奇异性.箭形时间(以年为单位)取决于问题的定义.设备的关键部件可用1.5~±/2.5~±/3.5~±/5.5~±寿命分布和总寿命为13~±年(a)的皮观/纳观/微观/宏观尺度来设计运行.上标±表示多于或少于实际运行的时间.累进损伤被假定为发生在皮观→纳观→微观→宏观方向.同样的方案用于20年总寿命的2024-T3铝板的疲劳损伤,按照1.5~±/2.5~±/3.5~±/5.5~±/7.0~±的方式将它的寿命分布在皮观、纳观、微观、宏观和结构的尺度上,这样的指定只是满足在每个尺度范围内损伤内部材料结构所用的能量匹配,因此可以强制执行在总寿命的跨度内精确的时间相关的材料性能劣化过程.