The Effects of Hot Corrosion Pits on the Fatigue Resistance of a Disk Superalloy

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Telesman, Jack; Hazel, Brian; Mourer, David P.

2009-01-01

The effects of hot corrosion pits on low cycle fatigue life and failure modes of the disk superalloy ME3 were investigated. Low cycle fatigue specimens were subjected to hot corrosion exposures producing pits, then tested at low and high temperatures. Fatigue lives and failure initiation points were compared to those of specimens without corrosion pits. Several tests were interrupted to estimate the fraction of fatigue life that fatigue cracks initiated at pits. Corrosion pits significantly reduced fatigue life by 60 to 98 percent. Fatigue cracks initiated at a very small fraction of life for high temperature tests, but initiated at higher fractions in tests at low temperature. Critical pit sizes required to promote fatigue cracking were estimated, based on measurements of pits initiating cracks on fracture surfaces.

Analytical Modeling of Pressure Wall Hole Size and Maximum Tip-to-Tip Crack Length for Perforating Normal and Oblique Orbital Debris Impacts

NASA Technical Reports Server (NTRS)

Schonberg, William P.; Mohamed, Essam

1997-01-01

This report presents the results of a study whose objective was to develop first-principles-based models of hole size and maximum tip-to-tip crack length for a spacecraft module pressure wall that has been perforated in an orbital debris particle impact. The hole size and crack length models are developed by sequentially characterizing the phenomena comprising the orbital debris impact event, including the initial impact, the creation and motion of a debris cloud within the dual-wall system, the impact of the debris cloud on the pressure wall, the deformation of the pressure wall due to debris cloud impact loading prior to crack formation, pressure wall crack initiation, propagation, and arrest, and finally pressure wall deformation following crack initiation and growth. The model development has been accomplished through the application of elementary shock physics and thermodynamic theory, as well as the principles of mass, momentum, and energy conservation. The predictions of the model developed herein are compared against the predictions of empirically-based equations for hole diameters and maximum tip-to-tip crack length for three International Space Station wall configurations. The ISS wall systems considered are the baseline U.S. Lab Cylinder, the enhanced U.S. Lab Cylinder, and the U.S. Lab Endcone. The empirical predictor equations were derived from experimentally obtained hole diameters and crack length data. The original model predictions did not compare favorably with the experimental data, especially for cases in which pressure wall petalling did not occur. Several modifications were made to the original model to bring its predictions closer in line with the experimental results. Following the adjustment of several empirical constants, the predictions of the modified analytical model were in much closer agreement with the experimental results.

Incidence of apical crack initiation and propagation during the removal of root canal filling material with ProTaper and Mtwo rotary nickel-titanium retreatment instruments and hand files.

PubMed

Topçuoğlu, Hüseyin Sinan; Düzgün, Salih; Kesim, Bertan; Tuncay, Oznur

2014-07-01

The aim of this study was to determine the incidence of crack initiation and propagation in apical root dentin after retreatment procedures performed by using 2 rotary retreatment systems and hand files with additional instrumentation. Eighty extracted mandibular premolars with single canals were selected. One millimeter from the apex of each tooth was ground perpendicular to the long axis of the tooth, and the apical surface was polished. Twenty teeth served as the control group, and no preparation was performed. The remaining 60 teeth were prepared to size 35 with rotary files and filled with gutta-percha and AH Plus sealer. Specimens were then divided into 3 groups (n = 20), and retreatment procedures were performed with the following devices and techniques: ProTaper Universal retreatment files, Mtwo retreatment files, and hand files. After retreatment, the additional instrumentation was performed by using size 40 ProTaper, Mtwo, and hand files. Digital images of the apical root surface were recorded before preparation, after instrumentation, after filling, after retreatment, and after additional instrumentation. The images were then inspected for the presence of any new apical cracks and propagation. Data were analyzed with the logistic regression and Fisher exact tests. All experimental groups caused crack initiation and propagation after use of retreatment instruments. The ProTaper and Mtwo retreatment groups caused greater crack initiation and propagation than the hand instrument group (P < .05) after retreatment. Additional instrumentation with ProTaper and Mtwo instruments after the use of retreatment instruments caused crack initiation and propagation, whereas hand files caused neither crack initiation nor propagation (P < .05). This study showed that retreatment procedures and additional instrumentation after the use of retreatment files may cause crack initiation and propagation in apical dentin. Copyright © 2014 American Association of Endodontists. Published by Elsevier Inc. All rights reserved.

Airframe integrity based on Bayesian approach

NASA Astrophysics Data System (ADS)

Hurtado Cahuao, Jose Luis

Aircraft aging has become an immense challenge in terms of ensuring the safety of the fleet while controlling life cycle costs. One of the major concerns in aircraft structures is the development of fatigue cracks in the fastener holes. A probabilistic-based method has been proposed to manage this problem. In this research, the Bayes' theorem is used to assess airframe integrity by updating generic data with airframe inspection data while such data are compiled. This research discusses the methodology developed for assessment of loss of airframe integrity due to fatigue cracking in the fastener holes of an aging platform. The methodology requires a probability density function (pdf) at the end of SAFE life. Subsequently, a crack growth regime begins. As the Bayesian analysis requires information of a prior initial crack size pdf, such a pdf is assumed and verified to be lognormally distributed. The prior distribution of crack size as cracks grow is modeled through a combined Inverse Power Law (IPL) model and lognormal relationships. The first set of inspections is used as the evidence for updating the crack size distribution at the various stages of aircraft life. Moreover, the materials used in the structural part of the aircrafts have variations in their properties due to their calibration errors and machine alignment. A Matlab routine (PCGROW) is developed to calculate the crack distribution growth through three different crack growth models. As the first step, the material properties and the initial crack size are sampled. A standard Monte Carlo simulation is employed for this sampling process. At the corresponding aircraft age, the crack observed during the inspections, is used to update the crack size distribution and proceed in time. After the updating, it is possible to estimate the probability of structural failure as a function of flight hours for a given aircraft in the future. The results show very accurate and useful values related to the reliability and integrity of airframes in aging aircrafts. Inspection data shown in this dissertation are not the actual data from known aircrafts and are only used to demonstrate the methodologies.

Subsize specimen testing of nuclear reactor pressure vessel material

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kumar, A.S.; Rosinski, S.T.; Cannon, N.S.

1991-12-31

A new methodology is proposed to correlate the upper shelf energy (USE) of full size and subsize Charpy specimens of a nuclear reactor pressure vessel plate material, A533B. The methodology appears to be more satisfactory than the methodologies proposed earlier. USE of a notched-only specimen is partitioned into macro-crack initiation and crack propagation energies. USE of a notched and precracked specimen provides the crack propagation energy. {Delta}USE, the difference between the USE`s of notched-only and precracked specimens, is an estimate of the crack initiation energy. {Delta}USE was normalized by a factor involving the dimensions of the Charpy specimen and themore » stress concentration factor at the notch root. The normalized values of the {Delta}USE were found to be invariant with specimen size.« less

Investigation of the effects of manufacturing variations and materials on fatigue crack detection methods in gear teeth

NASA Technical Reports Server (NTRS)

Wheitner, Jeffrey A.; Houser, Donald R.

1994-01-01

The fatigue life of a gear tooth can be thought of as the sum of the number of cycles required to initiate a crack, N(sub i), plus the number of cycles required to propagate the crack to such a length that fracture occurs, N(sub p). The factors that govern crack initiation are thought to be related to localized stress or strain at a point, while propagation of a fatigue crack is a function of the crack tip parameters such as crack shape, stress state, and stress intensity factor. During a test there is no clear transition between initiation and propagation. The mechanisms of initiation and propagation are quite different and modeling them separately produces a higher degree of accuracy, but then the question that continually arises is 'what is a crack?' The total life prediction in a fracture mechanics model presently hinges on the assumption of an initial crack length, and this length can significantly affect the total life prediction. The size of the initial crack is generally taken to be in the range of 0.01 in. to 0.2 in. Several researchers have used various techniques to determine the beginning of the crack propagation stage. Barhorst showed the relationship between dynamic stiffness changes and crack propagation. Acoustic emissions, which are stress waves produced by the sudden movement of stressed materials, have also been successfully used to monitor the growth of cracks in tensile and fatigue specimens. The purpose of this research is to determine whether acoustic emissions can be used to define the beginning of crack propagation in a gear using a single-tooth bending fatigue test.

A comparison of single-cycle versus multiple-cycle proof testing strategies

NASA Technical Reports Server (NTRS)

Hudak, S. J., Jr.; Mcclung, R. C.; Bartlett, M. L.; Fitzgerald, J. H.; Russell, D. A.

1990-01-01

An evaluation of single-cycle and multiple-cycle proof testing (MCPT) strategies for SSME components is described. Data for initial sizes and shapes of actual SSME hardware defects are analyzed statistically. Closed-form estimates of the J-integral for surface flaws are derived with a modified reference stress method. The results of load- and displacement-controlled stable crack growth tests on thin IN-718 plates with deep surface flaws are summarized. A J-resistance curve for the surface-cracked configuration is developed and compared with data from thick compact tension specimens. The potential for further crack growth during large unload/reload cycles is discussed, highlighting conflicting data in the literature. A simple model for ductile crack growth during MCPT based on the J-resistance curve is used to study the potential effects of key variables. The projected changes in the crack size distribution during MCPT depend on the interactions between several key parameters, including the number of proof cycles, the nature of the resistance curve, the initial crack size distribution, the component boundary conditions (load vs. displacement control), and the magnitude of the applied load or displacement. The relative advantages of single-cycle and multiple-cycle proof testing appear to be specific, therefore, to individual component geometry, material, and loading.

Decrepitation and crack healing of fluid inclusions in San Carlos olivine

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wanamaker, B.J.; Wong, Tengfong; Evans, B.

1990-09-10

Fluid inclusions break, or decrepitate, when the fluid pressure exceeds the least principal lithostatic stress by a critical amount. After decrepitation, excess fluid pressure is relaxed, resulting in crack arrest; subsequently, crack healing may occur. The authors developed a linear elastic fracture mechanics model to analyze new data on decrepitation and crack arrest in San Carlos Olivine, compared the model with previous fluid inclusion investigations, and used it to interpret some natural decrepitation microstructures. The common experimental observation that smaller inclusions may sustain higher internal fluid pressures without decrepitating may be rationalized by assuming that flaws associated with the inclusionmore » scale with the inclusion size. According to the model, the length of the crack formed by decrepitation depends on the lithostatic pressure at the initiation of cracking, the initial sizes of the flaw and the inclusion, and the critical stress intensity factor. Further experiments show that microcracks in San Carlos olivine heal within several days at 1,280 to 1,400{degree}C; healing rates depend on the crack geometry, temperature, and chemistry of the buffering gas. The regression distance of the crack tip during healing can be related to time through a power law with exponent n = 0.6. Chemical changes which become apparent after extremely long heat-treatments significantly affect the healing rates. Many of the inclusions in the San Carlos xenoliths stretched, decrepitated, and finally healed during uplift. The crack arrest model indicates that completely healed cracks had an initial fluid pressure of the order of 1 GPa. Using the crack arrest model and the healing kinetics, they estimate the ascent rate of these xenoliths to be between 0.001 and 0.1 m/s.« less

Probabalistic Risk Assessment of a Turbine Disk

NASA Astrophysics Data System (ADS)

Carter, Jace A.; Thomas, Michael; Goswami, Tarun; Fecke, Ted

Current Federal Aviation Administration (FAA) rotor design certification practices risk assessment using a probabilistic framework focused on only the life-limiting defect location of a component. This method generates conservative approximations of the operational risk. The first section of this article covers a discretization method, which allows for a transition from this relative risk to an absolute risk where the component is discretized into regions called zones. General guidelines were established for the zone-refinement process based on the stress gradient topology in order to reach risk convergence. The second section covers a risk assessment method for predicting the total fatigue life due to fatigue induced damage. The total fatigue life incorporates a dual mechanism approach including the crack initiation life and propagation life while simultaneously determining the associated initial flaw sizes. A microstructure-based model was employed to address uncertainties in material response and relate crack initiation life with crack size, while propagation life was characterized large crack growth laws. The two proposed methods were applied to a representative Inconel 718 turbine disk. The zone-based method reduces the conservative approaches, while showing effects of feature-based inspection on the risk assessment. In the fatigue damage assessment, the predicted initial crack distribution was found to be the most sensitive probabilistic parameter and can be used to establish an enhanced inspection planning.

Relationship between Defect Size and Fatigue Life Distributions in Al-7 Pct Si-Mg Alloy Castings

NASA Astrophysics Data System (ADS)

Tiryakioğlu, Murat

2009-07-01

A new method for predicting the variability in fatigue life of castings was developed by combining the size distribution for the fatigue-initiating defects and a fatigue life model based on the Paris-Erdoğan law for crack propagation. Two datasets for the fatigue-initiating defects in Al-7 pct Si-Mg alloy castings, reported previously in the literature, were used to demonstrate that (1) the size of fatigue-initiating defects follow the Gumbel distribution; (2) the crack propagation model developed previously provides respectable fits to experimental data; and (3) the method developed in the present study expresses the variability in both datasets, almost as well as the lognormal distribution and better than the Weibull distribution.

Dynamics of diffusive bubble growth and pressure recovery in a bubbly rhyolitic melt embedded in an elastic solid

USGS Publications Warehouse

Chouet, Bernard A.; Dawson, Phillip B.; Nakano, Masaru

2006-01-01

We present a model of gas exsolution and bubble expansion in a melt supersaturated in response to a sudden pressure drop. In our model, the melt contains a suspension of gas bubbles of identical sizes and is encased in a penny-shaped crack embedded in an elastic solid. The suspension is modeled as a three-dimensional lattice of spherical cells with slight overlap, where each elementary cell consists of a gas bubble surrounded by a shell of volatile-rich melt. The melt is then subjected to a step drop in pressure, which induces gas exsolution and bubble expansion, resulting in the compression of the melt and volumetric expansion of the crack. The dynamics of diffusion-driven bubble growth and volumetric crack expansion span 9 decades in time. The model demonstrates that the speed of the crack response depends strongly on volatile diffusivity in the melt and bubble number density and is markedly sensitive to the ratio of crack thickness to crack radius and initial bubble radius but is relatively insensitive to melt viscosity. The net drop in gas concentration in the melt after pressure recovery represents only a small fraction of the initial concentration prior to the drop, suggesting the melt may undergo numerous pressure transients before becoming significantly depleted of gases. The magnitude of pressure and volume recovery in the crack depends sensitively on the size of the input-pressure transient, becoming relatively larger for smaller-size transients in a melt containing bubbles with initial radii less than 10-5 m. Amplification of the input transient may be large enough to disrupt the crack wall and induce brittle failure in the rock matrix surrounding the crack. Our results provide additional basis for the interpretation of volume changes in the magma conduit under Popocatépetl Volcano during Vulcanian degassing bursts in its eruptive activity in April–May 2000.

Microstructural Features Controlling the Variability in Low-Cycle Fatigue Properties of Alloy Inconel 718DA at Intermediate Temperature

NASA Astrophysics Data System (ADS)

Texier, Damien; Gómez, Ana Casanova; Pierret, Stéphane; Franchet, Jean-Michel; Pollock, Tresa M.; Villechaise, Patrick; Cormier, Jonathan

2016-03-01

The low-cycle fatigue behavior of two direct-aged versions of the nickel-based superalloy Inconel 718 (IN718DA) was examined in the low-strain amplitude regime at intermediate temperature. High variability in fatigue life was observed, and abnormally short lifetimes were systematically observed to be due to crack initiation at (sub)-surface non-metallic inclusions. However, crack initiation within (sub)-surface non-metallic inclusions did not necessarily lead to short fatigue life. The macro- to micro-mechanical mechanisms of deformation and damage have been examined by means of detailed microstructural characterization, tensile and fatigue mechanical tests, and in situ tensile testing. The initial stages of crack micro-propagation from cracked non-metallic particles into the surrounding metallic matrix occupies a large fraction of the fatigue life and requires extensive local plastic straining in the matrix adjacent to the cracked inclusions. Differences in microstructure that influence local plastic straining, i.e., the δ-phase content and the grain size, coupled with the presence of non-metallic inclusions at the high end of the size distribution contribute strongly to the fatigue life variability.

The Effect of Boron on the Low Cycle Fatigue Behavior of Disk Alloy KM4

NASA Technical Reports Server (NTRS)

Gabb, Timothy; Gayda, John; Sweeney, Joseph

2000-01-01

The durability of powder metallurgy nickel base superalloys employed as compressor and turbine disks is often limited by low cycle fatigue (LCF) crack initiation and crack growth from highly stressed surface locations (corners, holes, etc.). Crack growth induced by dwells at high stresses during aerospace engine operation can be particularly severe. Supersolvus solution heat treatments can be used to produce coarse grain sizes approaching ASTM 6 for improved resistance to dwell fatigue crack growth. However, the coarse grain sizes reduce yield strength, which can lower LCF initiation life. These high temperature heat treatments also can encourage pores to form. In the advanced General Electric disk superalloy KM4, such pores can initiate fatigue cracks that limit LCF initiation life. Hot isostatic pressing (HIP) during the supersolvus solution heat treatment has been shown to improve LCF initiation life in KM4, as the HIP pressure minimizes formation of the pores. Reduction of boron levels in KM4 has also been shown to increase LCF initiation life after a conventional supersolvus heat treatment, again possibly due to effects on the formation tendencies of these pores. However, the effects of reduced boron levels on microstructure, pore characteristics, and LCF failure modes in KM4 still need to be fully quantified. The objective of this study was to determine the effect of boron level on the microstructure, porosity, LCF behavior, and failure modes of supersolvus heat treated KM4.

Statistical investigation of fatigue crack initiation and growth around chamfered rivet holes in Alclad 2024 T3 as affected by corrosion

NASA Technical Reports Server (NTRS)

Fadragas, M. I.; Fine, M. E.; Moran, B.

1994-01-01

In panel specimens with rivet holes cracks initiate in the blunted knife edge of the chamfered rivet hole and propagate inward as well as along the hole. The fatigue lifetime to dominant crack information was defined as the number of cycles, N500 micrometer, to formation of a 500 micrometer long crack. Statistical data on N500 micrometer and on crack propagation after N500 micrometer were obtained for a large number of uncorroded specimens and specimens corroded in an ASTM B 117 salt spray. Considerable variation in N500 micrometer and crack propagation behavior was observed from specimen to specimen of the same nominal geometry with chamfered rivet holes increased the probability for both early formation and later formation of a propagating 500 micrometer fatigue crack. The growth of fatigue cracks after 500 micrometer size was little affected by prior salt spray.

Precision diamond grinding of ceramics and glass

DOE Office of Scientific and Technical Information (OSTI.GOV)

Smith, S.; Paul, H.; Scattergood, R.O.

A new research initiative will be undertaken to investigate the effect of machine parameters and material properties on precision diamond grinding of ceramics and glass. The critical grinding depth to initiate the plastic flow-to-brittle fracture regime will be directly measured using plunge-grind tests. This information will be correlated with machine parameters such as wheel bonding and diamond grain size. Multiaxis grinding tests will then be made to provide data more closely coupled with production technology. One important aspect of the material property studies involves measuring fracture toughness at the very short crack sizes commensurate with grinding damage. Short crack toughnessmore » value`s can be much less than the long-crack toughness values measured in conventional fracture tests.« less

Fractography of a bis-GMA resin.

PubMed

Davis, D M; Waters, N E

1989-07-01

The fracture behavior of a bis-GMA resin was studied by means of the double-torsion test. The fracture parameter measured was the stress-intensity factor. Fracture occurred in either a stick-slip (unstable) or continuous (stable) manner, depending upon the test conditions. When stick-slip propagation occurred, the fracture surfaces showed characteristic crack-arrest lines. The fracture surfaces were examined by use of a reflected-light optical microscope. The stress-intensity factor for crack initiation was found to be related to the size of the crack-arrest line which, in turn, could be related to the Dugdale model for plastic zone size. The evidence supported the concept that the behavior of the crack during propagation was controlled by the amount of plastic deformation occurring at the crack tip.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simonen, F.A.; Johnson, K.I.; Liebetrau, A.M.

The VISA-II (Vessel Integrity Simulation Analysis code was originally developed as part of the NRC staff evaluation of pressurized thermal shock. VISA-II uses Monte Carlo simulation to evaluate the failure probability of a pressurized water reactor (PWR) pressure vessel subjected to a pressure and thermal transient specified by the user. Linear elastic fracture mechanics methods are used to model crack initiation and propagation. Parameters for initial crack size and location, copper content, initial reference temperature of the nil-ductility transition, fluence, crack-initiation fracture toughness, and arrest fracture toughness are treated as random variables. This report documents an upgraded version of themore » original VISA code as described in NUREG/CR-3384. Improvements include a treatment of cladding effects, a more general simulation of flaw size, shape and location, a simulation of inservice inspection, an updated simulation of the reference temperature of the nil-ductility transition, and treatment of vessels with multiple welds and initial flaws. The code has been extensively tested and verified and is written in FORTRAN for ease of installation on different computers. 38 refs., 25 figs.« less

Fatigue crack initiation and microcrack propagation in X7091 type aluminum P/M alloys

NASA Astrophysics Data System (ADS)

Hirose, S.; Fine, M. E.

1983-06-01

Fatigu crack initiation in extruded X7091 RSP-P/M aluminum type alloys o°Curs at grain boundaries at both low and high stresses. By a process of elimination this grain boundary embrittlement was attributed to Al2O3 particles formed mainly during atomization and segregated to some grain boundaries. It is not due to the small grain size, to Co2Al9, to η precipitates at grain boundaries, nor to a precipitate free zone. Thermomechanical processing after extrusion of X7091 with 0.8 pct Co was done by Alcoa to produce large recrystallized grains. This resulted in initiation of fatigue cracks at slip bands, and the resistance to initiation of fatigue cracks at low stresses was much greater. Microcrack growth is, however, much faster in the thermomechanically treated samples, as well as in ingot alloys, than in extruded and aged X7091.

Stochastic model for fatigue crack size and cost effective design decisions. [for aerospace structures

NASA Technical Reports Server (NTRS)

Hanagud, S.; Uppaluri, B.

1975-01-01

This paper describes a methodology for making cost effective fatigue design decisions. The methodology is based on a probabilistic model for the stochastic process of fatigue crack growth with time. The development of a particular model for the stochastic process is also discussed in the paper. The model is based on the assumption of continuous time and discrete space of crack lengths. Statistical decision theory and the developed probabilistic model are used to develop the procedure for making fatigue design decisions on the basis of minimum expected cost or risk function and reliability bounds. Selections of initial flaw size distribution, NDT, repair threshold crack lengths, and inspection intervals are discussed.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Stevens, D.L.; Simonen, F.A.; Strosnider, J. Jr.

The VISA (Vessel Integrity Simulation Analysis) code was developed as part of the NRC staff evaluation of pressurized thermal shock. VISA uses Monte Carlo simulation to evaluate the failure probability of a pressurized water reactor (PWR) pressure vessel subjected to a pressure and thermal transient specified by the user. Linear elastic fracture mechanics are used to model crack initiation and propagation. parameters for initial crack size, copper content, initial RT/sub NDT/, fluence, crack-initiation fracture toughness, and arrest fracture toughness are treated as random variables. This report documents the version of VISA used in the NRC staff report (Policy Issue frommore » J.W. Dircks to NRC Commissioners, Enclosure A: NRC Staff Evaluation of Pressurized Thermal Shock, November 1982, SECY-82-465) and includes a user's guide for the code.« less

Cohesive zone model for intergranular slow crack growth in ceramics: influence of the process and the microstructure

NASA Astrophysics Data System (ADS)

Romero de la Osa, M.; Estevez, R.; Olagnon, C.; Chevalier, J.; Tallaron, C.

2011-10-01

Ceramic polycrystals are prone to slow crack growth (SCG) which is stress and environmentally assisted, similarly to observations reported for silica glasses. The kinetics of fracture are known to be dependent on the load level, the temperature and the relative humidity. In addition, evidence is available on the influence of the microstructure on the SCG rate with an increase in the crack velocity with decreasing the grain size. Crack propagation takes place beyond a load threshold, which is grain size dependent. We present a cohesive zone model for the intergranular failure process. The methodology accounts for an intrinsic opening that governs the length of the cohesive zone and allows the investigation of grain size effects. A rate and temperature-dependent cohesive model is proposed (Romero de la Osa M, Estevez R et al 2009 J. Mech. Adv. Mater. Struct. 16 623-31) to mimic the reaction-rupture mechanism. The formulation is inspired by Michalske and Freiman's picture (Michalske and Freiman 1983 J. Am. Ceram. Soc. 66 284-8) together with a recent study by Zhu et al (2005 J. Mech. Phys. Solids 53 1597-623) of the reaction-rupture mechanism. The present investigation extends a previous work (Romero de la Osa et al 2009 Int. J. Fracture 158 157-67) in which the problem is formulated. Here, we explore the influence of the microstructure in terms of grain size, their elastic properties and residual thermal stresses originating from the cooling from the sintering temperature down to ambient conditions. Their influence on SCG for static loadings is reported and the predictions compared with experimental trends. We show that the initial stress state is responsible for the grain size dependence reported experimentally for SCG. Furthermore, the account for the initial stresses enables the prediction of a load threshold below which no crack growth is observed: a crack arrest takes place when the crack path meets a region in compression.

Automated predesign of aircraft

NASA Technical Reports Server (NTRS)

Poe, C. C., Jr.; Kruse, G. S.; Tanner, C. J.; Wilson, P. J.

1978-01-01

Program uses multistation structural-synthesis to size and design box-beam structures for transport aircraft. Program optimizes static strength and scales up to satisfy fatigue and fracture criteria. It has multimaterial capability and library of materials properties, including advanced composites. Program can be used to evaluate impact on weight of variables such as materials, types of construction, structural configurations, minimum gage limits, applied loads, fatigue lives, crack-growth lives, initial crack sizes, and residual strengths.

The Relationship Between Constraint and Ductile Fracture Initiation as Defined by Micromechanical Analyses

NASA Technical Reports Server (NTRS)

Panontin, Tina L.; Sheppard, Sheri D.

1994-01-01

The use of small laboratory specimens to predict the integrity of large, complex structures relies on the validity of single parameter fracture mechanics. Unfortunately, the constraint loss associated with large scale yielding, whether in a laboratory specimen because of its small size or in a structure because it contains shallow flaws loaded in tension, can cause the breakdown of classical fracture mechanics and the loss of transferability of critical, global fracture parameters. Although the issue of constraint loss can be eliminated by testing actual structural configurations, such an approach can be prohibitively costly. Hence, a methodology that can correct global fracture parameters for constraint effects is desirable. This research uses micromechanical analyses to define the relationship between global, ductile fracture initiation parameters and constraint in two specimen geometries (SECT and SECB with varying a/w ratios) and one structural geometry (circumferentially cracked pipe). Two local fracture criteria corresponding to ductile fracture micromechanisms are evaluated: a constraint-modified, critical strain criterion for void coalescence proposed by Hancock and Cowling and a critical void ratio criterion for void growth based on the Rice and Tracey model. Crack initiation is assumed to occur when the critical value in each case is reached over some critical length. The primary material of interest is A516-70, a high-hardening pressure vessel steel sensitive to constraint; however, a low-hardening structural steel that is less sensitive to constraint is also being studied. Critical values of local fracture parameters are obtained by numerical analysis and experimental testing of circumferentially notched tensile specimens of varying constraint (e.g., notch radius). These parameters are then used in conjunction with large strain, large deformation, two- and three-dimensional finite element analyses of the geometries listed above to predict crack initiation loads and to calculate the associated (critical) global fracture parameters. The loads are verified experimentally, and microscopy is used to measure pre-crack length, crack tip opening displacement (CTOD), and the amount of stable crack growth. Results for A516-70 steel indicate that the constraint-modified, critical strain criterion with a critical length approximately equal to the grain size (0.0025 inch) provides accurate predictions of crack initiation. The critical void growth criterion is shown to considerably underpredict crack initiation loads with the same critical length. The relationship between the critical value of the J-integral for ductile crack initiation and crack depth for SECT and SECB specimens has been determined using the constraint-modified, critical strain criterion, demonstrating that this micromechanical model can be used to correct in-plane constraint effects due to crack depth and bending vs. tension loading. Finally, the relationship developed for the SECT specimens is used to predict the behavior of circumferentially cracked pipe specimens.

Influence and Modeling of Residual Stresses in Thick Walled Pressure Vessels with Through Holes

DTIC Science & Technology

2012-02-28

9 FIGURE 4 ENVIRONMENTAL CRACKING OBSERVED IN EVACUATOR HOLE .......... 9 FIGURE 5 STRESSES PRESENT IN STRAIGHT EVACUATOR... ASSESMENT OF INITIAL DAMAGE Through investigation was undertaken on vessels similar in size and strength level to pressure vessels 85A and 85B...suggesting that the source of the residual stresses required to initiate and propagate these environmental cracks is not a resultant of the typical

Evaluation of the C* Model for Addressing Short Fatigue Crack Growth

DTIC Science & Technology

2008-10-01

FASTRAN/CGAP, the internal solution which evaluates the crack growth independently in the thickness and width direction was used . The analysis ...that used for the FASTRAN/CGAP analysis . The initial crack size used for all the models is 77 μm, as per [8]. From the viewpoint of engineering...Haddad Model, a0=0.05 mm El Haddad Model, a0=0.103 mm Figure 17: Comparison of crack growth analysis using modified El Haddad approach with

Fatigue-Life Prediction Methodology Using Small-Crack Theory

NASA Technical Reports Server (NTRS)

Newmann, James C., Jr.; Phillips, Edward P.; Swain, M. H.

1997-01-01

This paper reviews the capabilities of a plasticity-induced crack-closure model to predict fatigue lives of metallic materials using 'small-crack theory' for various materials and loading conditions. Crack-tip constraint factors, to account for three-dimensional state-of-stress effects, were selected to correlate large-crack growth rate data as a function of the effective-stress-intensity factor range (delta K(eff)) under constant-amplitude loading. Some modifications to the delta k(eff)-rate relations were needed in the near-threshold regime to fit measured small-crack growth rate behavior and fatigue endurance limits. The model was then used to calculate small- and large-crack growth rates, and to predict total fatigue lives, for notched and un-notched specimens made of two aluminum alloys and a steel under constant-amplitude and spectrum loading. Fatigue lives were calculated using the crack-growth relations and microstructural features like those that initiated cracks for the aluminum alloys and steel for edge-notched specimens. An equivalent-initial-flaw-size concept was used to calculate fatigue lives in other cases. Results from the tests and analyses agreed well.

Initiation and growth kinetics of solidification cracking during welding of steel

PubMed Central

Aucott, L.; Huang, D.; Dong, H. B.; Wen, S. W.; Marsden, J. A.; Rack, A.; Cocks, A. C. F.

2017-01-01

Solidification cracking is a key phenomenon associated with defect formation during welding. To elucidate the failure mechanisms, solidification cracking during arc welding of steel are investigated in situ with high-speed, high-energy synchrotron X-ray radiography. Damage initiates at relatively low true strain of about 3.1% in the form of micro-cavities at the weld subsurface where peak volumetric strain and triaxiality are localised. The initial micro-cavities, with sizes from 10 × 10−6 m to 27 × 10−6 m, are mostly formed in isolation as revealed by synchrotron X-ray micro-tomography. The growth of micro-cavities is driven by increasing strain induced to the solidifying steel. Cavities grow through coalescence of micro-cavities to form micro-cracks first and then through the propagation of micro-cracks. Cracks propagate from the core of the weld towards the free surface along the solidifying grain boundaries at a speed of 2–3 × 10−3 m s−1. PMID:28074852

Gear Crack Propagation Path Studies: Guidelines for Ultra-Safe Design

NASA Technical Reports Server (NTRS)

Lewicki, David G.

2001-01-01

Design guidelines have been established to prevent catastrophic rim fracture failure modes when considering gear tooth bending fatigue. Analysis was performed using the finite element method with principles of linear elastic fracture mechanics. Crack propagation paths were predicted for a variety of gear tooth and rim configurations. The effects of rim and web thicknesses, initial crack locations, and gear tooth geometry factors such as diametral pitch, number of teeth, pitch radius, and tooth pressure angle were considered. Design maps of tooth/rim fracture modes including effects of gear geometry, applied load, crack size, and material properties were developed. The occurrence of rim fractures significantly increased as the backup ratio (rim thickness divided by tooth height) decreased. The occurrence of rim fractures also increased as the initial crack location was moved down the root of the tooth. Increased rim and web compliance increased the occurrence of rim fractures. For gears with constant pitch radii, coarser-pitch teeth increased the occurrence of tooth fractures over rim fractures. Also, 25 deg pressure angle teeth had an increased occurrence of tooth fractures over rim fractures when compared to 20 deg pressure angle teeth. For gears with constant number of teeth or gears with constant diametral pitch, varying size had little or no effect on crack propagation paths.

Subcritical growth of natural hydraulic fractures

NASA Astrophysics Data System (ADS)

Garagash, D.

2014-12-01

Joints are the most common example of brittle tensile failure in the crust. Their genesis at depth is linked to the natural hydraulic fracturing, which requires pore fluid pressure in excess of the minimum in situ stress [Pollard and Aidyn, JSG1988]. Depending on the geological setting, high pore pressure can result form burial compaction of interbedded strata, diagenesis, or tectonics. Common to these loading scenarios is slow build-up of pore pressure over a geological timescale, until conditions for initiation of crack growth are met on favorably oriented/sized flaws. The flaws can vary in size from grain-size cracks in igneous rocks to a fossil-size flaws in clastic rock, and once activated, are inferred to propagate mostly subcritically [Segall JGR 1984; Olson JGR 1993]. Despite many observational studies of natural hydraulic fractures, the modeling attempts appear to be few [Renshaw and Harvey JGR 1994]. Here, we use boundary integral formulation for the pore fluid inflow from the permeable rock into a propagating joint [Berchenko et al. IJRMMS 1997] coupled with the criteria for subcritical propagation assisted by the environmental effects of pore fluid at the crack tip to solve for the evolution of a penny-shape joint, which, in interbedded rock, may eventually evolve to short-blade geometry (propagation confined to a bed). Initial growth is exceedingly slow, paced by the stress corrosion reaction kinetics at the crack tip. During this stage the crack is fully-drained (i.e. the fluid pressure in the crack is equilibrated with the ambient pore pressure). This "slow" stage is followed by a rapid acceleration, driven by the increase of the mechanical stress intensity factor with the crack length, towards the terminal joint velocity. We provide an analytical expression for the latter as a function of the rock diffusivity, net pressure loading at the initiation (or flaw lengthscale), and parameters describing resistance to fracture growth. Due to a much slower rate of the crack volume expansion of short-blade joints compared to that of penny-shape joints, the former would propagate much faster than the latter under otherwise identical conditions. Finally, we speculate about possible relation of the predicted patterns of joint development with morphology of joint fracture surfaces observed in sedimentary rock.

Back-Face Strain for Monitoring Stable Crack Extension in Precracked Flexure Specimens

NASA Technical Reports Server (NTRS)

Salem, Jonathan A.; Ghosn, Louis J.

2010-01-01

Calibrations relating back-face strain to crack length in precracked flexure specimens were developed for different strain gage sizes. The functions were verified via experimental compliance measurements of notched and precracked ceramic beams. Good agreement between the functions and experiments occurred, and fracture toughness was calculated via several operational methods: maximum test load and optically measured precrack length; load at 2 percent crack extension and optical precrack length; maximum load and back-face strain crack length. All the methods gave vary comparable results. The initiation toughness, K(sub Ii) , was also estimated from the initial compliance and load.The results demonstrate that stability of precracked ceramics specimens tested in four-point flexure is a common occurrence, and that methods such as remotely-monitored load-point displacement are only adequate for detecting stable extension of relatively deep cracks.

Probability of brittle failure

NASA Technical Reports Server (NTRS)

Kim, A.; Bosnyak, C. P.; Chudnovsky, A.

1991-01-01

A methodology was developed for collecting statistically representative data for crack initiation and arrest from small number of test specimens. An epoxy (based on bisphenol A diglycidyl ether and polyglycol extended diglycyl ether and cured with diethylene triamine) is selected as a model material. A compact tension specimen with displacement controlled loading is used to observe multiple crack initiation and arrests. The energy release rate at crack initiation is significantly higher than that at a crack arrest, as has been observed elsewhere. The difference between these energy release rates is found to depend on specimen size (scale effect), and is quantitatively related to the fracture surface morphology. The scale effect, similar to that in statistical strength theory, is usually attributed to the statistics of defects which control the fracture process. Triangular shaped ripples (deltoids) are formed on the fracture surface during the slow subcritical crack growth, prior to the smooth mirror-like surface characteristic of fast cracks. The deltoids are complementary on the two crack faces which excludes any inelastic deformation from consideration. Presence of defects is also suggested by the observed scale effect. However, there are no defects at the deltoid apexes detectable down to the 0.1 micron level.

A new fracture mechanics model for multiple matrix cracks of SiC fiber reinforced brittle-matrix composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Okabe, T.; Takeda, N.; Komotori, J.

1999-11-26

A new model is proposed for multiple matrix cracking in order to take into account the role of matrix-rich regions in the cross section in initiating crack growth. The model is used to predict the matrix cracking stress and the total number of matrix cracks. The model converts the matrix-rich regions into equivalent penny shape crack sizes and predicts the matrix cracking stress with a fracture mechanics crack-bridging model. The estimated distribution of matrix cracking stresses is used as statistical input to predict the number of matrix cracks. The results show good agreement with the experimental results by replica observations.more » Therefore, it is found that the matrix cracking behavior mainly depends on the distribution of matrix-rich regions in the composite.« less

Effect of main inclusions on crack initiation in bearing steel in the very high cycle fatigue regime

NASA Astrophysics Data System (ADS)

Gu, Chao; Bao, Yan-ping; Gan, Peng; Wang, Min; He, Jin-shan

2018-06-01

This work aims to investigate the effect of main inclusions on crack initiation in bearing steel in the very high cycle fatigue (VHCF) regime. The size and type of inclusions in the steel were quantitatively analyzed, and VHCF tests were performed. Some fatigue cracks were found to be initiated in the gaps between inclusions (Al2O3, MgO-Al2O3) and the matrix, while other cracks originated from the interior of inclusions (TiN, MnS). To explain the related mechanism, the tessellated stresses between inclusions and the matrix were calculated and compared with the yield stress of the matrix. Results revealed that the inclusions could be classified into two types under VHCF; of these two, only one type could be regarded as holes. Findings in this research provide a better understanding of how inclusions affect the high cycle fatigue properties of bearing steel.

The Effect of Defects on the Fatigue Initiation Process in Two P/M Superalloys.

DTIC Science & Technology

1980-09-01

determine the effect of Sdfect size, shape, and population on the fatigue initiation process in two high strength P/M superalloys, AF-l5 and AF2-lDA. The...to systematically determine the effects of defect size, shape, and population on fatigue. It is true that certain trends have been established...to determine the relative effects of defect size, shape, and population on the crack initiation life of a representative engineering material

Location, location & size: defects close to surfaces dominate fatigue crack initiation

NASA Astrophysics Data System (ADS)

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-03-01

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards

Location, location &size: defects close to surfaces dominate fatigue crack initiation.

PubMed

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-03-27

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards.

Location, location & size: defects close to surfaces dominate fatigue crack initiation

PubMed Central

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-01-01

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards PMID:28345599

Some Observations on Damage Tolerance Analyses in Pressure Vessels

NASA Technical Reports Server (NTRS)

Raju, Ivatury S.; Dawicke, David S.; Hampton, Roy W.

2017-01-01

AIAA standards S080 and S081 are applicable for certification of metallic pressure vessels (PV) and composite overwrap pressure vessels (COPV), respectively. These standards require damage tolerance analyses with a minimum reliable detectible flaw/crack and demonstration of safe life four times the service life with these cracks at the worst-case location in the PVs and oriented perpendicular to the maximum principal tensile stress. The standards require consideration of semi-elliptical surface cracks in the range of aspect ratios (crack depth a to half of the surface length c, i.e., (a/c) of 0.2 to 1). NASA-STD-5009 provides the minimum reliably detectible standard crack sizes (90/95 probability of detection (POD) for several non-destructive evaluation (NDE) methods (eddy current (ET), penetrant (PT), radiography (RT) and ultrasonic (UT)) for the two limits of the aspect ratio range required by the AIAA standards. This paper tries to answer the questions: can the safe life analysis consider only the life for the crack sizes at the two required limits, or endpoints, of the (a/c) range for the NDE method used or does the analysis need to consider values within that range? What would be an appropriate method to interpolate 90/95 POD crack sizes at intermediate (a/c) values? Several procedures to develop combinations of a and c within the specified range are explored. A simple linear relationship between a and c is chosen to compare the effects of seven different approaches to determine combinations of aj and cj that are between the (a/c) endpoints. Two of the seven are selected for evaluation: Approach I, the simple linear relationship, and a more conservative option, Approach III. For each of these two Approaches, the lives are computed for initial semi-elliptic crack configurations in a plate subjected to remote tensile fatigue loading with an R-ratio of 0.1, for an assumed material evaluated using NASGRO (registered 4) version 8.1. These calculations demonstrate that for this loading, using Approach I and the initial detectable crack sizes at the (a/c) endpoints in 5009 specified for the ET and UT NDE methods, the smallest life is not at the two required limits of the (a/c) range, but rather is at an intermediate configuration in the range (a/c) of 0.4 to 0.6. Similar analyses using both Approach I and III with the initial detectable crack size at the (a/c) endpoints in 5009 for PT NDE showed the smallest life may be at an (a/c) endpoint or an intermediate (a/c), depending upon which Approach is used. As such, analyses that interrogate only the two (a/c) values of 0.2 and 1 may result in unconservative life predictions. The standard practice may need to be revised based on these results.

Analytical and experimental investigation of microstructural alterations in bearing steel in rolling contact fatigue

NASA Astrophysics Data System (ADS)

Mobasher Moghaddam, Sina

Rolling Contact Fatigue (RCF) is one the most common failure modes in bearings. RCF is usually associated with particular microstructural alterations. Such alterations (i.e. white etching cracks, butterflies, etc.) which lead to RCF failure are known to be among the most concerning matters to bearing industry. In the current work, an analytical as well as experimental approaches are used to investigate "butterfly wing" formation, crack initiation and propagation from inclusions. A new damage evolution equation coupled with a FE model is employed to account for the effect of mean stresses and alternating stresses simultaneously to investigate butterfly formation. The proposed damage evolution law matches experimentally observed butterfly orientation, shape, and size successfully. The model is used to obtain S-N results for butterfly formation at different Hertzian load levels. The results corroborate well with the experimental data available in the open literature. The model is used to predict debonding at the inclusion/matrix interface and the most vulnerable regions for crack initiation on butterfly/matrix interface. A new variable called butterfly formation index (BFI) is introduced to manifest the dependence of wing formation on depth. The value of critical damage inside the butterfly wings was obtained experimentally and was then used to simulate damage evolution. Voronoi tessellation was used to develop the FEM domains to capture the effect of microstructural randomness on butterfly wing formation, crack initiation and propagation. Then, the effects of different inclusion characteristics such as size, depth, and stiffness on RCF life are studied. The results show that stiffness of an inclusion and its location has a significant effect on the RCF life: stiffer inclusions and inclusions located at the depth of maximum shear stress reversal are more detrimental to the RCF life. Stress concentrations are not significantly affected by inclusion size for the cases investigated; however, a stereology study showed that larger inclusions have a higher chance to be located at the critical depth and cause failure. Crack maps were recorded and compared to spall geometries observed experimentally. The results show that crack initiation locations and final spall shapes are similar to what has been observed in failed bearings.

Strength and Microstructure of Ceramics.

DTIC Science & Technology

1987-11-01

triangular slab. 12-mm edge length and 2-mm thickness. to produce crack 7 mm long. Starter notch length portantly. the strength plateau at small flaw sizes...however. a tapered the starter notch tip. "Pop-in" behavior of this kind is not uncom- geometry was used. width increasing in the direction of ultimate...mon in notched specimens, of course: in such cases the initial crack propagation. The main crack was started at a sawcut notch fracture response can be

Effect of precrack halos on kic determined by the surface crack in flexure method. Final report, August 1995-May 1997

DOE Office of Scientific and Technical Information (OSTI.GOV)

Swab, J.J.; Quinn, G.D.

1997-12-01

The surface crack in flexure (SCF) method, which is used to determine the fracture toughness of dense ceramics necessitates the measurement of precrack sizes by fractographic examination. Stable crack extension may occur from flaws under ambient room-temperature conditions, even in the relatively short time under load during fast fracture strength or fracture toughness testing. In this paper, fractographic techniques are used to characterize evidence of stable crack extension, a halo, around Knoop indentation surface cracks. Optical examination of the fracture surfaces of a high-purity Al2O3, an AlN, a glass-ceramic, and a MgF2 revealed the presence of a halo around themore » periphery of each precrack. The halo in the AlN was merely an optical effect due to crack reorientation, while the halo in the MgF2 was due to indentation-induced residual stresses initiating crack growth. However, for the Al2O3 and the glass-ceramic, environmentally assisted slow crack growth (SCG) was the cause of the halo. In the latter two materials, this stable crack extension must be included as part of the critical crack size in order to determine the appropriate fracture toughness.« less

Detection, discrimination, and real-time tracking of cracks in rotating disks

NASA Astrophysics Data System (ADS)

Haase, Wayne C.; Drumm, Michael J.

2002-06-01

The purpose of this effort was to develop a system* to detect, discriminate and track fatigue cracks in rotating disks. Aimed primarily at jet engines in flight applications, the system also has value for detecting cracks in a spin pit during low cycle fatigue testing, and for monitoring the health of steam turbines and land-based gas turbine engines for maintenance purposes. The results of this effort produced: a physics-based model that describes the change in the center of mass of a rotating disk using damping ratio, initial unbalance and crack size as parameters; the development of a data acquisition and analysis system that can detect and discriminate a crack using a single cycle of data; and initial validation of the model through testing in a spin pit. The development of the physics-based model also pointed to the most likely regimes for crack detection; identified specific powers of (omega) search for in specific regimes; dictated a particular type of data acquisition for crack discrimination; and demonstrated a need for a higher signal-to-noise ratio in the measurement of the basic vibration signal.

Effects of Grain Size on the Fatigue Properties in Cold-Expanded Austenitic HNSs

NASA Astrophysics Data System (ADS)

Shin, Jong-Ho; Kim, Young-Deak; Lee, Jong-Wook

2018-05-01

Cold-expanded austenitic high nitrogen steel (HNS) was subjected to investigate the effects of grain size on the stress-controlled high cycle fatigue (HCF) as well as the strain-controlled low cycle fatigue (LCF) properties. The austenitic HNSs with two different grain sizes (160 and 292 μm) were fabricated by the different hot forging strain. The fine-grained (FG) specimen exhibited longer LCF life and higher HCF limit than those of the coarse-grained (CG) specimen. Fatigue crack growth testing showed that crack propagation rate in the FG specimen was the same as that in the CG specimen, implying that crack propagation rate did not affect the discrepancy of LCF life and HCF limit between two cold-expanded HNSs. Therefore, it was estimated that superior LCF and HCF properties in the FG specimen resulted from the retardation of the fatigue crack initiation as compared with the CG specimen. Transmission electron microscopy showed that the effective grain size including twin boundaries are much finer in the FG specimen than that in the CG specimen, which can give favorable contributions to strengthening.

NASA/FLAGRO - FATIGUE CRACK GROWTH COMPUTER PROGRAM

NASA Technical Reports Server (NTRS)

Forman, R. G.

1994-01-01

Structural flaws and cracks may grow under fatigue inducing loads and, upon reaching a critical size, cause structural failure to occur. The growth of these flaws and cracks may occur at load levels well below the ultimate load bearing capability of the structure. The Fatigue Crack Growth Computer Program, NASA/FLAGRO, was developed as an aid in predicting the growth of pre-existing flaws and cracks in structural components of space systems. The earlier version of the program, FLAGRO4, was the primary analysis tool used by Rockwell International and the Shuttle subcontractors for fracture control analysis on the Space Shuttle. NASA/FLAGRO is an enhanced version of the program and incorporates state-of-the-art improvements in both fracture mechanics and computer technology. NASA/FLAGRO provides the fracture mechanics analyst with a computerized method of evaluating the "safe crack growth life" capabilities of structural components. NASA/FLAGRO could also be used to evaluate the damage tolerance aspects of a given structural design. The propagation of an existing crack is governed by the stress field in the vicinity of the crack tip. The stress intensity factor is defined in terms of the relationship between the stress field magnitude and the crack size. The propagation of the crack becomes catastrophic when the local stress intensity factor reaches the fracture toughness of the material. NASA/FLAGRO predicts crack growth using a two-dimensional model which predicts growth independently in two directions based on the calculation of stress intensity factors. The analyst can choose to use either a crack growth rate equation or a nonlinear interpolation routine based on tabular data. The growth rate equation is a modified Forman equation which can be converted to a Paris or Walker equation by substituting different values into the exponent. This equation provides accuracy and versatility and can be fit to data using standard least squares methods. Stress-intensity factor numerical values can be computed for making comparisons or checks of solutions. NASA/FLAGRO can check for failure of a part-through crack in the mode of a through crack when net ligament yielding occurs. NASA/FLAGRO has a number of special subroutines and files which provide enhanced capabilities and easy entry of data. These include crack case solutions, cyclic load spectrums, nondestructive examination initial flaw sizes, table interpolation, and material properties. The materials properties files are divided into two types, a user defined file and a fixed file. Data is entered and stored in the user defined file during program execution, while the fixed file contains already coded-in property value data for many different materials. Prompted input from CRT terminals consists of initial crack definition (which can be defined automatically), rate solution type, flaw type and geometry, material properties (if they are not in the built-in tables of material data), load spectrum data (if not included in the loads spectrum file), and design limit stress levels. NASA/FLAGRO output includes an echo of the input with any error or warning messages, the final crack size, whether or not critical crack size has been reached for the specified stress level, and a life history profile of the crack propagation. NASA/FLAGRO is modularly designed to facilitate revisions and operation on minicomputers. The program was implemented on a DEC VAX 11/780 with the VMS operating system. NASA/FLAGRO is written in FORTRAN77 and has a memory requirement of 1.4 MB. The program was developed in 1986.

Fracture Test Methods for Plastically Responding COPV Liners

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Lewis, Joseph C.

2009-01-01

An experimental procedure for evaluating the validity of using uniaxial tests to provide a conservative bound on the fatigue crack growth rate behavior small cracks in bi-axially loaded Composite Overwrapped Pressure Vessel (COPV) liners is described. The experimental procedure included the use of a laser notch to quickly generate small surface fatigue cracks with the desired size and aspect ratios. An out-of-plane constraint system was designed to allow fully reversed, fully plastic testing of thin sheet uniaxial coupons. Finally, a method was developed to determine to initiate small cracks in the liner of COPVs.

Experimental and Numerical Analysis of Fracture in 41Cr4 Steel - Issues of the Stationary Cracks

NASA Astrophysics Data System (ADS)

Graba, M.

2018-02-01

This paper analyzes the process of fracture in 41Cr4 steel on the basis of experimental and numerical data obtained for non-propagating cracks. The author's previous and latest experimental results were used to determine the apparent crack initiation moment and fracture toughness for the material under plane strain conditions. Numerical simulations were carried out to assess changes in the J-integral, the crack tip opening displacement, the size of the plastic region and the distribution of stresses around the crack tip. A complex numerical analysis based on the true stress-strain curve was performed to determine the behavior of 41Cr4 steel under increasing external loads.

The Role of Retained Austenite on the Mechanical Properties of a Low Carbon 3Mn-1.5Ni Steel

NASA Astrophysics Data System (ADS)

Chen, Jun; Zhang, Wei-na; Liu, Zhen-yu; Wang, Guo-dong

2017-12-01

The present studies focus on the correlation between retained austenite characteristics and the cryogenic temperature Charpy impact toughness, strength, and plasticity. The steels with different volume fractions and stabilities of retained austenite were prepared by quenching followed by intercritical heat treatment, and the microstructure was characterized using scanning electron microscope, electron back-scattered diffraction, and X-ray diffraction. The grain size, dislocation density, crack initiation energy, and crack propagation energy were quantified. It has been demonstrated that the volume fraction of retained austenite plays a significant role in the reduction of the measured yield strength and the effect of tempered martensite/ferrite matrix on cryogenic temperature impact toughness can be assumed to be similar due to the similar grain size, dislocation density and element content in solution for different heat treatments. It was found that the stability of retained austenite plays a determining role in the increase of cryogenic temperature impact toughness. Furthermore, the dependence of the crack propagation energy on retained austenite is much greater than that of the crack initiation energy. Generally, an excellent UTS × TEL does not produce good cryogenic temperature impact toughness.

Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nelaturu, Phalgun; Jana, Saumyadeep; Mishra, Rajiv S.

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution –more » the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.« less

Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

DOE PAGES

Nelaturu, Phalgun; Jana, Saumyadeep; Mishra, Rajiv S.; ...

2018-01-11

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution –more » the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.« less

Assessment of crack growth in a space shuttle main engine first-stage, high-pressure fuel turbopump blade

NASA Technical Reports Server (NTRS)

Abdul-Aziz, Ali

1993-01-01

A two-dimensional finite element fracture mechanics analysis of a space shuttle main engine (SSME) turbine blade firtree was performed using the MARC finite element code. The analysis was conducted under combined effects of thermal and mechanical loads at steady-state conditions. Data from a typical engine stand cycle of the SSME were used to run a heat transfer analysis and, subsequently, a thermal structural fracture mechanics analysis. Temperature and stress contours for the firtree under these operating conditions were generated. High stresses were found at the firtree lobes where crack initiation was triggered. A life assessment of the firtree was done by assuming an initial and a final crack size.

Polygonal crack patterns by drying thin films under quasi-two-dimensional confinement

NASA Astrophysics Data System (ADS)

Ma, Xiaolei; Lowensohn, Janna; Burton, Justin

Cracks patterns such as T/Y junction cracks in dried mud are ubiquitous in nature. Although the conditions for cracking in solids is well-known, cracks in colloidal and granular systems are more complex. Here we report the formations of polygonal cracks by drying thin films of corn starch ( 10 μm in diameter) under quasi-2D confinement. We find there are two drying stages before the films are completely dried. Initially, a compaction front invades throughout the film. Then, a second drying stage ''percolates'' throughout the film with a characteristic branching pattern, leading to a dense packing of particles connected by liquid capillary bridges. Finally, polygonal cracks appear as the remaining liquid dries. The same drying kinetics occur for films with different thickness, h, except that fractal-like fracture patterns form in thin films, where the thickness is comparable to the particle size, while polygons form in thick films with many layers of particles. We also find that the average area of the polygons, A, in fully dried films scales with the thickness, A hβ , where β 1 . 5 , and the prefactor depends on the initial packing fraction of the suspension. This form is consistent with a simple energy balance criterion for crack formation.

The Effect of Porosity on Fatigue of Die Cast AM60

NASA Astrophysics Data System (ADS)

Yang, Zhuofei; Kang, Jidong; Wilkinson, David S.

2016-07-01

AM60 high-pressure die castings are known to contain significant porosity which can affect fatigue life. We have studied this using samples drawn from prototype AM60 shock towers by conducting strain-controlled fatigue tests accompanied by X-ray computed tomography analysis. The results show that the machined surface is the preferential location for fatigue crack development, with pores close to these surfaces serving as initiation sites. Fatigue life shows a strong inverse correlation with the size of the fatigue-crack-initiating pore. Pore shape and pore orientation also influence the response. A supplemental study on surface roughness shows that porosity is the dominant factor in fatigue. Tomography enables the link between porosity and fatigue crack initiation to be clearly identified. These data are complemented by SEM observations of the fracture surfaces which are generally flat and full of randomly oriented serration patterns but without long-range fatigue striations.

Gear Crack Propagation Path Studies-- Guidelines Developed for Ultrasafe Design

NASA Technical Reports Server (NTRS)

Lewicki, David G.

2002-01-01

Effective gear designs balance strength, durability, reliability, size, weight, and cost. However, unexpected gear failures may occur even with adequate gear tooth design. To design an extremely safe system, the designer must ask and address the question "What happens when a failure occurs?" With regard to gear-tooth bending fatigue, tooth or rim fractures may occur. For aircraft, a crack that propagated through a rim would be catastrophic, leading to the disengagement of a rotor or propeller, the loss of an aircraft, and possible fatalities. This failure mode should be avoided. However, a crack that propagated through a tooth might or might not be catastrophic, depending on the design and operating conditions. Also, early warning of this failure mode might be possible because of advances in modern diagnostic systems. An analysis was performed at the NASA Glenn Research Center to develop design guidelines to prevent catastrophic rim fracture failure modes in the event of gear-tooth bending fatigue. The finite element method was used with principles of linear elastic fracture mechanics. Crack propagation paths were predicted for a variety of gear tooth and rim configurations. The effects of rim and web thicknesses, initial crack locations, and gear-tooth geometry factors such as diametral pitch, number of teeth, pitch radius, and tooth pressure angle were considered. Design maps of tooth and rim fracture modes, including the effects of gear geometry, applied load, crack size, and material properties were developed. The occurrence of rim fractures significantly increased as the backup ratio (rim thickness divided by tooth height) decreased. The occurrence of rim fractures also increased as the initial crack location was moved down the root of the tooth. Increased rim and web compliance increased the occurrence of rim fractures. For gears with constant-pitch radii, coarser-pitch teeth increased the occurrence of tooth fractures over rim fractures. Also, 25 degree pressure angle teeth increased the occurrence of tooth fractures over rim fractures in comparison to 20 pressure angle teeth. For gears with a constant number of teeth or for gears with constant diametral pitch, varying size had little or no effect on crack propagation paths.

Analytical Methodology for Predicting the Onset of Widespread Fatigue Damage in Fuselage Structure

NASA Technical Reports Server (NTRS)

Harris, Charles E.; Newman, James C., Jr.; Piascik, Robert S.; Starnes, James H., Jr.

1996-01-01

NASA has developed a comprehensive analytical methodology for predicting the onset of widespread fatigue damage in fuselage structure. The determination of the number of flights and operational hours of aircraft service life that are related to the onset of widespread fatigue damage includes analyses for crack initiation, fatigue crack growth, and residual strength. Therefore, the computational capability required to predict analytically the onset of widespread fatigue damage must be able to represent a wide range of crack sizes from the material (microscale) level to the global structural-scale level. NASA studies indicate that the fatigue crack behavior in aircraft structure can be represented conveniently by the following three analysis scales: small three-dimensional cracks at the microscale level, through-the-thickness two-dimensional cracks at the local structural level, and long cracks at the global structural level. The computational requirements for each of these three analysis scales are described in this paper.

A study of fiber volume fraction effects in notched unidirectional SCS-6/Ti-15V-3Cr-3Al-3Sn composite. Ph.D. Thesis Final Report

NASA Technical Reports Server (NTRS)

Covey, Steven J.

1993-01-01

Notched unidirectional SCS-6/Ti-15-3 composite of three different fiber volume fractions (vf = 0.15, 0.37, and 0.41) was investigated for various room temperature microstructural and material properties including: fatigue crack initiation, fatigue crack growth, and fracture toughness. While the matrix hardness is similar for all fiber volume fractions, the fiber/matrix interfacial shear strength and matrix residual stress increases with fiber volume fraction. The composite fatigue crack initiation stress is shown to be matrix controlled and occurs when the net maximum matrix stress approaches the endurance limit stress of the matrix. A model is presented which includes residual stresses and presents the composite initiation stress as a function of fiber volume fraction. This model predicts a maximum composite initiation stress at vf approximately 0.15 which agrees with the experimental data. The applied composite stress levels were increased as necessary for continued crack growth. The applied Delta(K) values at crack arrest increase with fiber volume fraction by an amount better approximated using an energy based formulation rather than when scaled linear with modulus. After crack arrest, the crack growth rate exponents for vf37 and vf41 were much lower and toughness much higher, when compared to the unreinforced matrix, because of the bridged region which parades with the propagating fatigue crack. However, the vf15 material exhibited a higher crack growth rate exponent and lower toughness than the unreinforced matrix because once the bridged fibers nearest the crack mouth broke, the stress redistribution broke all bridged fibers, leaving an unbridged crack. Degraded, unbridged behavior is modeled using the residual stress state in the matrix ahead of the crack tip. Plastic zone sizes were directly measured using a metallographic technique and allow prediction of an effective matrix stress intensity which agrees with the fiber pressure model if residual stresses are considered. The sophisticated macro/micro finite element models of the 0.15 and 0.37 fiber volume fractions presented show good agreement with experimental data and the fiber pressure model when an estimated effective fiber/matrix debond length is used.

Crack Turning in Integrally Stiffened Aircraft Structures

NASA Technical Reports Server (NTRS)

Pettit, Richard Glen

2000-01-01

Current emphasis in the aircraft industry toward reducing manufacturing cost has created a renewed interest in integrally stiffened structures. Crack turning has been identified as an approach to improve the damage tolerance and fail-safety of this class of structures. A desired behavior is for skin cracks to turn before reaching a stiffener, instead of growing straight through. A crack in a pressurized fuselage encounters high T-stress as it nears the stiffener--a condition favorable to crack turning. Also, the tear resistance of aluminum alloys typically varies with crack orientation, a form of anisotropy that can influence the crack path. The present work addresses these issues with a study of crack turning in two-dimensions, including the effects of both T-stress and fracture anisotropy. Both effects are shown to have relation to the process zone size, an interaction that is central to this study. Following an introduction to the problem, the T-stress effect is studied for a slightly curved semi-infinite crack with a cohesive process zone, yielding a closed form expression for the future crack path in an infinite medium. For a given initial crack tip curvature and tensile T-stress, the crack path instability is found to increase with process zone size. Fracture orthotropy is treated using a simple function to interpolate between the two principal fracture resistance values in two-dimensions. An extension to three-dimensions interpolates between the six principal values of fracture resistance. Also discussed is the transition between mode I and mode II fracture in metals. For isotropic materials, there is evidence that the crack seeks out a direction of either local symmetry (pure mode I) or local asymmetry (pure mode II) growth. For orthotropic materials the favored states are not pure modal, and have mode mixity that is a function of crack orientation.

Interpretation of Fracture Toughness and R-Curve Behavior by Direct Observation of Microfracture Process in Ti-Based Dendrite-Containing Amorphous Alloys

NASA Astrophysics Data System (ADS)

Jeon, Changwoo; Kim, Choongnyun Paul; Kim, Hyoung Seop; Lee, Sunghak

2015-04-01

Fracture properties of Ti-based amorphous alloys containing ductile β dendrites were explained by directly observing microfracture processes. Three Ti-based amorphous alloys were fabricated by adding Ti, Zr, V, Ni, Al, and Be into a Ti-6Al-4V alloy by a vacuum arc melting method. The effective sizes of dendrites varied from 63 to 104 μm, while their volume fractions were almost constant within the range from 74 to 76 pct. The observation of the microfracture of the alloy containing coarse dendrites revealed that a microcrack initiated at the amorphous matrix of the notch tip and propagated along the amorphous matrix. In the alloy containing fine dendrites, the crack propagation was frequently blocked by dendrites, and many deformation bands were formed near or in front of the propagating crack, thereby resulting in a zig-zag fracture path. Crack initiation toughness was almost the same at 35 to 36 MPa√m within error ranges in the three alloys because it was heavily affected by the stress applied to the specimen at the time of crack initiation at the crack tip as well as strength levels of the alloys. According to the R-curve behavior, however, the best overall fracture properties in the alloy containing fine dendrites were explained by mechanisms of blocking of the crack growth and crack blunting and deformation band formation at dendrites.

Fatigue Behavior and the Relationship Between Crack Propagation and the Slit Configuration of C/c Composites

NASA Astrophysics Data System (ADS)

Ferdous, Md. Shafiul; Setyabudi, Sofyan Arief; Makabe, Chobin; Fujikawa, Masaki

2013-05-01

The fatigue and fracture behavior of C/C composites fabricated using fine-woven carbon fiber laminates with α = 0/90° direction were investigated. Also, the phenomenon of crack growth behavior and the shear damage in the fiber bundle was discussed. Slits of several sizes were cut on both sides of a test section and different sizes of slit length were chosen. The effect of the slit configuration on crack initiation and growth behavior was observed. Specimens with blunt-notches and center-holes were also used to compare the fatigue strength and crack growth behavior. Non-propagating cracks were observed and fatigue limit was defined as the maximum stress at which specimen did not break for N = 107 cycles stress application. The longest fatigue life was obtained in the case of specimens with shorter slits. The relationships between fatigue strengths and specimen shapes were analyzed by stress concentration, Kt, and stress intensity factor, KI. The effect of slit configuration on fatigue strength was then discussed regarding both the experimental and calculated consequences.

Nano-Pore Size Analysis by SAXS Method of Cementitious Mortars Undergoing Delayed Ettringite Formation

NASA Astrophysics Data System (ADS)

Shekar, Yamini

This research investigates the nano-scale pore structure of cementitious mortars undergoing delayed ettringite formation (DEF) using small angle x-ray scattering (SAXS). DEF has been known to cause expansion and cracking during later ages (around 4000 days) in concrete that has been heat cured at temperatures of 70°C or above. Though DEF normally occurs in heat cured concrete, mass cured concrete can also experience DEF. Large crystalline pressures result in smaller pore sizes. The objectives of this research are: (1) to investigate why some samples expand early than later expansion, (2) to evaluate the effects of curing conditions and pore size distributions at high temperatures, and (3) to assess the evolution of the pore size distributions over time. The most important outcome of the research is the pore sizes obtained from SAXS were used in the development of a 3-stage model. From the data obtained, the pore sizes increase in stage 1 due to initial ettringite formation and in turn filling up the smallest pores. Once the critical pore size threshold is reached (around 20nm) stage 2 is formed due to cracking which tends to decrease in the pore sizes. Finally, in stage 3, the cracking continues, therefore increasing in the pore size.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anikovsky, V.V.; Karzov, G.P.; Timofeev, B.T.

The paper demonstrates an insufficiency of some requirements native Norms (when comparing them with the foreign requirements for the consideration of calculating situations): (1) leak before break (LBB); (2) short cracks; (3) preliminary loading (warm prestressing). In particular, the paper presents (1) Comparison of native and foreign normative requirements (PNAE G-7-002-86, Code ASME, BS 1515, KTA) on permissible stress levels and specifically on the estimation of crack initiation and propagation; (2) comparison of RF and USA Norms of pressure vessel material acceptance and also data of pressure vessel hydrotests; (3) comparison of Norms on the presence of defects (RF andmore » USA) in NPP vessels, developments of defect schematization rules; foundation of a calculated defect (semi-axis correlation a/b) for pressure vessel and piping components: (4) sequence of defect estimation (growth of initial defects and critical crack sizes) proceeding from the concept LBB; (5) analysis of crack initiation and propagation conditions according to the acting Norms (including crack jumps); (6) necessity to correct estimation methods of ultimate states of brittle an ductile fracture and elastic-plastic region as applied to calculating situation: (a) LBB and (b) short cracks; (7) necessity to correct estimation methods of ultimate states with the consideration of static and cyclic loading (warm prestressing effect) of pressure vessel; estimation of the effect stability; (8) proposals on PNAE G-7-002-86 Norm corrections.« less

Simulation of crack propagation in rock in plasma blasting technology

NASA Astrophysics Data System (ADS)

Ikkurthi, V. R.; Tahiliani, K.; Chaturvedi, S.

Plasma Blasting Technology (PBT) involves the production of a pulsed electrical discharge by inserting a blasting probe in a water-filled cavity drilled in a rock, which produces shocks or pressure waves in the water. These pulses then propagate into the rock, leading to fracture. In this paper, we present the results of two-dimensional hydrodynamic simulations using the SHALE code to study crack propagation in rock. Three separate issues have been examined. Firstly, assuming that a constant pressure P is maintained in the cavity for a time τ , we have determined the P- τ curve that just cracks a given rock into at least two large-sized parts. This study shows that there exists an optimal pressure level for cracking a given rock-type and geometry. Secondly, we have varied the volume of water in which the initial energy E is deposited, which corresponds to different initial peak pressures Ppeak. We have determined the E- Ppeak curve that just breaks the rock into four large-sized parts. It is found that there must be an optimal Ppeak that lowers the energy consumption, but with acceptable probe damage. Thirdly, we have attempted to identify the dominant mechanism of rock fracture. We also highlight some numerical errors that must be kept in mind in such simulations.

Grainex Mar-M 247 Turbine Disk Life Study for NASA's High Temperature High Speed Turbine Seal Test Facility

NASA Technical Reports Server (NTRS)

Delgado, Irebert R.

2015-01-01

An experimental and analytical fatigue life study was performed on the Grainex Mar-M 247 disk used in NASA s Turbine Seal Test Facility. To preclude fatigue cracks from growing to critical size in the NASA disk bolt holes due to cyclic loading at severe test conditions, a retirement-for-cause methodology was adopted to detect and monitor cracks within the bolt holes using eddy-current inspection. For the NASA disk material that was tested, the fatigue strain-life to crack initiation at a total strain of 0.5 percent, a minimum to maximum strain ratio of 0, and a bolt hole temperature of 649 C was calculated to be 665 cycles using -99.95 percent prediction intervals. The fatigue crack propagation life was calculated to be 367 cycles after implementing a safety factor of 2 on life. Thus, the NASA disk bolt hole total life or retirement life was determined to be 1032 cycles at a crack depth of 0.501 mm. An initial NASA disk bolt hole inspection at 665 cycles is suggested with 50 cycle inspection intervals thereafter to monitor fatigue crack growth.

Fatigue pre-cracking and fracture toughness in polycrystalline tungsten and molybdenum

NASA Astrophysics Data System (ADS)

Taguchi, Katsuya; Nakadate, Kazuhito; Matsuo, Satoru; Tokunaga, Kazutoshi; Kurishita, Hiroaki

2018-01-01

Fatigue pre-cracking performance and fracture toughness in polycrystalline tungsten (W) and molybdenum (Mo) have been investigated in relation to grain boundary (GB) configuration with respect to the crack advance direction. Sub-sized, single edge notched bend (SENB) specimens with three different orientations, R-L (ASTM notation) for a forged Mo rod and L-S and T-S for a rolled W plate, were pre-cracked in two steps: fully uniaxial compression fatigue loading to provoke crack initiation and its stable growth from the notch root, and subsequent 3-point bend (3PB) fatigue loading to extend the crack. The latter step intends to minimize the influence of the residual tensile stresses generated during compression fatigue by moving the crack tip away from the plastic zone. It is shown that fatigue pre-cracking performance, especially pre-crack extension behavior, is significantly affected by the specimen orientation. The R-L orientation, giving the easiest cracking path, permitted crack extension completely beyond the plastic zone, while the L-S and T-S orientations with the thickness cracking direction of the rolled plate sustained the crack lengths around or possibly within the plastic zone size due to difficulty in crack advance through an aligned grain structure. Room temperature fracture toughness tests revealed that the 3PB fatigued specimens exhibited appreciably higher fracture toughness by about 30% for R-L, 40% for L-S and 60% for T-S than the specimens of each orientation pre-cracked by compression fatigue only. This indicates that 3PB fatigue provides the crack tip front out of the residual tensile stress zone by crack extension or leads to reduction in the residual stresses at the crack tip front. Strong dependence of fracture toughness on GB configuration was evident. The obtained fracture toughness values are compared with those in the literature and its strong GB configuration dependence is discussed in connection with the appearance of pop-in.

Transient features and growth behavior of artificial cracks during the initial damage period.

PubMed

Ma, Bin; Wang, Ke; Lu, Menglei; Zhang, Li; Zhang, Lei; Zhang, Jinlong; Cheng, Xinbin; Wang, Zhanshan

2017-02-01

The laser damage of transmission elements contains a series of complex processes and physical phenomena. The final morphology is a crater structure with different sizes and shapes. The formation and development of the crater are also accompanied by the generation, extension, and submersion of cracks. The growth characteristics of craters and cracks are important in the thermal-mechanism damage research. By using pump-probe detection and an imaging technique with a nanosecond pulsewidth probe laser, we obtained the formation time of the crack structure in the radial and circumferential directions. We carried out statistical analysis in angle, number, and crack length. We further analyzed the relationship between cracks and stress intensity or laser irradiation energy as well as the crack evolution process and the inner link between cracks and pit growth. We used an artificial indentation defect to investigate the time-domain evolution of crack growth, growth speed, transient morphology, and the characteristics of crater expansion. The results can be used to elucidate thermal stress effects on cracks, time-domain evolution of the damage structure, and the damage growth mechanism.

The interaction of fatigue cracks with a residual stress field using thermoelastic stress analysis and synchrotron X-ray diffraction experiments

PubMed Central

Amjad, Khurram; Asquith, David; Sebastian, Christopher M.; Wang, Wei-Chung

2017-01-01

This article presents an experimental study on the fatigue behaviour of cracks emanating from cold-expanded holes utilizing thermoelastic stress analysis (TSA) and synchrotron X-ray diffraction (SXRD) techniques with the aim of resolving the long-standing ambiguity in the literature regarding potential relaxation, or modification, of beneficial compressive residual stresses as a result of fatigue crack propagation. The crack growth rates are found to be substantially lower as the crack tip moved through the residual stress zone induced by cold expansion. The TSA results demonstrated that the crack tip plastic zones were reduced in size by the presence of the residual compressive stresses induced by cold expansion. The crack tip plastic zones were found to be insignificant in size in comparison to the residual stress zone resulting from cold expansion, which implied that they were unlikely to have had a notable impact on the surrounding residual stresses induced by cold expansion. The residual stress distributions measured along the direction of crack growth, using SXRD, showed no signs of any significant stress relaxation or redistribution, which validates the conclusions drawn from the TSA data. Fractographic analysis qualitatively confirmed the influence on crack initiation of the residual stresses induced by the cold expansion. It was found that the application of single compressive overload caused a relaxation, or reduction in the residual stresses, which has wider implications for improving the fatigue life. PMID:29291095

The Effects of Shot and Laser Peening on Fatigue Life and Crack Growth in 2024 Aluminum Alloy and 4340 Steel

NASA Technical Reports Server (NTRS)

Everett, R. A., Jr.; Matthews, W. T.; Prabhakaran, R.; Newman, J. C., Jr.; Dubberly, M. J.

2001-01-01

Fatigue and crack growth tests have been conducted on 4340 steel and 2024-T3 aluminum alloy, respectively, to assess the effects of shot peening on fatigue life and the effects of shot and laser peening on crack growth. Two current programs involving fixed and rotary-wing aircraft will not be using shot peened structures. Since the shot peening compressive residual stress depth is usually less than the 0.05-inch initial damage tolerance crack size, it is believed by some that shot peening should have no beneficial effects toward retarding crack growth. In this study cracks were initiated from an electronic-discharged machining flaw which was cycled to produce a fatigue crack of approximately 0.05-inches in length and then the specimens were peened. Test results showed that after peening the crack growth rates were noticeably slower when the cracks were fairly short for both the shot and laser peened specimens resulting in a crack growth life that was a factor of 2 to 4 times greater than the results of the average unpeened test. Once the cracks reached a length of approximately 0.1-inches the growth rates were about the same for the peened and unpeened specimens. Fatigue tests on 4340 steel showed that the endurance limit of a test specimen with a 0.002-inch-deep machining-like scratch was reduced by approximately 40 percent. However, if the "scratched" specimen was shot peened after inserting the scratch, the fatigue life returned to almost 100 percent of the unflawed specimens original fatigue life.

Structure, Dynamic Cracking Resistance, and Crack Growth Micromechanism in Pipe Billets after Thermomechanical Treatment

NASA Astrophysics Data System (ADS)

Simonov, M. Yu.; Simonov, Yu. N.; Shaimanov, G. S.

2018-01-01

The structure, dynamic cracking resistance, and micromechanisms of crack growth in initially highly tempered pipe billets made of structural carbon steel are studied after thermomechanical treatment, including cold plastic deformation by radial forging followed by annealing, under various conditions. The strength is found to be maximum after cold radial forging followed by annealing at 300°C. Cold radial forging and annealing at 600°C are shown to cause the formation of an ultrafine-grained structure with an average grain/subgrain size of 900 nm. The structural features formed in both the axial and the transverse direction after cold radial forging have been revealed. The mechanism of crack growth after heat treatment and thermomechanical treatment has been studied. The fracture surface elements formed during dynamic-crackingresistance tests have been qualitatively analyzed.

Biaxial fatigue crack propagation behavior of perfluorosulfonic-acid membranes

NASA Astrophysics Data System (ADS)

Lin, Qiang; Shi, Shouwen; Wang, Lei; Chen, Xu; Chen, Gang

2018-04-01

Perfluorosulfonic-acid membranes have long been used as the typical electrolyte for polymer-electrolyte fuel cells, which not only transport proton and water but also serve as barriers to prevent reactants mixing. However, too often the structural integrity of perfluorosulfonic-acid membranes is impaired by membrane thinning or cracks/pinholes formation induced by mechanical and chemical degradations. Despite the increasing number of studies that report crack formation, such as crack size and shape, the underlying mechanism and driving forces have not been well explored. In this paper, the fatigue crack propagation behaviors of Nafion membranes subjected to biaxial loading conditions have been investigated. In particular, the fatigue crack growth rates of flat cracks in responses to different loading conditions are compared, and the impact of transverse stress on fatigue crack growth rate is clarified. In addition, the crack paths for slant cracks under both uniaxial and biaxial loading conditions are discussed, which are similar in geometry to those found after accelerated stress testing of fuel cells. The directions of initial crack propagation are calculated theoretically and compared with experimental observations, which are in good agreement. The findings reported here lays the foundation for understanding of mechanical failure of membranes.

Vascularized networks with two optimized channel sizes

NASA Astrophysics Data System (ADS)

Wang, K.-M.; Lorente, S.; Bejan, A.

2006-07-01

This paper reports the development of optimal vascularization for supplying self-healing smart materials with liquid that fills and seals the cracks that may occur throughout their volume. The vascularization consists of two-dimensional grids of interconnected orthogonal channels with two hydraulic diameters (D1, D2). The smallest square loop is designed to match the size (d) of the smallest crack. The network is sealed with respect to the outside and is filled with pressurized liquid. In this work, the crack site is modelled as a small spherical volume of diameter d. When a crack is formed, fluid flows from neighbouring channels to the crack site. This volume-to-point flow is optimized using two formulations: (1) incompressible liquid from steady constant-strength sources located in every node of the grid and from sources located equidistantly on the perimeter of the vascularized body of length scale L and (2) slightly compressible liquid from an initially pressurized grid discharging in time-dependent fashion into one crack site. The flow in every channel is laminar and fully developed. The objectives are (a) to minimize the global resistance to the flow from the grid to the crack site and (b) to minimize the time of discharge from the pressurized grid to the crack site. It is shown that methods (a) and (b) yield similar results. There is an optimal ratio of channel diameters D2/D1 < 1, and it decreases as the grid fineness (L/d) increases. The global flow resistance of the grid with optimized ratio of diameters is approximately half of the resistance of the corresponding grid with one channel size (D1 = D2). The optimized ratio of diameters and the minimized global resistance depend on how the grid intersects the crack site: this effect is minor and stresses the robustness of the vascularized design.

Fracture analysis for a penny-shaped crack problem of a superconducting cylinder in a parallel magnetic field

NASA Astrophysics Data System (ADS)

Gao, S. W.; Feng, W. J.; Fang, X. Q.; Zhang, G. L.

2014-11-01

In this work, the penny-shaped crack problem is investigated for an infinite long superconducting cylinder under electromagnetic forces. The distributions of magnetic flux density in the superconducting cylinder are obtained analytically for both the zero-field cooling (ZFC) and the field cooling (FC) activation processes, where the magnetically impermeable crack surface condition and the Bean model outside the crack region are adopted. Based on the finite element method (FEM), the stress intensity factor (SIF) and energy release rate (ERR) at the crack tips in the process of field descent are further numerically calculated. Numerical results obtained show that according to the maximal energy release rate criterion, the FC process is generally easier to enhance crack initiation and propagation than the ZFC activation process. On the other hand, for the FC activation process, the larger the maximal applied magnetic field, more likely the crack propagates. Additionally, crack size has important and slightly different effects on the crack extension forces for the ZFC and FC cases. Thus, all of the activation processes, the applied field and the diameter of the penny-shaped crack have significant effects on the intensity analysis and design of superconducting materials.

Study on underclad cracking in nuclear reactor vessel steels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Horiya, T.; Takeda, T.; Yamato, K.

1985-02-01

Susceptibility to underclad cracking in nuclear reactor vessel steels, such as SA533 Grade B Class 1 and SA508 Class 2, was studied in detail. A convenient simulation test method using simulated HAZ specimens of small size has been developed for quantitative evaluation of susceptibility to underclad cracks. The method can predict precisely the cracking behavior in weldments of steels with relative low crack susceptibility. The effect of chemical compositions on susceptibility to the cracking was examined systematically using the developed simulation test method and the following index was obtained from the test results: U = 20(V) + 7(C) + 4(Mo)more » + (Cr) + (Cu) - 0.5(Mn) + 1.5 log(X) X = Al . . . Al/2N less than or equal to 1 X = 2N . . . Al/2N > 1 It was confirmed that the new index (U) is useful for the prediction of crack susceptibility of the nuclear vessel steels; i.e., no crack initiation is detected in weldments in the roller bend test for steels having U value below 0.90.« less

Application of Viscoelastic Fracture Model and Non-uniform Crack Initiation at Clinically Relevant Notches in Crosslinked UHMWPE

PubMed Central

Sirimamilla, P. Abhiram; Furmanski, Jevan; Rimnac, Clare M.

2012-01-01

The mechanism of crack initiation from a clinically relevant notch is not well-understood for crosslinked ultra high molecular weight polyethylene (UHMWPE) used in total joint replacement components. Static mode driving forces, rather than the cyclic mode conditions typically associated with fatigue processes, have been shown to drive crack propagation in this material. Thus, in this study, crack initiation in a notched specimen under a static load was investigated. A video microscope was used to monitor the notch surface of the specimen and crack initiation time was measured from the video by identifying the onset of crack initiation at the notch. Crack initiation was considered using a viscoelastic fracture theory. It was found that the mechanism of crack initiation involved both single layer and a distributed multi-layer phenomenon and that multi-layer crack initiation delayed the crack initiation time for all loading conditions examined. The findings of this study support that the viscoelastic fracture theory governs fracture mechanics in crosslinked UHMWPE. The findings also support that crack initiation from a notch in UHMWPE is a more complex phenomenon than treated by traditional fracture theories for polymers. PMID:23127638

Slow Crack Growth Analysis of Brittle Materials with Finite Thickness Subjected to Constant Stress-Rate Flexural Loading

NASA Technical Reports Server (NTRS)

Chio, S. R.; Gyekenyesi, J. P.

1999-01-01

A two-dimensional, numerical analysis of slow crack growth (SCG) was performed for brittle materials with finite thickness subjected to constant stress-rate ("dynamic fatigue") loading in flexure. The numerical solution showed that the conventional, simple, one-dimensional analytical solution can be used with a maximum error of about 5% in determining the SCG parameters of a brittle material with the conditions of a normalized thickness (a ratio of specimen thickness to initial crack size) T > 3.3 and of a SCG parameter n > 10. The change in crack shape from semicircular to elliptical configurations was significant particularly at both low stress rate and low T, attributed to predominant difference in stress intensity factor along the crack front. The numerical solution of SCG parameters was supported within the experimental range by the data obtained from constant stress-rate flexural testing for soda-lime glass microslides at ambient temperature.

Fracture Mechanics Analysis of LH2 Feed Line Flow Liners

NASA Technical Reports Server (NTRS)

James, Mark A.; Dawicke, David S.; Brzowski, Matthew B.; Raju, Ivatury S.; Elliott, Kenny B.; Harris, Charles E.

2006-01-01

Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.

Obtaining Crack-free WC-Co Alloys by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Khmyrov, R. S.; Safronov, V. A.; Gusarov, A. V.

Standard hardmetals of WC-Co system are brittle and often crack at selective laser melting (SLM). The objective of this study is to estimate the range of WC/Co ratio where cracking can be avoided. Micron-sized Co powder was mixed with WC nanopowder in a ball mill to obtain uniform distribution of WC over the surface of Co particles. Continuous layers of remelted material on the surface of a hardmetal plate were obtained from this composite powder by SLM at 1.07μm wavelength. The layers have satisfactory porosity and are well bound to the substrate. The chemical composition of the layers matches the composition of the initial powder mixtures. The powder mixture with 25wt.%WC can be used for SLM to obtain materials without cracks. The powder mixture with 50wt.%WC cracks because of formation of brittle W3Co3C phase. Cracking can considerably reduce the mechanical strength, so that the use of this composition is not advised.

Natural Crack Sizing Based on Eddy Current Image and Electromagnetic Field Analyses

DOE Office of Scientific and Technical Information (OSTI.GOV)

Endo, H.; Uchimoto, T.; Takagi, T.

2006-03-06

An eddy current testing (ECT) system with multi-coil type probes is applied to size up cracks fabricated on austenite stainless plates. We have developed muti-channel ECT system to produce data as digital images. The probes consist of transmit-receive type sensors as elements to classify crack directions, working as two scan direction modes simultaneously. Template matching applied to the ECT images determines regions of interest in sizing up cracks. Finite element based inversion sizes up the crack depth from the measured ECT signal. The present paper demonstrates this approach for fatigue crack and stress corrosion cracking.

A fracture mechanics approach for estimating fatigue crack initiation in carbon and low-alloy steels in LWR coolant environments

DOE Office of Scientific and Technical Information (OSTI.GOV)

Park, H. B.; Chopra, O. K.

2000-04-10

A fracture mechanics approach for elastic-plastic materials has been used to evaluate the effects of light water reactor (LWR) coolant environments on the fatigue lives of carbon and low-alloy steels. The fatigue life of such steel, defined as the number of cycles required to form an engineering-size crack, i.e., 3-mm deep, is considered to be composed of the growth of (a) microstructurally small cracks and (b) mechanically small cracks. The growth of the latter was characterized in terms of {Delta}J and crack growth rate (da/dN) data in air and LWR environments; in water, the growth rates from long crack testsmore » had to be decreased to match the rates from fatigue S-N data. The growth of microstructurally small cracks was expressed by a modified Hobson relationship in air and by a slip dissolution/oxidation model in water. The crack length for transition from a microstructurally small crack to a mechanically small crack was based on studies on small crack growth. The estimated fatigue S-N curves show good agreement with the experimental data for these steels in air and water environments. At low strain amplitudes, the predicted lives in water can be significantly lower than the experimental values.« less

Ballistic Impact of Braided Composites With a Soft Projectile

NASA Technical Reports Server (NTRS)

Roberts, Gary D.; Pereira, J. Michael; Revilock, Duane M., Jr.; Binienda, Wieslaw; Xie, Ming; Braley, Mike

2004-01-01

Impact tests using a soft gelatin projectile were performed to identify failure modes that occur at high strain energy density during impact loading. Use of a soft projectile allows a large amount of kinetic energy to be transferred into strain energy in the target before penetration occurs. Failure modes were identified for flat aluminum plates and for flat composite plates made from a triaxial braid having a quasi-isotropic fiber architecture with fibers in the 0 and +/- 60 deg. directions. For the aluminum plates, a large hole formed as a result of crack propagation from the initiation site at the center of the plate to the fixed boundaries. For the composite plates, fiber tensile failure occurred in the back ply at the center of the plate. Cracks then propagated from this site along the +/- 60 deg. fiber directions until triangular flaps opened to allow the projectile to pass through the plate. The damage size was only slightly larger than the initial impact area. It was difficult to avoid slipping of the fixed edges of the plates during impact, and slipping was shown to have a large effect on the penetration threshold. Failure modes were also identified for composite half-rings fabricated with the 0 deg. fibers aligned circumferentially. Slipping of the edges was not a problem in the half-ring tests. For the composite half-rings, fiber tensile failure also occurred in the back ply. However, cracks initially propagated from this site in a direction transverse to the 0 deg. fibers. The cracks then turned to follow the +/- 60 deg. fibers for a short distance before turning again to follow 0 deg. fibers until two approximately rectangular flaps opened to allow the projectile to pass through the plate. The damage size in the composite half-rings was also only slightly larger than the initial impact area. Cracks did not propagate to the boundaries, and no delamination was observed. The damage tolerance demonstrated by the quasi-isotropic triaxial braid composites indicate that composites of this type can reasonably be considered as a lightweight alternative to metals for fan cases in commercial jet engines.

Stable Tearing and Buckling Responses of Unstiffened Aluminum Shells with Long Cracks

NASA Technical Reports Server (NTRS)

Starnes, James H., Jr.; Rose, Cheryl A.

1999-01-01

The results of an analytical and experimental study of the nonlinear response of thin, unstiffened, aluminum cylindrical shells with a long longitudinal crack are presented. The shells are analyzed with a nonlinear shell analysis code that accurately accounts for global and local structural response phenomena. Results are presented for internal pressure and for axial compression loads. The effect of initial crack length on the initiation of stable crack growth and unstable crack growth in typical shells subjected to internal pressure loads is predicted using geometrically nonlinear elastic-plastic finite element analyses and the crack-tip-opening angle (CTOA) fracture criterion. The results of these analyses and of the experiments indicate that the pressure required to initiate stable crack growth and unstable crack growth in a shell subjected to internal pressure loads decreases as the initial crack length increases. The effects of crack length on the prebuckling, buckling and postbuckling responses of typical shells subjected to axial compression loads are also described. For this loading condition, the crack length was not allowed to increase as the load was increased. The results of the analyses and of the experiments indicate that the initial buckling load and collapse load for a shell subjected to axial compression loads decrease as the initial crack length increases. Initial buckling causes general instability or collapse of a shell for shorter initial crack lengths. Initial buckling is a stable local response mode for longer initial crack lengths. This stable local buckling response is followed by a stable postbuckling response, which is followed by general or overall instability of the shell.

Stable Tearing and Buckling Responses of Unstiffened Aluminum Shells with Long Cracks

NASA Technical Reports Server (NTRS)

Starnes, James H., Jr.; Rose, Cheryl A.

1998-01-01

The results of an analytical and experimental study of the nonlinear response of thin, unstiffened, aluminum cylindrical shells with a long longitudinal crack are presented. The shells are analyzed with a nonlinear shell analysis code that accurately accounts for global and local structural response phenomena. Results are presented for internal pressure and for axial compression loads. The effect of initial crack length on the initiation of stable crack growth and unstable crack growth in typical shells subjected to internal pressure loads is predicted using geometrically nonlinear elastic-plastic finite element analyses and the crack-tip-opening angle (CTOA) fracture criterion. The results of these analyses and of the experiments indicate that the pressure required to initiate stable crack growth and unstable crack growth in a shell subjected to internal pressure loads decreases as the initial crack length increases. The effects of crack length on the prebuckling, buckling and postbuckling responses of typical shells subjected to axial compression loads are also described. For this loading condition, the crack length was not allowed to increase as the load was increased. The results of the analyses and of the experiments indicate that the initial buckling load and collapse load for a shell subjected to axial compression loads decrease as the initial crack length increases. Initial buckling causes general instability or collapse of a shell for shorter initial crack lengths. Initial buckling is a stable local response mode for longer initial crack lengths. This stable local buckling response is followed by a stable postbuckling response, which is followed by general or overall instability of the shell.

Evaluation of hydrogen embrittlement and temper embrittlement by key curve method in instrumented Charpy test

NASA Astrophysics Data System (ADS)

Ohtsuka, N.; Shindo, Y.; Makita, A.

2010-06-01

Instrumented Charpy test was conducted on small sized specimen of 21/4Cr-1Mo steel. In the test the single specimen key curve method was applied to determine the value of fracture toughness for the initiation of crack extension with hydrogen free, KIC, and for hydrogen embrittlement cracking, KIH. Also the tearing modulus as a parameter for resistance to crack extension was determined. The role of these parameters was discussed at an upper shelf temperature and at a transition temperature. Then the key curve method combined with instrumented Charpy test was proven to be used to evaluate not only temper embrittlement but also hydrogen embrittlement.

Comparative study of electromechanical impedance and Lamb wave techniques for fatigue crack detection and monitoring in metallic structures

NASA Astrophysics Data System (ADS)

Lim, Say Ian; Liu, Yu; Soh, Chee Kiong

2012-04-01

Fatigue cracks often initiate at the weld toes of welded steel connections. Usually, these cracks cannot be identified by the naked eyes. Existing identification methods like dye-penetration test and alternating current potential drop (ACPD) may be useful for detecting fatigue cracks at the weld toes. To apply these non-destructive evaluation (NDE) techniques, the potential sites have to be accessible during inspection. Therefore, there is a need to explore other detection and monitoring techniques for fatigue cracks especially when their locations are inaccessible or cost of access is uneconomical. Electro-mechanical Impedance (EMI) and Lamb wave techniques are two fast growing techniques in the Structural Health Monitoring (SHM) community. These techniques use piezoelectric ceramics (PZT) for actuation and sensing. Since the monitoring site is only needed to be accessed once for the instrumentation of the transducers, remote monitoring is made possible. The permanent locations of these transducers also translate to having consistent measurement for monitoring. The main focus of this study is to conduct a comparative investigation on the effectiveness and efficiency of the EMI technique and the Lamb wave technique for successful fatigue crack identification and monitoring of welded steel connections using piezoelectric transducers. A laboratory-sized non-load carrying fillet weld specimen is used in this study. The specimen is subjected to cyclic tensile load and data for both techniques are acquired at stipulated intervals. It can be concluded that the EMI technique is sensitive to the crack initiation phase while the Lamb wave technique correlates well with the crack propagation phase.

The Characteristics of Fatigue Damage in the Fuselage Riveted Lap Splice Joint

NASA Technical Reports Server (NTRS)

Piascik, Robert S.; Willard, Scott A.

1997-01-01

An extensive data base has been developed to form the physical basis for new analytical methodology to predict the onset of widespread fatigue damage in the fuselage lap splice joint. The results of detailed destructive examinations have been cataloged to describe the physical nature of MSD in the lap splice joint. ne catalog includes a detailed description, e.g., crack initiation, growth rates, size, location, and fracture morphology, of fatigue damage in the fuselage lap splice joint structure. Detailed examinations were conducted on a lap splice joint panel removed from a full scale fuselage test article after completing a 60,000 cycle pressure test. The panel contained a four bay region that exhibited visible outer skin cracks and regions of crack link-up along the upper rivet row. Destructive examinations revealed undetected fatigue damage in the outer skin, inner skin, and tear strap regions. Outer skin fatigue cracks were found to initiate by fretting damage along the faying surface. The cracks grew along the faying surface to a length equivalent to two to three skin thicknesses before penetrating the outboard surface of the outer skin. Analysis of fracture surface marker bands produced during full scale testing revealed that all upper rivet row fatigue cracks contained in a dim bay region grow at similar rates; this important result suggests that fracture mechanics based methods can be used to predict the growth of outer skin fatigue cracks in lap splice structure. Results are presented showing the affects of MSD and out-of-plane pressure loads on outer skin crack link-up.

Three-Dimensional BEM and FEM Submodelling in a Cracked FML Full Scale Aeronautic Panel

NASA Astrophysics Data System (ADS)

Citarella, R.; Cricrì, G.

2014-06-01

This paper concerns the numerical characterization of the fatigue strength of a flat stiffened panel, designed as a fiber metal laminate (FML) and made of Aluminum alloy and Fiber Glass FRP. The panel is full scale and was tested (in a previous work) under fatigue biaxial loads, applied by means of a multi-axial fatigue machine: an initial through the thickness notch was created in the panel and the aforementioned biaxial fatigue load applied, causing a crack initiation and propagation in the Aluminum layers. Moreover, (still in a previous work), the fatigue test was simulated by the Dual Boundary Element Method (DBEM) in a bidimensional approach. Now, in order to validate the assumptions made in the aforementioned DBEM approach and concerning the delamination area size and the fiber integrity during crack propagation, three-dimensional BEM and FEM submodelling analyses are realized. Due to the lack of experimental data on the delamination area size (normally increasing as the crack propagates), such area is calculated by iterative three-dimensional BEM or FEM analyses, considering the inter-laminar stresses and a delamination criterion. Such three-dimensional analyses, but in particular the FEM proposed model, can also provide insights into the fiber rupture problem. These DBEM-BEM or DBEM-FEM approaches aims at providing a general purpose evaluation tool for a better understanding of the fatigue resistance of FML panels, providing a deeper insight into the role of fiber stiffness and of delamination extension on the stress intensity factors.

Finite element analysis of heat load of tungsten relevant to ITER conditions

NASA Astrophysics Data System (ADS)

Zinovev, A.; Terentyev, D.; Delannay, L.

2017-12-01

A computational procedure is proposed in order to predict the initiation of intergranular cracks in tungsten with ITER specification microstructure (i.e. characterised by elongated micrometre-sized grains). Damage is caused by a cyclic heat load, which emerges from plasma instabilities during operation of thermonuclear devices. First, a macroscopic thermo-mechanical simulation is performed in order to obtain temperature- and strain field in the material. The strain path is recorded at a selected point of interest of the macroscopic specimen, and is then applied at the microscopic level to a finite element mesh of a polycrystal. In the microscopic simulation, the stress state at the grain boundaries serves as the marker of cracking initiation. The simulated heat load cycle is a representative of edge-localized modes, which are anticipated during normal operations of ITER. Normal stresses at the grain boundary interfaces were shown to strongly depend on the direction of grain orientation with respect to the heat flux direction and to attain higher values if the flux is perpendicular to the elongated grains, where it apparently promotes crack initiation.

Eddy current crack detection capability assessment approach using crack specimens with differing electrical conductivity

NASA Astrophysics Data System (ADS)

Koshti, Ajay M.

2018-03-01

Like other NDE methods, eddy current surface crack detectability is determined using probability of detection (POD) demonstration. The POD demonstration involves eddy current testing of surface crack specimens with known crack sizes. Reliably detectable flaw size, denoted by, a90/95 is determined by statistical analysis of POD test data. The surface crack specimens shall be made from a similar material with electrical conductivity close to the part conductivity. A calibration standard with electro-discharged machined (EDM) notches is typically used in eddy current testing for surface crack detection. The calibration standard conductivity shall be within +/- 15% of the part conductivity. This condition is also applicable to the POD demonstration crack set. Here, a case is considered, where conductivity of the crack specimens available for POD testing differs by more than 15% from that of the part to be inspected. Therefore, a direct POD demonstration of reliably detectable flaw size is not applicable. Additional testing is necessary to use the demonstrated POD test data. An approach to estimate the reliably detectable flaw size in eddy current testing for part made from material A using POD crack specimens made from material B with different conductivity is provided. The approach uses additional test data obtained on EDM notch specimens made from materials A and B. EDM notch test data from the two materials is used to create a transfer function between the demonstrated a90/95 size on crack specimens made of material B and the estimated a90/95 size for part made of material A. Two methods are given. For method A, a90/95 crack size for material B is given and POD data is available. Objective of method A is to determine a90/95 crack size for material A using the same relative decision threshold that was used for material B. For method B, target crack size a90/95 for material A is known. Objective is to determine decision threshold for inspecting material A.

Generation mechanism of nonlinear ultrasonic Lamb waves in thin plates with randomly distributed micro-cracks.

PubMed

Zhao, Youxuan; Li, Feilong; Cao, Peng; Liu, Yaolu; Zhang, Jianyu; Fu, Shaoyun; Zhang, Jun; Hu, Ning

2017-08-01

Since the identification of micro-cracks in engineering materials is very valuable in understanding the initial and slight changes in mechanical properties of materials under complex working environments, numerical simulations on the propagation of the low frequency S 0 Lamb wave in thin plates with randomly distributed micro-cracks were performed to study the behavior of nonlinear Lamb waves. The results showed that while the influence of the randomly distributed micro-cracks on the phase velocity of the low frequency S 0 fundamental waves could be neglected, significant ultrasonic nonlinear effects caused by the randomly distributed micro-cracks was discovered, which mainly presented as a second harmonic generation. By using a Monte Carlo simulation method, we found that the acoustic nonlinear parameter increased linearly with the micro-crack density and the size of micro-crack zone, and it was also related to the excitation frequency and friction coefficient of the micro-crack surfaces. In addition, it was found that the nonlinear effect of waves reflected by the micro-cracks was more noticeable than that of the transmitted waves. This study theoretically reveals that the low frequency S 0 mode of Lamb waves can be used as the fundamental waves to quantitatively identify micro-cracks in thin plates. Copyright © 2017 Elsevier B.V. All rights reserved.

Mode I and mixed I/III crack initiation and propagation behavior of V-4Cr-4Ti alloy at 25{degrees}C

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, H.X.; Kurtz, R.J.; Jones, R.H.

1997-04-01

The mode I and mixed-mode I/III fracture behavior of the production-scale heat (No. 832665) of V-4Cr-4Ti has been investigated at 25{degrees}C using compact tension (CT) specimens for a mode I crack and modified CT specimens for a mixed-mode I/III crack. The mode III to mode I load ratio was 0.47. Test specimens were vacuum annealed at 1000{degrees}C for 1 h after final machining. Both mode I and mixed-mode I/III specimens were fatigue cracked prior to J-integral testing. It was noticed that the mixed-mode I/III crack angle decreased from an initial 25 degrees to approximately 23 degrees due to crack planemore » rotation during fatigue cracking. No crack plane rotation occurred in the mode I specimen. The crack initiation and propagation behavior was evaluated by generating J-R curves. Due to the high ductility of this alloy and the limited specimen thickness (6.35 mm), plane strain requirements were not met so valid critical J-integral values were not obtained. However, it was found that the crack initiation and propagation behavior was significantly different between the mode I and the mixed-mode I/III specimens. In the mode I specimen crack initiation did not occur, only extensive crack tip blunting due to plastic deformation. During J-integral testing the mixed-mode crack rotated to an increased crack angle (in contrast to fatigue precracking) by crack blunting. When the crack initiated, the crack angle was about 30 degrees. After crack initiation the crack plane remained at 30 degrees until the test was completed. Mixed-mode crack initiation was difficult, but propagation was easy. The fracture surface of the mixed-mode specimen was characterized by microvoid coalescence.« less

Modeling crack growth during Li insertion in storage particles using a fracture phase field approach

NASA Astrophysics Data System (ADS)

Klinsmann, Markus; Rosato, Daniele; Kamlah, Marc; McMeeking, Robert M.

2016-07-01

Fracture of storage particles is considered to be one of the major reasons for capacity fade and increasing power loss in many commercial lithium ion batteries. The appearance of fracture and cracks in the particles is commonly ascribed to mechanical stress, which evolves from inhomogeneous swelling and shrinkage of the material when lithium is inserted or extracted. Here, a coupled model of lithium diffusion, mechanical stress and crack growth using a phase field method is applied to investigate how the formation of cracks depends on the size of the particle and the presence or absence of an initial crack, as well as the applied flux at the boundary. The model shows great versatility in that it is free of constraints with respect to particle geometry, dimension or crack path and allows simultaneous observation of the evolution of lithium diffusion and crack growth. In this work, we focus on the insertion process. In particular, we demonstrate the presence of intricate fracture phenomena, such as, crack branching or complete breakage of storage particles within just a single half cycle of lithium insertion, a phenomenon that was only speculated about before.

Characterization of the Microstructures and the Cryogenic Mechanical Properties of Electron Beam Welded Inconel 718

NASA Astrophysics Data System (ADS)

Kwon, Soon Il; Bae, Sang Hyun; Do, Jeong Hyeon; Jo, Chang Yong; Hong, Hyun Uk

2016-02-01

The microstructures and the cryogenic mechanical properties of electron beam (EB) welds between cast and forged Inconel 718 superalloys with a thickness of 10 mm were investigated in comparison with gas tungsten arc (GTA) welds. EB welding with a heat input lower than 250 J/mm caused the formation of liquation microfissuring in the cast-side heat-affected-zone (HAZ) of the EB welds. HAZ liquation microfissuring appeared to be associated with the constitutional liquation of primary NbC carbides at the grain boundaries. Compared with the GTA welding process, the EB welding produced welds with superior microstructure, exhibiting fine dendritic structure associated with the reduction in size and fraction of the Laves phase due to the rapid cooling rate. This result was responsible for the superior mechanical properties of the EB welds at 77 K (-196 °C). Laves particles in both welds were found to provide the preferential site for the crack initiation and propagation, leading to a significant decrease in the Charpy impact toughness at 77 K (-196 °C). Crack initiation and propagation induced by Charpy impact testing were discussed in terms of the dendrite arm spacing, the Laves size and the dislocation structure ahead of the crack arisen from the fractured Laves phase in the two welds.

Dynamic delamination crack propagation in a graphite/epoxy laminate

NASA Technical Reports Server (NTRS)

Grady, J. E.; Sun, C. T.

1991-01-01

Dynamic delamination crack propagation in a (90/0) 5s Graphite/Epoxy laminate with an embedded interfacial crack was investigated experimentally using high speed photography. The dynamic motion was produced by impacting the beamlike laminate specimen with a silicon rubber ball. The threshold impact velocities required to initiate dynamic crack propagation in laminates with varying initial crack positions were determined. The crack propagation speeds were estimated from the photographs. Results show that the through the thickness position of the embedded crack can significantly affect the dominant mechanism and the threshold impact velocity for the onset of crack movement. If the initial delamination is placed near the top of bottom surface of the laminate, local buckling of the delaminated plies may cause instability of the crack. If the initial delamination lies on the midplane, local buckling does not occur and the initiation of crack propagation appears to be dominated by Mode II fracture. The crack propagation and arrest observed was seen to be affected by wave motion within the delamination region.

Effects of powder characteristics on injection molding and burnout cracking

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bandyopadhyay, G.; French, K.W.

Silicon nitride particle size and size distributions were varied widely to determine their effects on burnout cracking of injection-molded test parts containing thick and thin sections. Elimination of internal cracking required significant burnout shrinkage, which did not occur by changes of particle size and size distribution. However, isopressing of test parts after burnout provided the dimensional shrinkage necessary for producing crack-free components.

Effect of Understress on Fretting Fatigue Crack Initiation of Press-Fitted Axle

NASA Astrophysics Data System (ADS)

Kubota, Masanobu; Niho, Sotaro; Sakae, Chu; Kondo, Yoshiyuki

Axles are one of the most important components in railway vehicles with regard to safety, since a fail-safe design is not available. The problems of fretting fatigue crack initiation in a press-fitted axle have not been completely solved even though up-to-date fatigue design methods are employed. The objective of the present study is to clarify the effect of understress on fretting fatigue crack initiation behavior in the press-fitted axle. Most of the stress amplitude given to the axle in service is smaller than the fretting fatigue limit based on the stress to initiate cracks under a constant load σwf1. Rotating bending fatigue tests were performed using a 40mm-diameter press-fitted axle assembly. Two-step variable stresses consisting of σwf1 and half or one-third of σwf1 were used in the experiment. Crack initiation life was defined as the number of cycles when a fretting fatigue crack, which is longer than 30µm, was found using a metallurgical microscope. Fretting fatigue cracks were initiated even when the variable stress did not contain the stress above the fretting fatigue crack initiation limit. The crack initiation life varied from 4.0×107 to 1.2×108 depending on the stress frequency ratio nL/nH. The sum of the number of cycles of higher stress at crack initiation NH was much smaller than the number of cycles to initiate cracks estimated from the modified Miner's rule. The value of the modified Miner's damage ranged from 0.013 to 0.185. To clarify the effect of variable amplitude on the fretting fatigue crack initiation, a comprehensive investigation related to relative slip, tangential force and fretting wear is necessary.

Anxiety symptoms in crack cocaine and inhalant users admitted to a psychiatric hospital in southern Brazil.

PubMed

Zubaran, Carlos; Foresti, Katia; Thorell, Mariana Rossi; Franceschini, Paulo Roberto

2013-01-01

The occurrence of psychiatric comorbidity among individuals with crack or inhalant dependence is frequently observed. The objective of this study was to investigate anxiety symptoms among crack cocaine and inhalant users in southern Brazil. The study investigated two groups of volunteers of equal size (n=50): one group consisted of crack cocaine users, and the other group consisted of inhalant users. Research volunteers completed the Portuguese versions of the State-Trait Anxiety Inventory (STAI), Hamilton Anxiety Rating Scale (HAM-A), and Self-Report Questionnaire (SRQ). Both crack and inhalant users experience significant symptoms of anxiety. Inhalant users presented significantly more anxiety symptoms than crack users according to the HAM-A questionnaire only. In contrast to the results of the HAM-A, the STAI failed to demonstrate a significant difference between the two groups of substance users. SRQ scores revealed that crack and inhalants users had significant degrees of morbidity. A significant difference regarding anxiety symptomatology, especially state anxiety, was observed among inhalant and crack users. Anxiety and overall mental psychopathology were significantly correlated in this sample. The results indicate that screening initiatives to detect anxiety and additional psychiatric comorbidities among crack and inhalant users are feasible and relevant. Copyright © 2013 Elsevier Editora Ltda. All rights reserved.

Influence of tempering and contraction mismatch on crack development in ceramic surfaces.

PubMed

Anusavice, K J; DeHoff, P H; Hojjatie, B; Gray, A

1989-07-01

Tempering of glass produces a state of compressive stress in surface regions which can enhance the resistance to crack initiation and growth. The objective of this study was to determine the influence of tempering on the sizes of surface cracks induced within the tempered surfaces of opaque porcelain-body porcelain discs, with contraction coefficient differences (alpha O-alpha B) of +3.2, +0.7, 0.0, -0.9, and -1.5 ppm/degrees C. We fired the discs to the maturing temperature (982 degrees C) of body porcelain and then subjected them to three cooling procedures: slow cooling in a furnace (SC), fast cooling in air (FC), and tempering (T) by blasting the body porcelain surface with compressed air for 90 s. We used body porcelain discs as the thermally compatible (delta alpha = 0) control specimens. We measured the diameters of cracks induced by a microhardness indenter at an applied load of 4.9 N at 80 points along diametral lines within the surface of body porcelain. The mean values of the crack diameters varied from 75.9 microns (delta alpha = -1.5 ppm/degrees C) to 103.3 microns (delta alpha = +3.2 ppm/degrees C). The results of ANOVA indicate that significant differences in crack dimensions were controlled by cooling rate, contraction mismatch, and their combined effect (p less than 0.0001). Multiple contrast analysis (Tukey's HSD Test) revealed significantly lower (p less than 0.05) crack sizes for tempered specimens compared with those of fast-cooled and slow-cooled specimens.(ABSTRACT TRUNCATED AT 250 WORDS)

Study of microstructure and fracture properties of blunt notched and sharp cracked high density polyethylene specimens.

PubMed

Pan, Huanyu; Devasahayam, Sheila; Bandyopadhyay, Sri

2017-07-21

This paper examines the effect of a broad range of crosshead speed (0.05 to 100 mm/min) and a small range of temperature (25 °C and 45 °C) on the failure behaviour of high density polyethylene (HDPE) specimens containing a) standard size blunt notch and b) standard size blunt notch plus small sharp crack - all tested in air. It was observed that the yield stress properties showed linear increase with the natural logarithm of strain rate. The stress intensity factors under blunt notch and sharp crack conditions also increased linearly with natural logarithm of the crosshead speed. The results indicate that in the practical temperature range of 25 °C and 45 °C under normal atmosphere and increasing strain rates, HDPE specimens with both blunt notches and sharp cracks possess superior fracture properties. SEM microstructure studies of fracture surfaces showed craze initiation mechanisms at lower strain rate, whilst at higher strain rates there is evidence of dimple patterns absorbing the strain energy and creating plastic deformation. The stress intensity factor and the yield strength were higher at 25 °C compared to those at 45 °C.

Simulation and experiment for depth sizing of cracks in anchor bolts by ultrasonic phased array technology

NASA Astrophysics Data System (ADS)

Lin, Shan

2018-04-01

There have been lots of reports about the occurrence of cracks in bolts in aging nuclear and thermal power plants. Sizing of such cracks is crucial for assessing the integrity of bolts. Currently, hammering and visual tests are used to detect cracks in bolts. However, they are not applicable for sizing cracks. Although the tip diffraction method is well known as a crack sizing technique, reflection echoes from threads make it difficult to apply this technique to bolts. This paper addresses a method for depth sizing of cracks in bolts by means of ultrasonic phased array technology. Numerical results of wave propagation in bolts by the finite element method (FEM) shows that a peak associated within the vicinity of a crack tip can be observed in the curve of echo intensity versus refraction angle for deep cracks. The refraction angle with respect to this peak decreases as crack depth increases. Such numerical results are verified by experiments on bolt specimens that have electrical discharge machining notches or fatigue cracks with different depths. In the experiment, a 10-MHz linear array probe is used. Depth of cracks in bolts using the refraction angle associated with the peak is determined and compared to actual depths. The comparison shows that accurately determining a crack depth from the inspection results is possible.

Investigation of Cracks Found in Helicopter Longerons

NASA Technical Reports Server (NTRS)

Newman, John A.; Baughman, James M.; Wallace, Terryl A.

2009-01-01

Four cracked longerons, containing a total of eight cracks, were provided for study. Cracked regions were cut from the longerons. Load was applied to open the cracks, enabling crack surface examination. Examination revealed that crack propagation was driven by fatigue loading in all eight cases. Fatigue crack initiation appears to have occurred on the top edge of the longerons near geometric changes that affect component bending stiffness. Additionally, metallurigical analysis has revealed a local depletion in alloying elements in the crack initiation regions that may be a contributing factor. Fatigue crack propagation appeared to be initially driven by opening-mode loading, but at a crack length of approximately 0.5 inches (12.7 mm), there is evidence of mixed-mode crack loading. For the longest cracks studied, shear-mode displacements destroyed crack-surface features of interest over significant portions of the crack surfaces.

Investigation of Helicopter Longeron Cracks

NASA Technical Reports Server (NTRS)

Newman, John A.; Baughman, James; Wallace, Terryl A.

2009-01-01

Four cracked longerons, containing a total of eight cracks, were provided for study. Cracked regions were cut from the longerons. Load was applied to open the cracks, enabling crack surface examination. Examination revealed that crack propagation was driven by fatigue loading in all eight cases. Fatigue crack initiation appears to have occurred on the top edge of the longerons near geometric changes that affect component bending stiffness. Additionally, metallurgical analysis has revealed a local depletion in alloying elements in the crack initiation regions that may be a contributing factor. Fatigue crack propagation appeared to be initially driven by opening-mode loading, but at a crack length of approximately 0.5 inches (12.7 mm), there is evidence of mixed-mode crack loading. For the longest cracks studied, shear-mode displacements destroyed crack-surface features of interest over significant portions of the crack surfaces.

Detection and Sizing of Fatigue Cracks in Steel Welds with Advanced Eddy Current Techniques

NASA Astrophysics Data System (ADS)

Todorov, E. I.; Mohr, W. C.; Lozev, M. G.

2008-02-01

Butt-welded specimens were fatigued to produce cracks in the weld heat-affected zone. Advanced eddy current (AEC) techniques were used to detect and size the cracks through a coating. AEC results were compared with magnetic particle and phased-array ultrasonic techniques. Validation through destructive crack measurements was also conducted. Factors such as geometry, surface treatment, and crack tightness interfered with depth sizing. AEC inspection techniques have the potential of providing more accurate and complete sizing flaw data for manufacturing and in-service inspections.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kruska, Karen; Zhai, Ziqing; Bruemmer, Stephen M.

Due to its superior resistance to corrosion and stress corrosion cracking (SCC), high Cr, Ni-base Alloy 690 is now commonly used in pressurized water reactors (PWRs). Even though highly cold-worked (CW) Alloy 690 has been shown to be susceptible to SCC crack growth in PWR primary water environments, an open question remains whether SCC initiation was possible for these materials under constant load test conditions. Testing has been performed on a series of CW alloy 690 CRDM tubing specimens at constant load for up to 9,220 hours in 360°C simulated PWR primary water. A companion paper will discuss the overallmore » testing approach and describe results on different alloy 690 heats and cold work levels. The focus of the current paper is to illustrate the use of focused ion beam (FIB), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) for the high-resolution investigation of precursor damage and intergranular (IG) crack nucleation in these specimens. Three-dimensional (3D) FIB/SEM imaging has been conducted on a series of grain boundary (GB) damage precursors, such as IG small cavities, local corrosion and even shallow cracks observed at the specimen surface. Contrast variations and EDS mapping were used to distinguish oxides, carbides and cavities from the matrix material. Nanometer-sized cavities were observed associated with GB carbides in the highly CW specimens. Shallow IG cracks were present in the 30%CW specimens and exhibited oxidized crack flanks and a higher density of cavities ahead of the oxide front in all cases. The shape and distribution of carbides and cavities in the plane of the cracked GBs was analyzed in 3D to gain a mechanistic understanding of the processes that may be leading to crack initiation in highly CW alloy 690.« less

Tectonic Processes on Europa: Tidal Stresses, Mechanical Response, and Visible Features

USGS Publications Warehouse

Greenberg, R.; Geissler, P.; Hoppa, G.; Tufts, B.R.; Durda, D.D.; Pappalardo, R.; Head, J.W.; Greeley, R.; Sullivan, R.; Carr, M.H.

1998-01-01

Europa's orbital eccentricity, driven by the resonance with Io and Ganymede, results in "diurnal" tides (3.5-day period) and possibly in nonsynchronous rotation. Both diurnal variation and nonsynchronous rotation can create significant stress fields on Europa's surface, and both effects may produce cracking. Patterns and time sequences of apparent tectonic features on Europa include lineaments that correlate with both sources of stress, if we take into account nonsynchronous rotation, after initial crack formation, by amounts ranging up to several tens of degrees. For example, the crosscutting time sequence of features in the Cadmus and Minos Linea region is consistent with a combined diurnal and nonsynchronous tensile-stress field, as it evolves during tens of degrees of nonsynchronous rotation. Constraints on the rotation rate from comparing Voyager and Galileo images show that significant rotation requires 104yr, but could be fast enough to have allowed significant rotation since the last global resurfacing, even if such resurfacing was as recent as a few million years ago. Once cracking is initiated, diurnal tides work cracks so that they open and close daily. Although the daily effect is small, over 105yr double ridges could plausibly be built along the cracks with sizes and morphologies consistent with observed structures, according to a model in which underlying liquid water fills the open cracks, partially freezes, and is extruded during the daily closing of the cracks. Thus, several lines of observational and theoretical evidence can be integrated if we assume nonsynchronous rotation and the existence of a liquid water layer. ?? 1998 Academic Press.

Cracking process of Fe-26Cr-1Mo during low cycle corrosion fatigue

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, J.Q.; Li, J.; Wang, Z.F.

1994-12-01

The corrosion fatigue (CF) life has been divided classically into the initiation'' and propagation'' periods. Usually, the crack initiation process dominates the component lifetime under the low cycle CF condition because the crack propagates rapidly one initiated. Despite much work done on the research of the CF crack initiation mechanisms, however, a full understanding of crack initiation is still lacking. There are some limitations in explaining the CF crack initiation in an aqueous solution using the above four mechanisms individually. And, it is difficult to conduct experiments in which one mechanism along can be examined. Although CF is complicated, itmore » is possible to reproduce a specific experiment condition which will have the dominant factor affecting the CF crack initiation. Once the cracks initiate on the smooth metal surface, their coalescence, micropropagation and macropropagation will take place successively. The initiated cracks propagate first in the range of several grains, and the behavior of the microcrack propagation is different from that of macrocrack propagation. For Fe-26Cr-1Mo ferritic stainless steel, the fundamental research work of straining electrode has been done by many investigators, but the observation of the material surface at different deformation processes has not been reported. In the present study, the detailed observation of the cracking process of the material has been carried out in low cycle CF.« less

Avoidance of stress corrosion susceptibility in high strength aluminum alloys by control of grain boundary and matrix microstructure

NASA Technical Reports Server (NTRS)

Adler, P.; Deiasi, R.

1974-01-01

The relation of microstructure to the mechanical strength and stress corrosion resistance of highest strength and overaged tempers of BAR and 7050 aluminum alloys was investigated. Comparison is made with previously studied 7075 aluminum alloy. Optical microscopy, transmission electron microscopy, and differential scanning calorimetry were used to characterize the grain morphology, matrix microstructure, and grain boundary microstructure of these tempers. Grain boundary interparticle spacing was significant to stress corrosion crack propagation for all three alloys; increasing interparticle spacing led to increased resistance to crack propagation. In addition, the fire grain size in Bar and 7050 appears to enhance crack propagation. The highest strength temper of 7050 has a comparatively high resistance to crack initiation. Overall stress corrosion behavior is dependent on environment pH, and evaluation over a range of pH is recommended.

The role of cyclic plastic zone size on fatigue crack growth behavior in high strength steels

NASA Astrophysics Data System (ADS)

Korda, Akhmad A.; Miyashita, Y.; Mutoh, Y.

2015-09-01

The role of cyclic plastic zone in front of the crack tip was studied in high strength steels. Estimated plastic zone size would be compared with actual observation. Strain controlled fatigue tests of the steels were carried out to obtain cyclic stress-strain curves for plastic zone estimation. Observations of plastic zone were carried out using in situ SEM fatigue crack growth tests under a constant-ΔK. Hard microstructures in structural steels showed to inhibit the extent of plastic deformation around the crack tip. The rate of crack growth can be correlated with the size of plastic zone. The smaller the plastic zone size, the slower the fatigue crack growth.

Multimillion to billion atom simulations of nanosystems under extreme conditions

NASA Astrophysics Data System (ADS)

Vashishta, P.

2008-12-01

Advanced materials and devices with nanometer grain/feature sizes are being developed to achieve higher strength and toughness in ceramic materials and greater speeds in electronic devices. Below 100 nm, however, continuum description of materials and devices must be supplemented by atomistic descriptions. Current state of the art atomistic simulations involve 10 million - 1 billion atoms. We investigate initiation, growth and healing of wing cracks in confined silica glass by multimillion atom molecular dynamics (MD) simulations. Under dynamic compression, frictional sliding of pre-crack surfaces nucleates nanovoids, which evolve into nanocrack columns at the pre-crack tip. Nanocrack columns merge to form a wing crack, which grows via coalescence with nanovoids in the direction of maximum compression. Lateral confinement arrests the growth and partially heals the wing crack. Growth and arrest of the wing crack occur repeatedly, as observed in dynamic compression experiments on brittle solids under lateral confinement. MD simulation of hypervelocity projectile impact in aluminum nitride and alumina has also been studied. The simulations reveal strong interplay between shock- induced structural phase transformation, plastic deformation and brittle cracks. The shock wave splits into an elastic precursor and a wurtzite-to-rocksalt structural transformation wave. When the elastic wave reflected from the boundary of the sample interacts with the transformation wave front, nanocavities are generated along the penetration path of the projectile and dislocations in adjacent regions. The nanocavities coalesce to form mode I brittle cracks while dislocations generate kink bands that give rise to mode II cracks. These simulations provide a microscopic view of defects associated with simultaneous tensile and shear cracking at the structural phase transformation boundary due to shock impact in high-strength ceramics. Initiation of chemical reactions at shock fronts prior to detonation and dynamic transition in the shock structure of an energetic material (RDX) and reaction of aluminium nanoparticles in oxygen atmosphere followed by explosive burning is also discussed.

Engineering Evaluation of International Low Impact Docking System Latch Hooks

NASA Technical Reports Server (NTRS)

Martinez, J.; Patin, R.; Figert, J.

2013-01-01

The international Low Impact Docking System (iLIDS) provides a structural arrangement that allows for visiting vehicles to dock with the International Space Station (ISS) (Fig 1). The iLIDS docking units are mechanically joined together by a series of active and passive latch hooks. In order to preserve docking capability at the existing Russian docking interfaces, the iLIDS latch hooks are required to conform to the existing Russian design. The latch hooks are classified as being fail-safe. Since the latch hooks are fail-safe, the hooks are not fracture critical and a fatigue based service life assessment will satisfy the structural integrity requirements. Constant amplitude fatigue testing to failure on four sets of active/passive iLIDS latch hooks was performed at load magnitudes of 10, 11, and 12 kips. Failure analysis of the hook fatigue failures identified multi-site fatigue initiation that was effectively centered about the hook mid-plane (consistent with the 3D model results). The fatigue crack initiation distribution implies that the fatigue damage accumulation effectively results in a very low aspect ratio surface crack (which can be simulated as thru-thickness crack). Fatigue damage progression resulted in numerous close proximity fatigue crack initiation sites. It was not possible to determine if fatigue crack coalescence occurs during cyclic loading or as result of the fast fracture response. The presence of multiple fatigue crack initiation sites on different planes will result in the formation of ratchet marks as the cracks coalesce. Once the stable fatigue crack becomes unstable and the fast fracture advances across the remaining ligament and the plane stress condition at a free-surface will result in failure along a 45 deg. shear plane (slant fracture) and the resulting inclined edge is called a shear lip. The hook thickness on the plane of fatigue crack initiation is 0.787". The distance between the shear lips on this plane was on the order of 0.48" and it was effectively centered about the mid-plane of the section. The numerous ratchet marks between the shear lips on the fracture initiation plane are indicative of multiple fatigue initiation sites within this region. The distribution of the fatigue damage about the centerline of the hook is consistent with the analytical results that demonstrate peak stress/strain response at the mid-plane that decreases in the direction of the hook outer surfaces. Scanning electron microscope images of the failed sections detected fatigue crack striations in close proximity to the free surface of the hook radius. These findings were documented at three locations on the fracture surface : 1) adjacent to the left shear lip, 2) adjacent to the right shear lip, and 3) near the centerline of the section. The features of the titanium fracture surface did not allow for a determination of a critical crack size via identification of the region where the fatigue crack propagation became unstable. The fracture based service life projections where benchmarked with strain-life analyses. The strainrange response in the hook radius was defined via the correlated finite element models and the modified method of universal slopes was incorporated to define the strain-life equation for the titanium alloy. The strain-life assessment confirmed that the fracture based projections were reasonable for the loading range of interest. Based upon the analysis and component level fatigue test data a preliminary service life capability for the iLIDS active and passive hooks of 2 lifetimes is projected (includes a scatter factor of 4).

Durability and life prediction modeling in polyimide composites

NASA Technical Reports Server (NTRS)

Binienda, Wieslaw K.

1995-01-01

Sudden appearance of cracks on a macroscopically smooth surface of brittle materials due to cooling or drying shrinkage is a phenomenon related to many engineering problems. Although conventional strength theories can be used to predict the necessary condition for crack appearance, they are unable to predict crack spacing and depth. On the other hand, fracture mechanics theory can only study the behavior of existing cracks. The theory of crack initiation can be summarized into three conditions, which is a combination of a strength criterion and laws of energy conservation, the average crack spacing and depth can thus be determined. The problem of crack initiation from the surface of an elastic half plane is solved and compares quite well with available experimental evidence. The theory of crack initiation is also applied to concrete pavements. The influence of cracking is modeled by the additional compliance according to Okamura's method. The theoretical prediction by this structural mechanics type of model correlates very well with the field observation. The model may serve as a theoretical foundation for future pavement joint design. The initiation of interactive cracks of quasi-brittle material is studied based on a theory of cohesive crack model. These cracks may grow simultaneously, or some of them may close during certain stages. The concept of crack unloading of cohesive crack model is proposed. The critical behavior (crack bifurcation, maximum loads) of the cohesive crack model are characterized by rate equations. The post-critical behavior of crack initiation is also studied.

Cohesive detachment of an elastic pillar from a dissimilar substrate

NASA Astrophysics Data System (ADS)

Fleck, N. A.; Khaderi, S. N.; McMeeking, R. M.; Arzt, E.

The adhesion of micron-scale surfaces due to intermolecular interactions is a subject of intense interest spanning electronics, biomechanics and the application of soft materials to engineering devices. The degree of adhesion is sensitive to the diameter of micro-pillars in addition to the degree of elastic mismatch between pillar and substrate. Adhesion-strength-controlled detachment of an elastic circular cylinder from a dissimilar substrate is predicted using a Dugdale-type of analysis, with a cohesive zone of uniform tensile strength emanating from the interface corner. Detachment initiates when the opening of the cohesive zone attains a critical value, giving way to crack formation. When the cohesive zone size at crack initiation is small compared to the pillar diameter, the initiation of detachment can be expressed in terms of a critical value Hc of the corner stress intensity. The estimated pull-off force is somewhat sensitive to the choice of stick/slip boundary condition used on the cohesive zone, especially when the substrate material is much stiffer than the pillar material. The analysis can be used to predict the sensitivity of detachment force to the size of pillar and to the degree of elastic mismatch between pillar and substrate.

Prediction of corrosion fatigue crack initiation behavior of A7N01P-T4 aluminum alloy welded joints

NASA Astrophysics Data System (ADS)

An, J.; Chen, J.; Gou, G.; Chen, H.; Wang, W.

2017-07-01

Through investigating the corrosion fatigue crack initiation behavior of A7N01P-T4 aluminum alloy welded joints in 3.5 wt.% NaCl solution, corrosion fatigue crack initiation life is formulated as Ni = 6.97 × 1012[Δσeqv1.739 - 491.739]-2 and the mechanism of corrosion fatigue crack initiation is proposed. SEM and TEM tests revealed that several corrosion fatigue cracks formed asynchronously and the first crack does not necessarily develop into the leading crack. The uneven reticular dislocations produced by fatigue loading are prone to piling up and tangling near the grain boundaries or the second phases and form the “high dislocation-density region” (HDDR), which acts as an anode in microbatteries and dissolved to form small crack. Thus the etching pits, HDDR near the grain boundaries and second phases are confirmed as the main causes inducing the initiation of fatigue crack.

An Experimental Study of Incremental Surface Loading of an Elastic Plate: Application to Volcano Tectonics

NASA Technical Reports Server (NTRS)

Williams, K. K.; Zuber, M. T.

1995-01-01

Models of surface fractures due to volcanic loading an elastic plate are commonly used to constrain thickness of planetary lithospheres, but discrepancies exist in predictions of the style of initial failure and in the nature of subsequent fracture evolution. In this study, we perform an experiment to determine the mode of initial failure due to the incremental addition of a conical load to the surface of an elastic plate and compare the location of initial failure with that predicted by elastic theory. In all experiments, the mode of initial failure was tension cracking at the surface of the plate, with cracks oriented circumferential to the load. The cracks nucleated at a distance from load center that corresponds the maximum radial stress predicted by analytical solutions, so a tensile failure criterion is appropriate for predictions of initial failure. With continued loading of the plate, migration of tensional cracks was observed. In the same azimuthal direction as the initial crack, subsequent cracks formed at a smaller radial distance than the initial crack. When forming in a different azimuthal direction, the subsequent cracks formed at a distance greater than the radial distance of the initial crack. The observed fracture pattern may explain the distribution of extensional structures in annular bands around many large scale, circular volcanic features.

Very High Cycle Fatigue of Ni-Based Single-Crystal Superalloys at High Temperature

NASA Astrophysics Data System (ADS)

Cervellon, A.; Cormier, J.; Mauget, F.; Hervier, Z.; Nadot, Y.

2018-05-01

Very high cycle fatigue (VHCF) properties at high temperature of Ni-based single-crystal (SX) superalloys and of a directionally solidified (DS) superalloy have been investigated at 20 kHz and a temperature of 1000 °C. Under fully reversed conditions (R = - 1), no noticeable difference in VHCF lifetimes between all investigated alloys has been observed. Internal casting pores size is the main VHCF lifetime-controlling factor whatever the chemical composition of the alloys. Other types of microstructural defects (eutectics, carbides), if present, may act as stress concentration sites when the number of cycles exceed 109 cycles or when porosity is absent by applying a prior hot isostatic pressing treatment. For longer tests (> 30 hours), oxidation also controls the main crack initiation sites leading to a mode I crack initiation from oxidized layer. Under such conditions, alloy's resistance to oxidation has a prominent role in controlling the VHCF. When creep damage is present at high ratios (R ≥ 0.8), creep resistance of SX/DS alloys governs VHCF lifetime. Under such high mean stress conditions, SX alloys developed to retard the initiation and creep propagation of mode I micro-cracks from pores have better VHCF lifetimes.

Effect of Initial Microstructure on Impact Toughness of 1200 MPa-Class High Strength Steel with Ultrafine Elongated Grain Structure

NASA Astrophysics Data System (ADS)

Jafari, Meysam; Garrison, Warren M.; Tsuzaki, Kaneaki

2014-02-01

A medium-carbon low-alloy steel was prepared with initial structures of either martensite or bainite. For both initial structures, warm caliber-rolling was conducted at 773 K (500 °C) to obtain ultrafine elongated grain (UFEG) structures with strong <110>//rolling direction (RD) fiber deformation textures. The UFEG structures consisted of spheroidal cementite particles distributed uniformly in a ferrite matrix of a transverse grain size of about 331 and 311 nm in samples with initial martensite and bainite structures, respectively. For both initial structures, the UFEG materials had similar tensile properties, upper shelf energy (145 J), and ductile-to-brittle transition temperatures 98 K (500 °C). Obtaining the martensitic structure requires more rapid cooling than is needed to obtain the bainitic structure and this more rapid cooling promote cracking. As the UFEG structures obtained from initial martensitic and bainitic structures have almost identical properties, but obtaining the bainitic structure does not require a rapid cooling which promotes cracking suggests the use of a bainitic structure in obtaining UFEG structures should be examined further.

Non-local damage rheology and size effect

NASA Astrophysics Data System (ADS)

Lyakhovsky, V.

2011-12-01

We study scaling relations controlling the onset of transiently-accelerating fracturing and transition to dynamic rupture propagation in a non-local damage rheology model. The size effect is caused principally by growth of a fracture process zone, involving stress redistribution and energy release associated with a large fracture. This implies that rupture nucleation and transition to dynamic propagation are inherently scale-dependent processes. Linear elastic fracture mechanics (LEFM) and local damage mechanics are formulated in terms of dimensionless strain components and thus do not allow introducing any space scaling, except linear relations between fracture length and displacements. Generalization of Weibull theory provides scaling relations between stress and crack length at the onset of failure. A powerful extension of the LEFM formulation is the displacement-weakening model which postulates that yielding is complete when the crack wall displacement exceeds some critical value or slip-weakening distance Dc at which a transition to kinetic friction is complete. Scaling relations controlling the transition to dynamic rupture propagation in slip-weakening formulation are widely accepted in earthquake physics. Strong micro-crack interaction in a process zone may be accounted for by adopting either integral or gradient type non-local damage models. We formulate a gradient-type model with free energy depending on the scalar damage parameter and its spatial derivative. The damage-gradient term leads to structural stresses in the constitutive stress-strain relations and a damage diffusion term in the kinetic equation for damage evolution. The damage diffusion eliminates the singular localization predicted by local models. The finite width of the localization zone provides a fundamental length scale that allows numerical simulations with the model to achieve the continuum limit. A diffusive term in the damage evolution gives rise to additional damage diffusive time scale associated with the structural length scale. The ratio between two time scales associated with damage accumulation and diffusion, the damage diffusivity ratio, reflects the role of the diffusion-controlled delocalization. We demonstrate that localized fracturing occurs at the damage diffusivity ratio below certain critical value leading to a linear scaling between stress and crack length compatible with size effect for failures at crack initiation. A subseuqent quasi-static fracture growth is self-similar with increasing size of the process zone proportional to the fracture length. At a certain stage, controlled by dynamic weakening, the self-similarity breaks down and crack velocity significantly deviates from that predicted by the quasi-static regime, the size of the process zone decreases, and the rate of crack growth ceases to be controlled by the rate of damage increase. Furthermore, the crack speed approaches that predicted by the elasto-dynamic equation. The non-local damage rheology model predicts that the nucleation size of the dynamic fracture scales with fault zone thickness distance of the stress interraction.

Estimate of Probability of Crack Detection from Service Difficulty Report Data.

DOT National Transportation Integrated Search

1995-09-01

The initiation and growth of cracks in a fuselage lap joint were simulated. Stochastic distribution of crack initiation and rivet interference were included. The simulation also contained a simplified crack growth. Nominal crack growth behavior of la...

Estimate of probability of crack detection from service difficulty report data

DOT National Transportation Integrated Search

1994-09-01

The initiation and growth of cracks in a fuselage lap joint were simulated. Stochastic distribution of crack initiation and rivet interference were included. The simulation also contained a simplified crack growth. Nominal crack growth behavior of la...

Thermoelastic analysis of matrix crack growth in particulate composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridhar, N.; Rickman, J.M.; Srolovitz, D.J.

1995-04-01

The authors examine the conditions under which differences in thermal expansion between a particle and the matrix lead to crack growth within the matrix. Using linear elasticity fracture mechanics, they obtain closed-form, analytical results for the case of a penny shaped crack present in the matrix interacting with a spherical inclusion which is misfitting with respect to the matrix. A simple and direct relationship is established between the strain energy release rate, the crack size, the crack orientation with respect to the inclusion, the crack/inclusion separation, the degree of thermal expansion mismatch and the elastic properties of the medium. Themore » authors also analyze the size to which these cracks can grow and find that for a given misfit strain and material properties, crack growth is inhibited beyond a certain critical crack size. They find that beyond this critical size, the elastic strain energy released upon crack growth is no longer sufficient to compensate for the energy expended in extending the crack, since the crack is growing into the rapidly decreasing stress field. The modification of the above conditions for crack growth due to the superposition of an external stress field has also been analyzed. The preferred orientation of these cracks as a function of misfit strain is predicted. The implication of these results for thermal cycling are analyzed.« less

Tension Strength, Failure Prediction and Damage Mechanisms in 2D Triaxial Braided Composites with Notch

NASA Technical Reports Server (NTRS)

Norman, Timothy L.; Anglin, Colin

1995-01-01

The unnotched and notched (open hole) tensile strength and failure mechanisms of two-dimensional (2D) triaxial braided composites were examined. The effect of notch size and notch position were investigated. Damage initiation and propagation in notched and unnotched coupons were also examined. Theory developed to predict the normal stress distribution near an open hole and failure for tape laminated composites was evaluated for its applicability to 2D triaxial braided textile composite materials. Four different fiber architectures were considered; braid angle, yarn and braider size, percentage of longitudinal yarns and braider angle varied. Tape laminates equivalent to textile composites were also constructed for comparison. Unnotched tape equivalents were stronger than braided textiles but exhibited greater notch sensitivity. Notched textiles and tape equivalents have roughly the same strength at large notch sizes. Two common damage mechanisms were found: braider yarn cracking and near notch longitudinal yarn splitting. Cracking was found to initiate in braider yarns in unnotched and notched coupons, and propagate in the direction of the braider yarns until failure. Damage initiation stress decreased with increasing braid angle. No significant differences in prediction of near notch strain between textile and tape equivalents could be detected for small braid angle, but the correlations were weak for textiles with large braid angle. Notch strength could not be predicted using existing anisotropic theory for braided textiles due to their insensitivity to notch.

Wave generation by fracture initiation and propagation in geomaterials with internal rotations

NASA Astrophysics Data System (ADS)

Esin, Maxim; Pasternak, Elena; Dyskin, Arcady; Xu, Yuan

2016-04-01

Crack or fracture initiation and propagation in geomaterials are sources of waves and is important in both stability and fracture (e.g. hydraulic fracture) monitoring. Many geomaterials consist of particles or other constituents capable of rotating with respect to each other, either due to the absence of the binder phase (fragmented materials) or due to extensive damage of the cement between the constituents inflicted by previous loading. In investigating the wave generated in fracturing it is important to distinguish between the cases when the fracture is instantaneously initiated to its full length or propagates from a smaller initial crack. We show by direct physical experiments and discrete element modelling of 2D arrangements of unbonded disks that under compressive load fractures are initiated instantaneously as a result of the material instability and localisation. Such fractures generate waves as a single impulse impact. When the fractures propagate, they produce a sequence of impulses associated with the propagation steps. This manifests itself as acoustic (microseismic) emission whose temporal pattern contains the information of the fracture geometry, such as fractal dimension of the fracture. The description of this process requires formulating criteria of crack growth capable of taking into account the internal rotations. We developed an analytical solution based on the Cosserat continuum where each point of body has three translational and three rotational degrees of freedom. When the Cosserat characteristic lengths are comparable with the grain sizes, the simplified equations of small-scale Cosserat continuum can be used. We established that the order of singularity of the main asymptotic term for moment stress is higher than the order of singularity for conventional stress. Therefore, the mutual rotation of particles and related bending and/or twisting of the bonds between the particles represent an unconventional mechanism of crack propagation.

Monitoring micro-crack healing in an engineered cementitious composite using the environmental scanning electron microscope

DOE Office of Scientific and Technical Information (OSTI.GOV)

Suryanto, B., E-mail: b.suryanto@hw.ac.uk; Buckman

Environmental Scanning Electron Microscopy (ESEM) is used to study the origin of micro-crack healing in an Engineered Cementitious Composite (ECC). ESEM images were acquired from ECC specimens cut from pre-cracked, dog-bone samples which then subjected to submerged curing followed by exposure to the natural environment. The mineralogical and chemical compositions of the healing products were determined using the EDX facility in the ESEM. It is shown that the precipitation of calcium carbonate is the main contributor to micro-crack healing at the crack mouth. The healing products initially appeared in an angular rhombohedral morphology which then underwent a discernable transformation inmore » size, shape and surface texture, from relatively flat and smooth to irregular and rough, resembling the texture of the original surface areas surrounding the micro-cracks. It is also shown that exposure to the natural environment, involving intermittent wetting/drying cycles, promotes additional crystal growth, which indicates enhanced self-healing capability in this environment. - Highlights: •ESEM with EDX used to characterize the origin of micro-crack healing in an ECC •Evolution of healing precipitates studied at three specific locations over four weeks •Specimens exposed to laboratory environment, followed by the natural environment •Calcium carbonate is the main contributor to crack healing at the crack mouth. •Outdoor exposure involving intermittent rain promotes additional crystal growth.« less

Review of progress in quantitative NDE

NASA Astrophysics Data System (ADS)

s of 386 papers and plenary presentations are included. The plenary sessions are related to the national technology initiative. The other sessions covered the following NDE topics: corrosion, electromagnetic arrays, elastic wave scattering and backscattering/noise, civil structures, material properties, holography, shearography, UT wave propagation, eddy currents, coatings, signal processing, radiography, computed tomography, EM imaging, adhesive bonds, NMR, laser ultrasonics, composites, thermal techniques, magnetic measurements, nonlinear acoustics, interface modeling and characterization, UT transducers, new techniques, joined materials, probes and systems, fatigue cracks and fracture, imaging and sizing, NDE in engineering and process control, acoustics of cracks, and sensors. An author index is included.

Matrix cracking with irregular fracture fronts as observed in fiber reinforced ceramic composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hu, K.X.; Yeh, C.P.; Wyatt, K.W.

1998-01-01

As a result of matrix cracking in fiber reinforced composites, fracture planforms assume a wide variation of profiles due to the fact that fiber bridging strongly affects the behavior of local crack fronts. This observation raises the question on the legitimacy of commonly used penny-shaped crack solutions when applied to fiber reinforced composites. Accordingly, investigation of the effects of fracture front profiles on mechanical responses is the thrust of this paper. The authors start with the solution of a penny-shaped crack in a unidirectional, fiber reinforced composite, which demonstrates necessity of considering wavy fracture fronts in fiber reinforced composites. Amore » theoretical framework for fiber reinforced composites with irregular fracture fronts due to matrix cracking is then established via a micromechanics model. The difference between small crack-size matrix cracking and large crack-size matrix cracking is investigated in detail. It is shown that the bridging effect is insignificant when matrix crack size is small and solution of effective property are obtained using Mori-Tanaka`s method by treating cracks and reinforcing fibers as distinct, but interacting phases. When the crack size becomes large, the bridging effects has to be taken into consideration. With bridging tractions obtained in consistency with the micromechanics solution, and corresponding crack energy backed out, the effective properties are obtained through a modification of standard Mori-Tanaka`s treatment of multiphase composites. Analytical solutions show that the generalization of a crack density of a penny-shaped planform is insufficient in describing the effective responses of fiber-reinforced composites with matrix cracking. Approximate solutions that account for the effects of the irregularity of crack planforms are given in closed forms for several irregular crack planforms, including cracks of cross rectangle, polygon and rhombus.« less

Crack turning in integrally stiffened aircraft structures

NASA Astrophysics Data System (ADS)

Pettit, Richard Glen

Current emphasis in the aircraft industry toward reducing manufacturing cost has created a renewed interest in integrally stiffened structures. Crack turning has been identified as an approach to improve the damage tolerance and fail-safety of this class of structures. A desired behavior is for skin cracks to turn before reaching a stiffener, instead of growing straight through. A crack in a pressurized fuselage encounters high T-stress as it nears the stiffener---a condition favorable to crack turning. Also, the tear resistance of aluminum alloys typically varies with crack orientation, a form of anisotropy that can influence the crack path. The present work addresses these issues with a study of crack turning in two-dimensions, including the effects of both T-stress and fracture anisotropy. Both effects are shown to have relation to the process zone size, an interaction that is central to this study. Following an introduction to the problem, the T-stress effect is studied for a slightly curved semi-infinite crack with a cohesive process zone, yielding a closed form expression for the future crack path in an infinite medium. For a given initial crack tip curvature and tensile T-stress, the crack path instability is found to increase with process zone size. Fracture orthotropy is treated using a simple function to interpolate between the two principal fracture resistance values in two-dimensions. An extension to three-dimensions interpolates between the six principal values of fracture resistance. Also discussed is the transition between mode I and mode II fracture in metals. For isotropic materials, there is evidence that the crack seeks out a direction of either local symmetry (pure mode I) or local asymmetry (pure mode II) growth. For orthotropic materials the favored states are not pure modal, and have mode mixity that is a function of crack orientation. Drawing upon these principles, two crack turning prediction approaches are extended to include fracture resistance orthotropy---a second-order linear elastic method with a characteristic length parameter to incorporate T-stress/process-zone effects, and an elastic-plastic method that uses the Crack Tip Opening Displacement (CTOD) to determine the failure response. Together with a novel method for obtaining enhanced accuracy T-stress calculations, these methods are incorporated into an adaptive-mesh, finite-element fracture simulation code. A total of 43 fracture tests using symmetrically and asymmetrically loaded double cantilever beam specimens were run to develop crack turning parameters and compare predicted and observed crack paths.

Accelerated Stress Corrosion Crack Initiation of Alloys 600 and 690 in Hydrogenated Supercritical Water

NASA Astrophysics Data System (ADS)

Moss, Tyler; Was, Gary S.

2017-04-01

The objective of this study is to determine whether stress corrosion crack initiation of Alloys 600 and 690 occurs by the same mechanism in subcritical and supercritical water. Tensile bars of Alloys 690 and 600 were strained in constant extension rate tensile experiments in hydrogenated subcritical and supercritical water from 593 K to 723 K (320 °C to 450 °C), and the crack initiation behavior was characterized by high-resolution electron microscopy. Intergranular cracking was observed across the entire temperature range, and the morphology, structure, composition, and temperature dependence of initiated cracks in Alloy 690 were consistent between hydrogenated subcritical and supercritical water. Crack initiation of Alloy 600 followed an Arrhenius relationship and did not exhibit a discontinuity or change in slope after crossing the critical temperature. The measured activation energy was 121 ± 13 kJ/mol. Stress corrosion crack initiation in Alloy 690 was fit with a single activation energy of 92 ± 12 kJ/mol across the entire temperature range. Cracks were observed to propagate along grain boundaries adjacent to chromium-depleted metal, with Cr2O3 observed ahead of crack tips. All measures of the SCC behavior indicate that the mechanism for stress corrosion crack initiation of Alloy 600 and Alloy 690 is consistent between hydrogenated subcritical and supercritical water.

DISFRAC Version 2.0 Users Guide

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cochran, Kristine B; Erickson, Marjorie A; Williams, Paul T

2013-01-01

DISFRAC is the implementation of a theoretical, multi-scale model for the prediction of fracture toughness in the ductile-to-brittle transition temperature (DBTT) region of ferritic steels. Empirically-derived models of the DBTT region cannot legitimately be extrapolated beyond the range of existing fracture toughness data. DISFRAC requires only tensile properties and microstructural information as input, and thus allows for a wider range of application than empirical, toughness data dependent models. DISFRAC is also a framework for investigating the roles of various microstructural and macroscopic effects on fracture behavior, including carbide particle sizes, grain sizes, strain rates, and material condition. DISFRAC s novelmore » approach is to assess the interaction effects of macroscopic conditions (geometry, loading conditions) with variable microstructural features on cleavage crack initiation and propagation. The model addresses all stages of the fracture process, from microcrack initiation within a carbide particle, to propagation of that crack through grains and across grain boundaries, finally to catastrophic failure of the material. The DISFRAC procedure repeatedly performs a deterministic analysis of microcrack initiation and propagation within a macroscopic crack plastic zone to calculate a critical fracture toughness value for each microstructural geometry set. The current version of DISFRAC, version 2.0, is a research code for developing and testing models related to cleavage fracture and transition toughness. The various models and computations have evolved significantly over the course of development and are expected to continue to evolve as testing and data collection continue. This document serves as a guide to the usage and theoretical foundations of DISFRAC v2.0. Feedback is welcomed and encouraged.« less

Dynamic Rupture and Energy Partition in Models of Earthquake Faults

NASA Astrophysics Data System (ADS)

Shi, Z.; Needleman, A.; Ben-Zion, Y.

2006-12-01

We study properties of dynamic rupture and the partition of energy between radiation and dissipative mechanisms using 2D finite element calculations. The goal is to improve the understanding of these processes on faults at different evolutionary stages associated with different levels of geometrical complexity and possible presence of contrasting elastic properties across the fault. The initial calculations employ homogeneous media and a planar internal interface governed by a general rate- and state-dependent friction law that accounts for the gradual response of shear stress to abrupt changes of normal stress. Ruptures are initiated by gradually increasing the shear traction in a limited nucleation zone near the origin. By changing the rate dependency of the friction law and the size of the nucleation zone, we obtain four rupture modes: (i) supershear crack-like rupture; (ii) subshear crack-like rupture; (iii) subshear single pulse; and (iv) supershear train of pulses. Increasing the initial shear stress produces a transition from a subshear crack to a supershear crack, while increasing the rate dependency of the friction produces self-healing and the transition from a crack-like to a pulse mode of rupture. Properties of the nucleation process can strongly affect the rupture mode. In the cases examined, the total release of strain energy (over the same propagation distance) decreases following the order: supershear crack, subshear crack, train of pulses and single pulse. The ratio of the radiated kinetic energy to the energy dissipated in friction is about 5% for the supershear crack case and about 2% for the other three cases. Future work will involve similar calculations accounting for the generation of plastic strain in the bulk, the material contrast across the fault, and the addition of cohesive surfaces in the bulk to allow for the generation of new surfaces. The study may provide fundamental information on rupture processes in geologically-relevant circumstances and improve the understanding of physical limits on extreme ground motion. The results may be used to check assumptions made in observational works and may help to guide new observational research.

Subcritical crack growth phenomenon and fractography of barium titanate and barium titanate-based composite

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hwang, H.J.; Niihara, Koichi

1997-01-15

Subcritical crack growth (SCG), the propagation of surface and subsurface flaws under subcritical stress, i.e., any stress less than that necessary to catastrophically propagate the flaw, is a general phenomenon frequently observed in ceramics. Recently, electrical devices are miniaturized and used under quite severe atmospheres. Such environments often lead to the initiation and propagation of cracks due to the repeated electrical cycling, stresses by the mismatch in thermal expansion coefficient between devices and other constituents and thermal shock. In this study, the authors fabricated BaTiO{sub 3} and BaTiO{sub 3}-based composites containing nano-sized SiC particulates. The SCG phenomenon and fractography weremore » discussed based on the data obtained from indentation-induced-fracture (IIF) method.« less

Fatigue crack initiation of magnesium alloys under elastic stress amplitudes: A review

NASA Astrophysics Data System (ADS)

Wang, B. J.; Xu, D. K.; Wang, S. D.; Han, E. H.

2017-12-01

The most advantageous property of magnesium (Mg) alloys is their density, which is lower compared with traditional metallic materials. Mg alloys, considered the lightest metallic structural material among others, have great potential for applications as secondary load components in the transportation and aerospace industries. The fatigue evaluation of Mg alloys under elastic stress amplitudes is very important in ensuring their service safety and reliability. Given their hexagonal close packed structure, the fatigue crack initiation of Mg and its alloys is closely related to the deformation mechanisms of twinning and basal slips. However, for Mg alloys with shrinkage porosities and inclusions, fatigue cracks will preferentially initiate at these defects, remarkably reducing the fatigue lifetime. In this paper, some fundamental aspects about the fatigue crack initiation mechanisms of Mg alloys are reviewed, including the 3 followings: 1) Fatigue crack initiation of as-cast Mg alloys, 2) influence of microstructure on fatigue crack initiation of wrought Mg alloys, and 3) the effect of heat treatment on fatigue initiation mechanisms. Moreover, some unresolved issues and future target on the fatigue crack initiation mechanism of Mg alloys are also described.

Crack-tip-opening angle measurements and crack tunneling under stable tearing in thin sheet 2024-T3 aluminum alloy

NASA Technical Reports Server (NTRS)

Dawicke, D. S.; Sutton, M. A.

1993-01-01

The stable tearing behavior of thin sheets 2024-T3 aluminum alloy was studied for middle crack tension specimens having initial cracks that were: flat cracks (low fatigue stress) and 45 degrees through-thickness slant cracks (high fatigue stress). The critical crack-tip-opening angle (CTOA) values during stable tearing were measured by two independent methods, optical microscopy and digital image correlation. Results from the two methods agreed well. The CTOA measurements and observations of the fracture surfaces showed 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, CTOA reached a constant value of 6 deg and after crack growth equal to about twice the thickness, crack tunneling stabilized. 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 cracks in the high fatigue stress tests reach the same constant CTOA value after crack growth equal to about the thickness, but produced only a slightly higher CTOA value during initial crack growth. For crack growth on the 45 degree slant, the crack front and local field variables are still highly three-dimensional. However, the constant CTOA values and stable crack front shape may allow the process to be approximated with two-dimensional models.

Effects of electric field on the fracture toughness (KIc) of ceramic PZT

NASA Astrophysics Data System (ADS)

Goljahi, Sam; Lynch, Christopher S.

2013-09-01

This work was motivated by the observation that a small percentage of the ceramic lead zirconate titanate (PZT) parts in a device application, one that requires an electrode pattern on the PZT surface, developed fatigue cracks at the edges of the electrodes; yet all of the parts were subjected to similar loading. To obtain additional information on the fracture behavior of this material, similar specimens were run at higher voltage in the laboratory under a microscope to observe the initiation and growth of the fatigue cracks. A sequence of experiments was next performed to determine whether there were fracture toughness variations that depended on material processing. Plates were cut from a single bar in different locations and the Vickers indentation technique was used to measure the relative fracture toughness as a function of position along the bar. Small variations in toughness were found, that may account for some of the devices developing fatigue cracks and not others. Fracture toughness was measured next as a function of electric field. The surface crack in flexure technique was modified to apply an electric field perpendicular to a crack. The results indicate that the fracture toughness drops under a positive electric field and increases under a negative electric field that is less than the coercive field, but as the negative coercive field is approached the fracture toughness drops. Examination of the fracture surfaces using an optical microscope and a surface profilometer reveal the initial indentation crack shape and (although less accurately) the crack shape and size at the transition from stable to unstable growth. These results are discussed in terms of a ferroelastic toughening mechanism that is dependent on electric field.

Microstructural characterization of hydrogen induced cracking in TRIP-assisted steel by EBSD

DOE Office of Scientific and Technical Information (OSTI.GOV)

Laureys, A., E-mail: Aurelie.Laureys@UGent.be; Depover, T.; Petrov, R.

2016-02-15

The present work evaluates hydrogen induced cracking by performing an elaborate EBSD (Electron BackScatter Diffraction) study in a steel with transformation induced plasticity (TRIP-assisted steel). This type of steel exhibits a multiphase microstructure which undergoes a deformation induced phase transformation. Additionally, each microstructural constituent displays a different behavior in the presence of hydrogen. The aim of this study is to obtain a better understanding on the mechanisms governing hydrogen induced crack initiation and propagation in the hydrogen saturated multiphase structure. Tensile tests on notched samples combined with in-situ electrochemical hydrogen charging were conducted. The tests were interrupted at stresses justmore » after reaching the tensile strength, i.e. before macroscopic failure of the material. This allowed to study hydrogen induced crack initiation and propagation by SEM (Scanning Electron Microscopy) and EBSD. A correlation was found between the presence of martensite, which is known to be very susceptible to hydrogen embrittlement, and the initiation of hydrogen induced cracks. Initiation seems to occur mostly by martensite decohesion. High strain regions surrounding the hydrogen induced crack tips indicate that further crack propagation may have occurred by the HELP (hydrogen-enhanced localized plasticity) mechanism. Small hydrogen induced cracks located nearby the notch are typically S-shaped and crack propagation was dominantly transgranularly. The second stage of crack propagation consists of stepwise cracking by coalescence of small hydrogen induced cracks. - Highlights: • Hydrogen induced cracking in TRIP-assisted steel is evaluated by EBSD. • Tensile tests were conducted on notched hydrogen saturated samples. • Crack initiation occurs by a H-Enhanced Interface DEcohesion (HEIDE) mechanism. • Crack propagation involves growth and coalescence of small cracks. • Propagation is governed by the characteristics of phases on the crack path.« less

Evaluation of morphology and size of cracks of the Interfacial Transition Zone (ITZ) in concrete containing fly ash (FA).

PubMed

Golewski, Grzegorz Ludwik

2018-06-07

Interfacial Transition Zone (ITZ) of coarse aggregate cement matrix is commonly regarded as the weakest element of concrete. In this phase - the first cracks in the material are initiated, and the process of destruction of the composite begins. An improvement of the ITZ properties are positively influenced by the mineral additives used for the composite. One of such a substitute for a binder is, potentially hazardous industrial waste, siliceous fly ash (FA). In this paper the ITZ between aggregate and cement paste in concretes containing FA is considered. The paper presents the results of tests on the effect of the addition of FA in the amount of: 0, 20 and 30% by weight of cement on morphology and size of cracks of the ITZ in composites. In matured concretes the smallest cracks occur in composite with the 20% FA additive. It can be concluded that composites with 20% addition of FA are characterized by low permeability and therefore high durability. The results of tests carried out can be helpful in obtaining concrete with the highest possible: strength, durability and reliability of operation. Moreover, such procedures also cause a restriction storage of hazardous materials, i.e. FA - by 160 million tons per year. Copyright © 2018 Elsevier B.V. All rights reserved.

Friction Stir Welding of Al Alloy 2219-T8: Part II-Mechanical and Corrosion

NASA Astrophysics Data System (ADS)

Kang, Ju; Feng, Zhi-Cao; Li, Ji-Chao; Frankel, G. S.; Wang, Guo-Qing; Wu, Ai-Ping

2016-09-01

In Part I of this series, abnormal agglomerations of θ particles with size of about 100 to 1000 µm were observed in friction stir welded AA2219-T8 joints. In this work, the effects of these agglomerated θ particles on the mechanical and corrosion properties of the joints are studied. Tensile testing with in situ SEM imaging was utilized to monitor crack initiation and propagation in base metal and weld nugget zone (WNZ) samples. These tests showed that cracks initiated in the θ particles and at the θ/matrix interfaces, but not in the matrix. The WNZ samples containing abnormal agglomerated θ particles had a similar ultimate tensile stress but 3 pct less elongation than other WNZ samples with only normal θ particles. Measurements using the microcell technique indicated that the agglomerated θ particles acted as a cathode causing the dissolution of adjacent matrix. The abnormal θ particle agglomerations led to more severe localized attack due to the large cathode/anode ratio. Al preferential dissolution occurred in the abnormal θ particle agglomerations, which was different from the corrosion behavior of normal size θ particles.

Stress corrosion crack initiation of alloy 600 in PWR primary water

DOE PAGES

Zhai, Ziqing; Toloczko, Mychailo B.; Olszta, Matthew J.; ...

2017-04-27

Stress corrosion crack (SCC) initiation of three mill-annealed alloy 600 heats in simulated pressurized water reactor primary water has been investigated using constant load tests equipped with in-situ direct current potential drop (DCPD) measurement capabilities. SCC initiation times were greatly reduced by a small amount of cold work. Shallow intergranular attack and/or cracks were found on most high-energy grain boundaries intersecting the surface with only a small fraction evolving into larger cracks and intergranular SCC growth. Crack depth profiles were measured and related to DCPD-detected initiation response. Lastly, we discuss processes controlling the SCC initiation in mill-annealed alloy 600.

Stress corrosion crack initiation of alloy 600 in PWR primary water

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhai, Ziqing; Toloczko, Mychailo B.; Olszta, Matthew J.

Stress corrosion crack (SCC) initiation of three mill-annealed alloy 600 heats in simulated pressurized water reactor primary water has been investigated using constant load tests equipped with in-situ direct current potential drop (DCPD) measurement capabilities. SCC initiation times were greatly reduced by a small amount of cold work. Shallow intergranular attack and/or cracks were found on most high-energy grain boundaries intersecting the surface with only a small fraction evolving into larger cracks and intergranular SCC growth. Crack depth profiles were measured and related to DCPD-detected initiation response. Lastly, we discuss processes controlling the SCC initiation in mill-annealed alloy 600.

A Constitutive Relationship between Fatigue Limit and Microstructure in Nanostructured Bainitic Steels

PubMed Central

Mueller, Inga; Rementeria, Rosalia; Caballero, Francisca G.; Kuntz, Matthias; Sourmail, Thomas; Kerscher, Eberhard

2016-01-01

The recently developed nanobainitic steels show high strength as well as high ductility. Although this combination seems to be promising for fatigue design, fatigue properties of nanostructured bainitic steels are often surprisingly low. To improve the fatigue behavior, an understanding of the correlation between the nanobainitic microstructure and the fatigue limit is fundamental. Therefore, our hypothesis to predict the fatigue limit was that the main function of the microstructure is not necessarily totally avoiding the initiation of a fatigue crack, but the microstructure has to increase the ability to decelerate or to stop a growing fatigue crack. Thus, the key to understanding the fatigue behavior of nanostructured bainite is to understand the role of the microstructural features that could act as barriers for growing fatigue cracks. To prove this hypothesis, we carried out fatigue tests, crack growth experiments, and correlated these results to the size of microstructural features gained from microstructural analysis by light optical microscope and EBSD-measurements. Finally, we were able to identify microstructural features that influence the fatigue crack growth and the fatigue limit of nanostructured bainitic steels. PMID:28773953

Demonstrating damage tolerance of composite airframes

NASA Technical Reports Server (NTRS)

Poe, Clarence C., Jr.

1993-01-01

Commercial transport aircraft operating in the United States are certified by the Federal Aviation Authority to be damage tolerant. On 28 April 1988, Aloha Airlines Flight 243, a Boeing 727-200 airplane, suffered an explosive decompression of the fuselage but landed safely. This event provides very strong justification for the damage tolerant design criteria. The likely cause of the explosive decompression was the linkup of numerous small fatigue cracks that initiated at adjacent fastener holes in the lap splice joint at the side of the body. Actually, the design should have limited the damage size to less than two frame spacings (about 40 inches), but this type of 'multi-site damage' was not originally taken into account. This cracking pattern developed only in the high-time airplanes (many flights). After discovery in the fleet, a stringent inspection program using eddy current techniques was inaugurated to discover these cracks before they linked up. Because of concerns about safety and the maintenance burden, the lap-splice joints of these high-time airplanes are being modified to remove cracks and prevent new cracking; newer designs account for 'multi-site damage'.

Investigation of eddy current examination on OD fatigue crack for steam generator tubes

NASA Astrophysics Data System (ADS)

Kong, Yuying; Ding, Boyuan; Li, Ming; Liu, Jinhong; Chen, Huaidong; Meyendorf, Norbert G.

2015-03-01

The opening width of fatigue crack was very small, and conventional Bobbin probe was very difficult to detect it in steam generator tubes. Different sizes of 8 fatigue cracks were inspected using bobbin probe rotating probe. The analysis results showed that, bobbin probe was not sensitive for fatigue crack even for small through wall crack mixed with denting signal. On the other hand, the rotating probe was easily to detect all cracks. Finally, the OD phase to depth curve for fatigue crack using rotating probe was established and the results agreed very well with the true crack size.

Detection of Cracking Levels in Brittle Rocks by Parametric Analysis of the Acoustic Emission Signals

NASA Astrophysics Data System (ADS)

Moradian, Zabihallah; Einstein, Herbert H.; Ballivy, Gerard

2016-03-01

Determination of the cracking levels during the crack propagation is one of the key challenges in the field of fracture mechanics of rocks. Acoustic emission (AE) is a technique that has been used to detect cracks as they occur across the specimen. Parametric analysis of AE signals and correlating these parameters (e.g., hits and energy) to stress-strain plots of rocks let us detect cracking levels properly. The number of AE hits is related to the number of cracks, and the AE energy is related to magnitude of the cracking event. For a full understanding of the fracture process in brittle rocks, prismatic specimens of granite containing pre-existing flaws have been tested in uniaxial compression tests, and their cracking process was monitored with both AE and high-speed video imaging. In this paper, the characteristics of the AE parameters and the evolution of cracking sequences are analyzed for every cracking level. Based on micro- and macro-crack damage, a classification of cracking levels is introduced. This classification contains eight stages (1) crack closure, (2) linear elastic deformation, (3) micro-crack initiation (white patch initiation), (4) micro-crack growth (stable crack growth), (5) micro-crack coalescence (macro-crack initiation), (6) macro-crack growth (unstable crack growth), (7) macro-crack coalescence and (8) failure.

Experimental study of crack initiation and propagation in high- and gigacycle fatigue in titanium alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bannikov, Mikhail, E-mail: mbannikov@icmm.ru, E-mail: oborin@icmm.ru, E-mail: naimark@icmm.ru; Oborin, Vladimir, E-mail: mbannikov@icmm.ru, E-mail: oborin@icmm.ru, E-mail: naimark@icmm.ru; Naimark, Oleg, E-mail: mbannikov@icmm.ru, E-mail: oborin@icmm.ru, E-mail: naimark@icmm.ru

Fatigue (high- and gigacycle) crack initiation and its propagation in titanium alloys with coarse and fine grain structure are studied by fractography analysis of fracture surface. Fractured specimens were analyzed by interferometer microscope and SEM to improve methods of monitoring of damage accumulation during fatigue test and to verify the models for fatigue crack kinetics. Fatigue strength was estimated for high cycle fatigue regime using the Luong method [1] by “in-situ” infrared scanning of the sample surface for the step-wise loading history for different grain size metals. Fine grain alloys demonstrated higher fatigue resistance for both high cycle fatigue andmore » gigacycle fatigue regimes. Fracture surface analysis for plane and cylindrical samples was carried out using optical and electronic microscopy method. High resolution profilometry (interferometer-profiler New View 5010) data of fracture surface roughness allowed us to estimate scale invariance (the Hurst exponent) and to establish the existence of two characteristic areas of damage localization (different values of the Hurst exponent). Area 1 with diameter ∼300 μm has the pronounced roughness and is associated with damage localization hotspot. Area 2 shows less amplitude roughness, occupies the rest fracture surface and considered as the trace of the fatigue crack path corresponding to the Paris kinetics.« less

Experimental Study on the Growth, Coalescence and Wrapping Behaviors of 3D Cross-Embedded Flaws Under Uniaxial Compression

NASA Astrophysics Data System (ADS)

Zhou, Xiao-Ping; Zhang, Jian-Zhi; Wong, Louis Ngai Yuen

2018-05-01

The crack initiation, growth, wrapping and coalescence of two 3D pre-existing cross-embedded flaws in PMMA specimens under uniaxial compression are investigated. The stress-strain curves of PMMA specimens with 3D cross-embedded flaws are obtained. The tested PMMA specimens exhibit dominant elastic deformation and eventual brittle failure. The experimental results show that four modes of crack initiation and five modes of crack coalescence are observed. The initiations of oblique secondary crack and anti-wing crack in 3D cracking behaviors are first reported as well as the coalescence of anti-wing cracks. Moreover, two types of crack wrapping are found. Substantial wrapping of petal cracks, which includes open and closed modes of wrapping, appears to be the major difference between 2D and 3D cracking behaviors of pre-existing flaws, which are also first reported. Petal crack wraps symmetrically from either the propagated wing cracks or the coalesced wing cracks. Besides, only limited growth of petal cracks is observed, and ultimate failure of specimens is induced by the further growth of the propagated wing crack. The fracture mechanism of the tested PMMA specimens is finally revealed. In addition, the initiation stress and the peak stress versus the geometry of two 3D pre-existing cross-embedded flaws are also investigated in detail.

Sub-micron fracture mechanism in silica-based glass activated by permanent densification from high-strain loading

DOE PAGES

Wereszczak, Andrew A.; Waters, Shirley B.; Parten, Randy J.; ...

2016-04-26

Several silica-based glasses were fractured at high strain energy via drop-weight testing on small specimens. A cylindrical specimen geometry was chosen to promote initially simple, axisymmetric, and uniform compressive loading. The imposed uniaxial compressive strain at impact was sufficiently high to qualitatively cause permanent densification. Produced fragments were collected for postmortem and a fraction of them, for all the silica-based glasses, consistently had distinct sub-micron-sized fractures (~ 300–1000 nm), designated here as “microkernels”, on their surfaces. They would most often appear as a sub-micron pore on the fragment - apparently if the microkernel had popped out as a consequence ofmore » the local crack plane running through it, tensile-strain release, and the associated formation of the fragment it was on. No fractographic evidence was found to show the microkernels were associated with local failure initiation. However, their positioning and habit sometimes suggested they were associated with localized crack branching and that they could have influenced secondary fracturing that occurred during overall crushing and comminution and associated fragment size and shape creation. Furthermore, the size range of these microkernels is much too small to affect structural flexure strength of these glasses for most applications but are of a size and concentration that may affect their ballistic, shock, crush, and comminution responses when permanent densification is concomitantly occurring.« less

Hierarchically-Driven Approach for Quantifying Fatigue Crack Initiation and Short Crack Growth Behavior in Aerospace Materials

DTIC Science & Technology

2016-08-31

crack initiation and SCG mechanisms (initiation and growth versus resistance). 2. Final summary Here, we present a hierarchical form of multiscale...prismatic faults in -Ti: A combined quantum mechanics /molecular mechanics study 2. Nano-indentation and slip transfer (critical in understanding crack...initiation) 3. An extended-finite element framework (XFEM) to study SCG mechanisms 4. Atomistic methods to develop a grain and twin boundaries database

Formation of Hot Tear Under Controlled Solidification Conditions

NASA Astrophysics Data System (ADS)

Subroto, Tungky; Miroux, Alexis; Bouffier, Lionel; Josserond, Charles; Salvo, Luc; Suéry, Michel; Eskin, Dmitry G.; Katgerman, Laurens

2014-06-01

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window—compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.

Deformation fields near a steady fatigue crack with anisotropic plasticity

DOE PAGES

Gao, Yanfei

2015-11-30

In this work, from finite element simulations based on an irreversible, hysteretic cohesive interface model, a steady fatigue crack can be realized if the crack extension exceeds about twice the plastic zone size, and both the crack increment per loading cycle and the crack bridging zone size are smaller than the plastic zone size. The corresponding deformation fields develop a plastic wake behind the crack tip and a compressive residual stress field ahead of the crack tip. In addition, the Hill’s plasticity model is used to study the role of plastic anisotropy on the retardation of fatigue crack growth andmore » the elastic strain fields. It is found that for Mode-I cyclic loading, an enhanced yield stress in directions that are inclined from the crack plane will lead to slower crack growth rate, but this retardation is insignificant for typical degrees of plastic anisotropy. Furthermore, these results provide key inputs for future comparisons to neutron and synchrotron diffraction measurements that provide full-field lattice strain mapping near fracture and fatigue crack tips, especially in textured materials such as wrought or rolled Mg alloys.« less

Deformation fields near a steady fatigue crack with anisotropic plasticity

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gao, Yanfei

In this work, from finite element simulations based on an irreversible, hysteretic cohesive interface model, a steady fatigue crack can be realized if the crack extension exceeds about twice the plastic zone size, and both the crack increment per loading cycle and the crack bridging zone size are smaller than the plastic zone size. The corresponding deformation fields develop a plastic wake behind the crack tip and a compressive residual stress field ahead of the crack tip. In addition, the Hill’s plasticity model is used to study the role of plastic anisotropy on the retardation of fatigue crack growth andmore » the elastic strain fields. It is found that for Mode-I cyclic loading, an enhanced yield stress in directions that are inclined from the crack plane will lead to slower crack growth rate, but this retardation is insignificant for typical degrees of plastic anisotropy. Furthermore, these results provide key inputs for future comparisons to neutron and synchrotron diffraction measurements that provide full-field lattice strain mapping near fracture and fatigue crack tips, especially in textured materials such as wrought or rolled Mg alloys.« less

Opening-mode cracking in asphalt pavements : crack initiation and saturation.

DOT National Transportation Integrated Search

2009-12-01

This paper investigates the crack initiation and saturation for opening-mode cracking. Using elastic governing equations : and a weak form stress boundary condition, we derive an explicit solution of elastic fields in the surface course and : obtain ...

The static breaking technique for sustainable and eco-environmental coal mining.

PubMed

Bing-yuan, Hao; Hui, Huang; Zi-jun, Feng; Kai, Wang

2014-01-01

The initiating explosive devices are prohibited in rock breaking near the goaf of the highly gassy mine. It is effective and applicable to cracking the hard roof with static cracking agent. By testing the static cracking of cubic limestone (size: 200 × 200 × 200 mm) with true triaxial rock mechanics testing machine under the effect of bidirectional stress and by monitoring the evolution process of the cracks generated during the acoustic emission experiment of static cracking, we conclude the following: the experiment results of the acoustic emission show that the cracks start from the lower part of the hole wall until they spread all over the sample. The crack growth rate follows a trend of "from rapidness to slowness." The expansion time is different for the two bunches of cracks. The growth rates can be divided into the rapid increasing period and the rapid declining period, of which the growth rate in declining period is less than that in the increasing period. Also, the growth rate along the vertical direction is greater than that of the horizontal direction. Then the extended model for the static cracking is built according to the theories of elastic mechanics and fracture mechanics. Thus the relation formula between the applied forces of cracks and crack expansion radius is obtained. By comparison with the test results, the model proves to be applicable. In accordance with the actual geological situation of Yangquan No. 3 Mine, the basic parameters of manpower manipulated caving breaking with static crushing are settled, which reaps bumper industrial effects.

Evaluation of enamel micro-cracks characteristics after removal of metal brackets in adult patients.

PubMed

Dumbryte, Irma; Linkeviciene, Laura; Malinauskas, Mangirdas; Linkevicius, Tomas; Peciuliene, Vytaute; Tikuisis, Kristupas

2013-06-01

The purpose of this study was to evaluate and compare enamel micro-crack characteristics of adult patients before and after removal of metal brackets. After the examination with scanning electron microscopy (SEM), 45 extracted human teeth were divided into three groups of equal size: group 1, the teeth having enamel micro-cracks, group 2, the teeth without initial enamel micro-cracks, and group 3, control group to study the effect of dehydration on existing micro-cracks or formation of new ones. For all the teeth in groups 1 and 2, the same bonding and debonding procedures of metal brackets were conducted. The length and width of the longest enamel micro-crack were measured for all the teeth before and after removal of metal brackets. The changes in the location of the micro-cracks were also evaluated. In group 3, teeth were subjected to the same analysis but not bonded. The mean overall width of micro-cracks after removal of metal brackets was 3.82 μm greater than before bonding procedure (P < 0.05). Also, a significant difference was noticed between the width of micro-cracks in first zone (cervical third) and third zone (occlusal third) after debonding procedure (P < 0.05). New enamel micro-cracks were found in 6 of 15 (40 per cent) examined teeth. Greatest changes in the width of enamel micro-cracks after debonding procedure appear in the cervical third of the tooth. On the basis of this result, the dentist must pay extra care and attention to this specific area of enamel during removal of metal brackets in adult patients.

Identification and prioritization of rail squat defects in the field using rail magnetisation technology

NASA Astrophysics Data System (ADS)

Kaewunruen, Sakdirat

2015-04-01

Inevitably, rail squats and studs are continuing to be a serious problem for railway organisations around the world in the 21st century. They are typically classified as the growth of any cracks that have grown longitudinally through the subsurface and some of the cracks propagating to the bottom of rails transversely, and have branched from initial longitudinal cracks with a depression of rail surface. The horizontal crack, which results in a depression of rail surface, induces increased maintenance level, more frequent monitoring, compromised rail testing (as the crack shields the signal echoes), and possible broken rails. This paper presents field investigations using a magnetised-rail testing device developed by MRX Technologies to identify and prioritise the rail squats. Most of the in situ squats were found on the high rail of the transition (variable-radius curved track), which is associated with rolling contact fatigue (RCF). This investigation highlights the field performance of the MRX's surface crack detection technology in comparison with the traditional ultrasonic method and detailed walking inspection. Visually, it was found in the field that the size of the RCF squats varies from very small to moderate. The predicted crack data were obtained by scanning the magnitised rails. The comparison of the actual crack depths (ultrasonic) and the predicted crack depths (MRX device) shows: • A possible correlation for small RCF/ squat cracks. • Poor interpretation of larger defects and welds. The field assessment also suggests some practical issues required for further development, including the detection of rail spalling, deep transverse crack, welding, and so on.

Assessment of the LC-2 Prelaunch Fatigue Spectra of the CM-to-SM Flange Weld

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Newman, John A.

2008-01-01

The pad stay and rollout components of the Ares I-X life cycle can generate cyclic stress oscillations to the vehicle that could initiate and grow fatigue cracks from weld defects. The Ares I-X Project requested that a study be performed to determine if stabilization of the vehicle is required to reduce the stresses that could initiate and grow fatigue cracks at the flange-to-skin weld of the Command Module (CM) and Service Module (SM) interface. A fatigue crack growth analysis was conducted that used loads (LC-2) and stress analyses developed by the Ares I-X Project and utilized material data and analysis methods developed by a critical initial flaw size (CIFS) analysis conducted by NASA Engineering and Safety Center (NESC) for the Upper Stage Simulator (USS) of the Ares I-X vehicle. A full CIFS analysis for the CM-to-SM flange-to-skin weld was not performed because the full flight spectrum was not provided and was not necessary to answer the question posed by the Ares I-X Project. Instead, an approach was developed to determine if the crack growth due to the pad stay and rollout components of the flight spectrum would adversely influence the CIFS. The approach taken used a number of conservative assumptions that eliminated the need for high-fidelity analyses and additional material testing, but still provided a bounding solution for the uncertainties of the problem. The results from this analysis indicate that the LC-2 pad stay and rollout spectrum components would not produce significant fatigue crack growth on the CM-to-SM flange-to-skin weld. Thus, from a fatigue crack growth standpoint, no stabilization is required to reduce the LC-2 pad stay and rollout cyclic stresses on the CM-to-SM flange-to-skin weld.

Progress in defect quantification in multi-layered structures using ultrasonic inspection

NASA Astrophysics Data System (ADS)

Dierken, Josiah; Aldrin, John C.; Holec, Robert; LaCivita, Michael; Shearer, Joshua; Lindgren, Eric

2013-01-01

This study investigates the ability to resolve flaws in aluminum panel stackups representative of aircraft structural components. Using immersion ultrasound techniques, the specimens were examined for known fatigue cracks and electric discharge machined (EDM) notches at various fastener sites. Initial assessments suggested a possible trend between measured ultrasound parameters of flaw intensity and size, and known physical defect length. To improve analytical reliability and efficiency, development of automated data analysis (ADA) algorithms has been initiated.

The relative stress-corrosion-cracking susceptibility of candidate aluminum-lithium alloys for aerospace applications

NASA Technical Reports Server (NTRS)

Pizzo, P. P.

1982-01-01

Stress corrosion tests of Al-Li-Cu powder metallurgy alloys are described. Alloys investigated were Al-2.6% Li-1.4% and Al-2.6% Li-1.4% Cu-1.6% Mg. The base properties of the alloys were characterized. Process, heat treatment, and size/orientational effects on the tensile and fracture behavior were investigated. Metallurgical and electrochemical conditions are identified which provide reproducible and controlled parameters for stress corrosion evaluation. Preliminary stress corrosion test results are reported. Both Al-Li-Cu alloys appear more susceptible to stress corrosion crack initiation than 7075-T6 aluminum, with the magnesium bearing alloy being the most susceptible. Tests to determine the threshold stress intensity for the base and magnesium bearing alloys are underway. Twelve each, bolt loaded DCB type specimens are under test (120 days) and limited crack growth in these precracked specimens has been observed. General corrosion in the aqueous sodium chloride environment is thought to be obscuring results through crack tip blunting.

The cellular transducer in bone: What is it?

PubMed

Taylor, David; Hazenberg, Jan; Lee, T Clive

2006-01-01

Bone is able to detect its strain environment and respond accordingly. In particular it is able to adapt to over-use and under-use by bone deposition or resorption. How can bone sense strain? Various physical mechanisms have been proposed for the so-called cellular transducer, but there is no conclusive proof for any one of them. This paper examines the theories and evidence, with particular reference to a new theory proposed by the authors, involving damage to cellular processes by microcracks. Experiments on bone samples ex-vivo showed that cracks cannot fracture osteocytes, but that cellular processes which span the crack can be broken. A theoretical model was developed for predicting the number of broken processes as a function of crack size and applied stress. This showed that signals emitted by fractured processes could be used to detect cracks which needed repairing and to provide information on the overall level of damage which could be used to initiate repair and adaptation responses.

Analytical determination of critical crack size in solar cells

NASA Technical Reports Server (NTRS)

Chen, C. P.

1988-01-01

Although solar cells usually have chips and cracks, no material specifications concerning the allowable crack size on solar cells are available for quality assurance and engineering design usage. Any material specifications that the cell manufacturers use were developed for cosmetic reasons that have no technical basis. Therefore, the Applied Solar Energy Corporation (ASEC) has sponsored a continuing program for the fracture mechanics evaluation of GaAs. Fracture mechanics concepts were utilized to develop an analytical model that can predict the critical crack size of solar cells. This model indicates that the edge cracks of a solar cell are more critical than its surface cracks. In addition, the model suggests that the material specifications on the allowable crack size used for Si solar cells should not be applied to GaAs solar cells. The analytical model was applied to Si and GaAs solar cells, but it would also be applicable to the semiconductor wafers of other materials, such as a GaAs thin film on a Ge substrate, using appropriate input data.

Fatigue crack propagation behavior of stainless steel welds

NASA Astrophysics Data System (ADS)

Kusko, Chad S.

The fatigue crack propagation behavior of austenitic and duplex stainless steel base and weld metals has been investigated using various fatigue crack growth test procedures, ferrite measurement techniques, light optical microscopy, stereomicroscopy, scanning electron microscopy, and optical profilometry. The compliance offset method has been incorporated to measure crack closure during testing in order to determine a stress ratio at which such closure is overcome. Based on this method, an empirically determined stress ratio of 0.60 has been shown to be very successful in overcoming crack closure for all da/dN for gas metal arc and laser welds. This empirically-determined stress ratio of 0.60 has been applied to testing of stainless steel base metal and weld metal to understand the influence of microstructure. Regarding the base metal investigation, for 316L and AL6XN base metals, grain size and grain plus twin size have been shown to influence resulting crack growth behavior. The cyclic plastic zone size model has been applied to accurately model crack growth behavior for austenitic stainless steels when the average grain plus twin size is considered. Additionally, the effect of the tortuous crack paths observed for the larger grain size base metals can be explained by a literature model for crack deflection. Constant Delta K testing has been used to characterize the crack growth behavior across various regions of the gas metal arc and laser welds at the empirically determined stress ratio of 0.60. Despite an extensive range of stainless steel weld metal FN and delta-ferrite morphologies, neither delta-ferrite morphology significantly influence the room temperature crack growth behavior. However, variations in weld metal da/dN can be explained by local surface roughness resulting from large columnar grains and tortuous crack paths in the weld metal.

The crack-inclusion interaction problem

NASA Technical Reports Server (NTRS)

Liu, X.-H.; Erdogan, F.

1986-01-01

The general plane elastostatic problem of interaction between a crack and an inclusion is considered. The Green's functions for a pair of dislocations and a pair of concentrated body forces are used to generate the crack and the inclusion. Integral equations are obtained for a line crack and an elastic line inclusion having an arbitrary relative orientation and size. The nature of stress singularity around the end points of rigid and elastic inclusions is described and three special cases of this intersection problem are studied. The problem is solved for an arbitrary uniform stress state away from the crack-inclusion region. The nonintersecting crack-inclusion problem is considered for various relative size, orientation, and stiffness parameters, and the stress intensity factors at the ends of the inclusion and the crack are calculated. For the crack-inclusion intersection case, special stress intensity factors are defined and are calculated for various values of the parameters defining the relative size and orientation of the crack and the inclusion and the stiffness of the inclusion.

The crack-inclusion interaction problem

NASA Technical Reports Server (NTRS)

Xue-Hui, L.; Erdogan, F.

1984-01-01

The general plane elastostatic problem of interaction between a crack and an inclusion is considered. The Green's functions for a pair of dislocations and a pair of concentrated body forces are used to generate the crack and the inclusion. Integral equations are obtained for a line crack and an elastic line inclusion having an arbitrary relative orientation and size. The nature of stress singularity around the end points of rigid and elastic inclusions is described and three special cases of this intersection problem are studied. The problem is solved for an arbitrary uniform stress state away from the crack-inclusion region. The nonintersecting crack-inclusion problem is considered for various relative size, orientation, and stiffness parameters, and the stress intensity factors at the ends of the inclusion and the crack are calculated. For the crack-inclusion intersection case, special stress intensity factors are defined and are calculated for various values of the parameters defining the relative size and orientation of the crack and the inclusion and the stiffness of the inclusion.

Predict the fatigue life of crack based on extended finite element method and SVR

NASA Astrophysics Data System (ADS)

Song, Weizhen; Jiang, Zhansi; Jiang, Hui

2018-05-01

Using extended finite element method (XFEM) and support vector regression (SVR) to predict the fatigue life of plate crack. Firstly, the XFEM is employed to calculate the stress intensity factors (SIFs) with given crack sizes. Then predicetion model can be built based on the function relationship of the SIFs with the fatigue life or crack length. Finally, according to the prediction model predict the SIFs at different crack sizes or different cycles. Because of the accuracy of the forward Euler method only ensured by the small step size, a new prediction method is presented to resolve the issue. The numerical examples were studied to demonstrate the proposed method allow a larger step size and have a high accuracy.

Crack identification and evolution law in the vibration failure process of loaded coal

NASA Astrophysics Data System (ADS)

Li, Chengwu; Ai, Dihao; Sun, Xiaoyuan; Xie, Beijing

2017-08-01

To study the characteristics of coal cracks produced in the vibration failure process, we set up a static load and static and dynamic combination load failure test simulation system, prepared with different particle size, formation pressure, and firmness coefficient coal samples. Through static load damage testing of coal samples and then dynamic load (vibration exciter) and static (jack) combination destructive testing, the crack images of coal samples under the load condition were obtained. Combined with digital image processing technology, an algorithm of crack identification with high precision and in real-time is proposed. With the crack features of the coal samples under different load conditions as the research object, we analyzed the distribution of cracks on the surface of the coal samples and the factors influencing crack evolution using the proposed algorithm and a high-resolution industrial camera. Experimental results showed that the major portion of the crack after excitation is located in the rear of the coal sample where the vibration exciter cannot act. Under the same disturbance conditions, crack size and particle size exhibit a positive correlation, while crack size and formation pressure exhibit a negative correlation. Soft coal is more likely to lead to crack evolution than hard coal, and more easily causes instability failure. The experimental results and crack identification algorithm provide a solid basis for the prevention and control of instability and failure of coal and rock mass, and they are helpful in improving the monitoring method of coal and rock dynamic disasters.

Understanding Irreversible Degradation of Nb3Sn Wires with Fundamental Fracture Mechanics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhai, Yuhu; Calzolaio, Ciro; Senatore, Carmine

2014-08-01

Irreversible performance degradation of advanced Nb3Sn superconducting wires subjected to transverse or axial mechanical loading is a critical issue for the design of large-scale fusion and accelerator magnets such as ITER and LHC. Recent SULTAN tests indicate that most cable-in-conduit conductors for ITER coils made of Nb3Sn wires processed by various fabrication techniques show similar performance degradation under cyclic loading. The irreversible degradation due to filament fracture and local strain accumulation in Nb3Sn wires cannot be described by the existing strand scaling law. Fracture mechanic modeling combined with X-ray diffraction imaging of filament micro-crack formation inside the wires under mechanicalmore » loading may reveal exciting insights to the wire degradation mechanisms. We apply fundamental fracture mechanics with a singularity approach to study influence of wire filament microstructure of initial void size and distribution to local stress concentration and potential crack propagation. We report impact of the scale and density of the void structure on stress concentration in the composite wire materials for crack initiation. These initial defects result in an irreversible degradation of the critical current beyond certain applied stress. We also discuss options to minimize stress concentration in the design of the material microstructure for enhanced wire performance for future applications.« less

Effect of open hole on tensile failure properties of 2D triaxial braided textile composites and tape equivalents

NASA Technical Reports Server (NTRS)

Norman, Timothy L.; Anglin, Colin; Gaskin, David; Patrick, Mike

1995-01-01

The unnotched and notched (open hole) tensile strength and failure mechanisms of two-dimensional (2D) triaxial braided composites were examined. The effect of notch size and notch position were investigated. Damage initiation and propagation in notched and unnotched coupons were also examined. Theory developed to predict the normal stress distribution near an open hole and failure for tape laminated composites was evaluated for its applicability to triaxial braided textile composite materials. Four fiber architectures were considered with different combinations of braid angle, longitudinal and braider yam size, and percentage of longitudinal yarns. Tape laminates equivalent to textile composites were also constructed for comparison. Unnotched tape equivalents were stronger than braided textiles but exhibited greater notch sensitivity. Notched textiles and tape equivalents have roughly the same strength at large notch sizes. Two common damage mechanisms were found: braider yams cracking and near notch longitudinal yarn splitting. Cracking was found to initiate in braider yarns in unnotched and notched coupons, and propagate in the direction of the braider yarns until failure. Longitudinal yarn splitting occurred in three of four architectures that were longitudinally fiber dominated. Damage initiation stress decreased with increasing braid angle. No significant differences in prediction of near notch stress between measured and predicted stress were weak for textiles with large braid angle. Notch strength could not be predicted using existing anisotropic theory for braided textiles due to their insensitivity to notch.

Variation of the distribution of crack lengths during corrosion fatigue

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ishihara, S.; Miyao, K.; Shiozawa, K.

1984-07-01

The detailed initiation and growth behaviour of distributed cracks on a specimen surface was investigated during corrosion fatigue. It can be clarified that the changes of the distribution of crack lengths with stress cycling reflect the behaviour of initiation and growth of distributed cracks. The distribution of crack lengths for certain stress cycles could be explained by a statistical calculation which takes into account both the variation of number of cracks during stress cycling and the scatter of crack growth rate.

Model based Inverse Methods for Sizing Cracks of Varying Shape and Location in Bolt hole Eddy Current (BHEC) Inspections (Postprint)

DTIC Science & Technology

2016-02-10

using bolt hole eddy current (BHEC) techniques. Data was acquired for a wide range of crack sizes and shapes, including mid- bore , corner and through...to select the most appropriate VIC-3D surrogate model for subsequent crack sizing inversion step. Inversion results for select mid- bore , through and...the flaw. 15. SUBJECT TERMS Bolt hole eddy current (BHEC); mid- bore , corner and through-thickness crack types; VIC-3D generated surrogate models

Effect of reinforcement morphology on matrix microcracking

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridhar, N.; Srolovitz, D.J.; Rickman, J.M.

1996-03-01

The authors quantitatively examine the conditions under which a particle matrix misfit leads to matrix crack growth as a function of inclusion shape. Such misfit stresses and cracks can be generated by thermal expansion mismatch, generated by cooling a brittle matrix containing ductile inclusions. Using fracture mechanics and perturbation theory, they analyze the case of a penny-shaped crack interacting with a misfitting spheroidal inclusion. A simple and direct relationship is established between the strain energy release rate and the physical and geometrical properties of the system including: the thermal expansion mismatch, temperature change, the crack and inclusion sizes, the elasticmore » properties of the medium and the shape of the inclusion. In particular, the effects of inclusion shape on the stress intensity factors and strain energy release rate are analytically determined for nearly spherical inclusions. The authors use this information to determine the minimum crack size for crack growth to occur and the maximum size to which cracks may grown. The maximum crack size corresponds to the case where the elastic strain energy released upon crack growth is no longer sufficient to compensate for energy expended in extending the crack as the crack is growing into the rapidly decreasing stress field. The authors employ a nominally exact numerical procedure to study the effects of whiskers and platelets (i.e. spheroids very different from spheres) on matrix cracking. It is found that upon cooling a composite containing ductile inclusions, the propensity for matrix cracking is maximized for reinforcement shapes close to that of a sphere.« less

Fatigue-Induced Damage in Zr-Based Bulk Metallic Glasses

PubMed Central

Chuang, Chih-Pin; Yuan, Tao; Dmowski, Wojciech; Wang, Gong-Yao; Freels, Matt; Liaw, Peter K.; Li, Ran; Zhang, Tao

2013-01-01

In the present work, we investigate the effect of “fatigue” on the fatigue behavior and atomic structure of Zr-based BMGs. Fatigue experiments on the failed-by-fatigue samples indicate that the remnants generally have similar or longer fatigue life than the as-cast samples. Meanwhile, the pair-distribution-function (PDF) analysis of the as-cast and post-fatigue samples showed very small changes of local atomic structures. These observations suggest that the fatigue life of the 6-mm in-diameter Zr-based BMG is dominated by the number of pre-existing crack-initiation sites in the sample. Once the crack initiates in the specimen, the fatigue-induced damage is accumulated locally on these initiated sites, while the rest of the region deforms elastically. The results suggest that the fatigue failure of BMGs under compression-compression fatigue experiments is a defect-controlled process. The present work indicates the significance of the improved fatigue resistance with decreasing the sample size. PMID:23999496

An initial investigation of the sub-microsecond features of dynamic crack propagation in PMMA and the RDX-based explosive PBX 9205

NASA Astrophysics Data System (ADS)

Washabaugh, Peter; Hill, Larry

2007-06-01

A dynamic crack propagating in a brittle material releases enough thermal energy to produce visible light. The dynamic fracture of even macroscopically amorphous materials becomes unsteady as the crack propagation velocity approaches the material wave-speeds. The heat generated at a crack-tip, especially as it jumps, may be a mechanism to initiate a self-sustaining reaction in an energetic material. Experiments were conducted in specimens to simulate an infinite plate for 20 μs. The initial specimens were 152 mm square by 6 mm thick acrylic sheets, and were fabricated to study non-steady near-wave-speed crack propagation. A variant of this specimen embedded a 25 mm x 3 mm PBX 9205 pellet to explore the influence of dynamic Mode-I cracks in these materials. The crack was initiated by up to 0.2 g of Detasheet placed along a precursor 50 mm long notch, with a shield to contain the reaction products and prevent propagation along the fractured surfaces. The crack was studied by means of a streak camera and a Fourier-filter of the light reflecting off the newly minted surfaces. The sub-microsecond behavior of holes initiating, preceding and coalescing with the main crack were observed in the PMMA samples. The embedding and mechanical loading of explosives by this technique did not initiate a self-sustaining reaction in preliminary testing.

Resistance to Fracture, Fatigue and Stress-Corrosion of Al-Cu-Li-Zr Alloys

DTIC Science & Technology

1985-02-19

alloys , in both smooth and notch fatigue conditions, are compared in Figure 15 giving a summary of Mg- effect on S-N fatigue behavior. Several ...crack initiation of conventional aluminum alloys and reported that fatigue cracks were associated with cracked constituent particles in 2024 -T3... fatigue cracks. Kung & Fine (14) investigated surface crack initiation in a 2024 -T4 alloy . They observed that at high stresses most cracks formed

Discrete Element Model for Simulations of Early-Life Thermal Fracturing Behaviors in Ceramic Nuclear Fuel Pellets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hai Huang; Ben Spencer; Jason Hales

2014-10-01

A discrete element Model (DEM) representation of coupled solid mechanics/fracturing and heat conduction processes has been developed and applied to explicitly simulate the random initiations and subsequent propagations of interacting thermal cracks in a ceramic nuclear fuel pellet during initial rise to power and during power cycles. The DEM model clearly predicts realistic early-life crack patterns including both radial cracks and circumferential cracks. Simulation results clearly demonstrate the formation of radial cracks during the initial power rise, and formation of circumferential cracks as the power is ramped down. In these simulations, additional early-life power cycles do not lead to themore » formation of new thermal cracks. They do, however clearly indicate changes in the apertures of thermal cracks during later power cycles due to thermal expansion and shrinkage. The number of radial cracks increases with increasing power, which is consistent with the experimental observations.« less

Stress corrosion crack initiation of alloy 600 in PWR primary water

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhai, Ziqing; Toloczko, Mychailo B.; Olszta, Matthew J.

Stress corrosion crack (SCC) initiation of three mill-annealed (MA) alloy 600 heats in simulated pressurized water reactor primary water has been investigated using constant load tests equipped with in-situ direct current potential drop (DCPD) measurement capabilities. SCC initiation times were greatly reduced by a small amount of cold work. Shallow intergranular (IG) attack and/or cracks were found on most high-energy grain boundaries intersecting the surface with only a small fraction evolving into larger cracks and IGSCC growth. Crack depth profiles were measured and related to DCPD-detected initiation response. Processes controlling the SCC initiation in MA alloy 600 are discussed. INmore » PRESS, CORRECTED PROOF, 05/02/2017 - mfl« less

Further Development of Crack Growth Detection Techniques for US Test and Research Reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kohse, Gordon; Carpenter, David M.; Ostrovsky, Yakov

One of the key issues facing Light Water Reactors (LWRs) in extending lifetimes beyond 60 years is characterizing the combined effect of irradiation and water chemistry on material degradation and failure. Irradiation Assisted Stress Corrosion Cracking (IASCC), in which a crack propagates in a susceptible material under stress in an aggressive environment, is a mechanism of particular concern. Full understanding of IASCC depends on real time crack growth data acquired under relevant irradiation conditions. Techniques to measure crack growth in actively loaded samples under irradiation have been developed outside the US - at the Halden Boiling Water Reactor, for example.more » Several types of IASCC tests have also been deployed at the MITR, including passively loaded crack growth measurements and actively loaded slow strain rate tests. However, there is not currently a facility available in the US to measure crack growth on actively loaded, pre-cracked specimens in LWR irradiation environments. A joint program between the Idaho National Laboratory (INL) and the Massachusetts Institute of Technology (MIT) Nuclear Reactor Laboratory (NRL) is currently underway to develop and demonstrate such a capability for US test and research reactors. Based on the Halden design, the samples will be loaded using miniature high pressure bellows and a compact loading mechanism, with crack length measured in real time using the switched Direct Current Potential Drop (DCPD) method. The basic design and initial mechanical testing of the load system and implementation of the DCPD method have been previously reported. This paper presents the results of initial autoclave testing at INL and the adaptation of the design for use in the high pressure, high temperature water loop at the MITR 6 MW research reactor, where an initial demonstration is planned in mid-2015. Materials considerations for the high pressure bellows are addressed. Design modifications to the loading mechanism required by the size constraints of the MITR water loop are described. The safety case for operation of the high pressure gas-driven bellows mechanism is also presented. Key issues are the design and response of systems to limit gas flow in the event of a high pressure gas leak in the in-core autoclave. Integrity of the autoclave must be maintained and reactivity effects due to voiding of the loop coolant must be shown to be within the reactor technical specifications. The technical development of the crack growth monitor for application in the INL Advanced Test Reactor or the MITR can act as a template for adaptation of this technology in other reactors. (authors)« less

The noncontinuum crack tip deformation behavior of surface microcracks

NASA Astrophysics Data System (ADS)

Morris, W. L.

1980-07-01

The crack tip opening displacement (CTOD) of small surface fatigue cracks (lengths of the grain size) in Al 2219-T851 depends upon the location of a crack relative to the grain boundaries. Both CTOD and crack tip closure stress are greatest when the crack tip is a large distance from the next grain boundary in the direction of crack propagation. Contrary to behavioral trends predicted by continuum fracture mechanics, crack length has no detectable effect on the contribution of plastic deformation to CTOD. It is apparent from these observations that the region of significant plastic deformation is confined by the grain boundaries, resulting in a plastic zone size that is insensitive to crack length and to external load.

Ductile Crack Initiation Criterion with Mismatched Weld Joints Under Dynamic Loading Conditions.

PubMed

An, Gyubaek; Jeong, Se-Min; Park, Jeongung

2018-03-01

Brittle failure of high toughness steel structures tends to occur after ductile crack initiation/propagation. Damages to steel structures were reported in the Hanshin Great Earthquake. Several brittle failures were observed in beam-to-column connection zones with geometrical discontinuity. It is widely known that triaxial stresses accelerate the ductile fracture of steels. The study examined the effects of geometrical heterogeneity and strength mismatches (both of which elevate plastic constraints due to heterogeneous plastic straining) and loading rate on critical conditions initiating ductile fracture. This involved applying the two-parameter criterion (involving equivalent plastic strain and stress triaxiality) to estimate ductile cracking for strength mismatched specimens under static and dynamic tensile loading conditions. Ductile crack initiation testing was conducted under static and dynamic loading conditions using circumferentially notched specimens (Charpy type) with/without strength mismatches. The results indicated that the condition for ductile crack initiation using the two parameter criterion was a transferable criterion to evaluate ductile crack initiation independent of the existence of strength mismatches and loading rates.

A Comparative Study on Dwell Fatigue of Ti-6Al-2Sn-4Zr- xMo ( x = 2 to 6) Alloys on a Microstructure-Normalized Basis

NASA Astrophysics Data System (ADS)

Qiu, Jianke; Ma, Yingjie; Lei, Jiafeng; Liu, Yuyin; Huang, Aijun; Rugg, David; Yang, Rui

2014-12-01

The dwell effects of Ti624 x ( x = 2 to 6) alloys, including dwell fatigue life debit, fracture mode and strain accumulation, were characterized and compared. With increasing Mo content, the dwell fatigue life debit decreases quickly, and dwell fatigue fracture exhibits a transition from subsurface to surface initiation. Accompanying these changes, the accumulated strain decreases, and the pattern of secondary cracks loses morphological features typical of dwell cracks. These variations in the fatigue behavior of Ti624 x were attributed on the fundamental level to the dual effects of Mo: It decreases the β transus of titanium and, as a slow diffuser, reduces the rate of phase transformation from β to α. A higher Mo content encourages nucleation of multiple variants of α laths and promotes the transition from aligned colonies to basketweave microstructure during cooling after β forging. As a result both the grain size and microtexture intensity of α grains in the two-phase processed and heat treated microstructure are reduced. Smaller grain size of the alloys with higher Mo content produces smaller slip band spacing and reduces accumulated strain during dwell fatigue, thus reducing propensity for crack initiation. Microtexture was shown to be the direct cause of dwell sensitivity, and their relationship was described with the aid of a two-region redistribution model based on a previous two-element redistribution model proposed by Bache.

The influence of the compression interface on the failure behavior and size effect of concrete

NASA Astrophysics Data System (ADS)

Kampmann, Raphael

The failure behavior of concrete materials is not completely understood because conventional test methods fail to assess the material response independent of the sample size and shape. To study the influence of strength and strain affecting test conditions, four typical concrete sample types were experimentally evaluated in uniaxial compression and analyzed for strength, deformational behavior, crack initiation/propagation, and fracture patterns under varying boundary conditions. Both low friction and conventional compression interfaces were assessed. High-speed video technology was used to monitor macrocracking. Inferential data analysis proved reliably lower strength results for reduced surface friction at the compression interfaces, regardless of sample shape. Reciprocal comparisons revealed statistically significant strength differences between most sample shapes. Crack initiation and propagation was found to differ for dissimilar compression interfaces. The principal stress and strain distributions were analyzed, and the strain domain was found to resemble the experimental results, whereas the stress analysis failed to explain failure for reduced end confinement. Neither stresses nor strains indicated strength reductions due to reduced friction, and therefore, buckling effects were considered. The high-speed video analysis revealed localize buckling phenomena, regardless of end confinement. Slender elements were the result of low friction, and stocky fragments developed under conventional confinement. The critical buckling load increased accordingly. The research showed that current test methods do not reflect the "true'' compressive strength and that concrete failure is strain driven. Ultimate collapse results from buckling preceded by unstable cracking.

Mechanical properties and crack growth behavior of polycrystalline copper using molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Qiu, Ren-Zheng; Li, Chi-Chen; Fang, Te-Hua

2017-08-01

This study investigated the mechanical properties and crack propagation behavior of polycrystalline copper using a molecular dynamics simulation. The effects of temperature, grain size, and crack length were evaluated in terms of atomic trajectories, slip vectors, common neighbor analysis, the material’s stress-strain diagram and Young’s modulus. The simulation results show that the grain boundary of the material is more easily damaged at high temperatures and that grain boundaries will combine at the crack tip. From the stress-strain diagram, it was observed that the maximum stress increased as the temperature decreased. In contrast, the maximum stress was reduced by increasing the temperature. With regard to the effect of the grain size, when the grain size was too small, the structure of the sample deformed due to the effect of atomic interactions, which caused the grain boundary structure to be disordered in general. However, when the grain size was larger, dislocations appeared and began to move from the tip of the crack, which led to a new dislocation phenomenon. With regards to the effect of the crack length, the tip of the crack did not affect the sample’s material when the crack length was less than 5 nm. However, when the crack length was above 7.5 nm, the grain boundary was damaged, and twinning structures and dislocations appeared on both sides of the crack tip. This is because the tip of the crack was blunt at first before sharpening due to the dislocation effect.

Plastic zone size and crack tip opening displacement of a Dugdale crack interacting with a coated circular inclusion

NASA Astrophysics Data System (ADS)

Hoh, H. J.; Xiao, Z. M.; Luo, J.

2010-09-01

An analytical investigation on the plastic zone size of a crack near a coated circular inclusion under three different loading conditions of uniaxial tension, uniform tension and pure shear was carried out. Both the crack and coated circular inclusion are embedded in an infinite matrix, with the crack oriented along the radial direction of the inclusion. In the solution procedure, the crack is simulated as a continuous distribution of edge dislocations. With the Dugdale model of small-scale yielding [J. Mech. Phys. Solids 8 (1960) p. 100], two thin strips of yielded plastic zones are introduced at both crack tips. Using the solution for a coated circular inclusion interacting with a single dislocation as the Green's function, the physical problem is formulated into a set of singular integral equations. Using the method of Erdogan and Gupta [Q. J. Appl. Math. 29 (1972) p. 525] and iterative numerical procedures, the singular integral equations are solved numerically for the plastic zone sizes and crack tip opening displacement.

Laser-Ultrasonic Testing and its Applications to Nuclear Reactor Internals

NASA Astrophysics Data System (ADS)

Ochiai, M.; Miura, T.; Yamamoto, S.

2008-02-01

A new nondestructive testing technique for surface-breaking microcracks in nuclear reactor components based on laser-ultrasonics is developed. Surface acoustic wave generated by Q-switched Nd:YAG laser and detected by frequency-stabilized long pulse laser coupled with confocal Fabry-Perot interferometer is used to detect and size the cracks. A frequency-domain signal processing is developed to realize accurate sizing capability. The laser-ultrasonic testing allows the detection of surface-breaking microcrack having a depth of less than 0.1 mm, and the measurement of their depth with an accuracy of 0.2 mm when the depth exceeds 0.5 mm including stress corrosion cracking. The laser-ultrasonic testing system combined with laser peening system, which is another laser-based maintenance technology to improve surface stress, for inner surface of small diameter tube is developed. The generation laser in the laser-ultrasonic testing system can be identical to the laser source of the laser peening. As an example operation of the system, the system firstly works as the laser-ultrasonic testing mode and tests the inner surface of the tube. If no cracks are detected, the system then changes its work mode to the laser peening and improves surface stress to prevent crack initiation. The first nuclear industrial application of the laser-ultrasonic testing system combined with the laser peening was completed in Japanese nuclear power plant in December 2004.

Small fatigue cracks; Proceedings of the Second International Conference/Workshop, Santa Barbara, CA, Jan. 5-10, 1986

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ritchie, R.O.; Lankford, J.

Topics discussed in this volume include crack initiation and stage I growth, microstructure effects, crack closure, environment effects, the role of notches, analytical modeling, fracture mechanics characterization, experimental techniques, and engineering applications. Papers are presented on fatigue crack initiation along slip bands, the effect of microplastic surface deformation on the growth of small cracks, short fatigue crack behavior in relation to three-dimensional aspects and the crack closure effect, the influence of crack depth on crack electrochemistry and fatigue crack growth, and nondamaging notches in fatigue. Consideration is also given to models of small fatigue cracks, short crack theory, assessment ofmore » the growth of small flaws from residual strength data, the relevance of short crack behavior to the integrity of major rotating aero engine components, and the relevance of short fatigue crack growth data to the durability and damage tolerance analyses of aircraft.« less

Investigation of the Quasi-Brittle Failure of Alashan Granite Viewed from Laboratory Experiments and Grain-Based Discrete Element Modeling

PubMed Central

Zhang, Luqing; Yang, Duoxing; Braun, Anika; Han, Zhenhua

2017-01-01

Granite is a typical crystalline material, often used as a building material, but also a candidate host rock for the repository of high-level radioactive waste. The petrographic texture—including mineral constituents, grain shape, size, and distribution—controls the fracture initiation, propagation, and coalescence within granitic rocks. In this paper, experimental laboratory tests and numerical simulations of a grain-based approach in two-dimensional Particle Flow Code (PFC2D) were conducted on the mechanical strength and failure behavior of Alashan granite, in which the grain-like structure of granitic rock was considered. The microparameters for simulating Alashan granite were calibrated based on real laboratory strength values and strain-stress curves. The unconfined uniaxial compressive test and Brazilian indirect tensile test were performed using a grain-based approach to examine and discuss the influence of mineral grain size and distribution on the strength and patterns of microcracks in granitic rocks. The results show it is possible to reproduce the uniaxial compressive strength (UCS) and uniaxial tensile strength (UTS) of Alashan granite using the grain-based approach in PFC2D, and the average mineral size has a positive relationship with the UCS and UTS. During the modeling, most of the generated microcracks were tensile cracks. Moreover, the ratio of the different types of generated microcracks is related to the average grain size. When the average grain size in numerical models is increased, the ratio of the number of intragrain tensile cracks to the number of intergrain tensile cracks increases, and the UCS of rock samples also increases with this ratio. However, the variation in grain size distribution does not have a significant influence on the likelihood of generated microcracks. PMID:28773201

Investigation of the Quasi-Brittle Failure of Alashan Granite Viewed from Laboratory Experiments and Grain-Based Discrete Element Modeling.

PubMed

Zhou, Jian; Zhang, Luqing; Yang, Duoxing; Braun, Anika; Han, Zhenhua

2017-07-21

Granite is a typical crystalline material, often used as a building material, but also a candidate host rock for the repository of high-level radioactive waste. The petrographic texture-including mineral constituents, grain shape, size, and distribution-controls the fracture initiation, propagation, and coalescence within granitic rocks. In this paper, experimental laboratory tests and numerical simulations of a grain-based approach in two-dimensional Particle Flow Code (PFC2D) were conducted on the mechanical strength and failure behavior of Alashan granite, in which the grain-like structure of granitic rock was considered. The microparameters for simulating Alashan granite were calibrated based on real laboratory strength values and strain-stress curves. The unconfined uniaxial compressive test and Brazilian indirect tensile test were performed using a grain-based approach to examine and discuss the influence of mineral grain size and distribution on the strength and patterns of microcracks in granitic rocks. The results show it is possible to reproduce the uniaxial compressive strength (UCS) and uniaxial tensile strength (UTS) of Alashan granite using the grain-based approach in PFC2D, and the average mineral size has a positive relationship with the UCS and UTS. During the modeling, most of the generated microcracks were tensile cracks. Moreover, the ratio of the different types of generated microcracks is related to the average grain size. When the average grain size in numerical models is increased, the ratio of the number of intragrain tensile cracks to the number of intergrain tensile cracks increases, and the UCS of rock samples also increases with this ratio. However, the variation in grain size distribution does not have a significant influence on the likelihood of generated microcracks.

On prediction of crack in different orientations in pipe using frequency based approach

NASA Astrophysics Data System (ADS)

Naniwadekar, M. R.; Naik, S. S.; Maiti, S. K.

2008-04-01

A technique based on measurement of change in natural frequencies and modeling of crack by rotational spring is employed to detect a crack with straight front in different orientations in a section of straight horizontal steel hollow pipe (outer diameter 0.0378 m and inner diameter 0.0278 m). Crack orientations in the range 0-60° with the vertical have been examined and sizes/depths in the range 1-4 mm through the wall of thickness 5 mm have been studied. Variation of rotational spring stiffness with crack size and orientation has been obtained experimentally by deflection and vibration methods. The spring stiffness reduces as expected, with an increase in crack size; it increases with an increase in the crack orientation angle. The crack location has been predicted with a maximum error of 7.29%. The sensitivity of the method for prediction of crack location on variations in experimental data has been examined by changing the difference between the frequencies of pipes with and without crack by ±10%. The method is found to be very robust; the maximum variation in location is 2.68%, which is much less than the change in frequency difference introduced.

Proof-test-based life prediction of high-toughness pressure vessels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Panontin, T.L.; Hill, M.R.

1996-02-01

The paper examines the problems associated with applying proof-test-based life prediction to vessels made of high-toughness metals. Two A106 Gr B pipe specimens containing long, through-wall circumferential flaws were tested. One failed during hydrostatic testing and the other during tension-tension cycling following a hydrostatic test. Quantitative fractography was used to verify experimentally obtained fatigue crack growth rates and a variety of LEFM and EPFM techniques were used to analyze the experimental results. The results show that: plastic collapse analysis provides accurate predictions of screened (initial) crack size when the flow stress is determined experimentally; LEFM analysis underestimates the crack sizemore » screened by the proof test and overpredicts the subsequent fatigue life of the vessel when retardation effects are small (i.e., low proof levels); and, at a high proof-test level (2.4 {times} operating pressure), the large retardation effect on fatigue crack growth due to the overload overwhelmed the deleterious effect on fatigue life from stable tearing during the proof test and alleviated the problem of screening only long cracks due to the high toughness of the metal.« less

An Experimental Study of the Fracture Coalescence Behaviour of Brittle Sandstone Specimens Containing Three Fissures

NASA Astrophysics Data System (ADS)

Yang, S. Q.; Yang, D. S.; Jing, H. W.; Li, Y. H.; Wang, S. Y.

2012-07-01

To analyse the fracture coalescence behaviour of rock, rectangular prismatic sandstone specimens (80 × 160 × 30 mm in size) containing three fissures were tested under uniaxial compression. The strength and deformation behaviours of the specimens are first analysed by investigating the effects of the ligament angle β2 on the peak strength, peak strain and crack initiation stress of the specimens. To confirm the sequence of crack coalescence, a photographic monitoring technique is used throughout the entire period of deformation. Based on the results, the relationship between the real-time crack coalescence process and the axial stress-strain curve of brittle sandstone specimens is also developed, and this relationship can be used to evaluate the macroscopic deformation characteristics of pre-cracked rock. The equivalent strain evolution fields of the specimen, with α = β1 = 45° and β2 = 90°, are obtained using the digital image correlation technique and show good agreement with the experimental results of pre-cracked brittle sandstone. These experimental results are expected to improve the understanding of fracture mechanisms and be used in rock engineering with intermittent structures, such as deep underground excavated tunnels.

Approximate stresses in 2-D flat elastic contact fretting problems

NASA Astrophysics Data System (ADS)

Urban, Michael Rene

Fatigue results from the cyclic loading of a solid body. If the body subject to fatigue is in contact with another body and relative sliding motion occurs between these two bodies, then rubbing surface damage can accelerate fatigue failure. The acceleration of fatigue failure is especially important if the relative motion between the two bodies results in surface damage without excessive surface removal via wear. The situation just described is referred to as fretting fatigue. Understanding of fretting fatigue is greatly enhanced if the stress state associated with fretting can be characterized. For Hertzian contact, this can readily be done. Unfortunately, simple stress formulae are not available for flat body contact. The primary result of the present research is the development of a new, reasonably accurate, approximate closed form expression for 2-dimensional contact stresses which has been verified using finite element modeling. This expression is also combined with fracture mechanics to provide a simple method of determining when a crack is long enough to no longer be affected by the contact stress field. Lower bounds on fatigue life can then easily be calculated using fracture mechanics. This closed form expression can also be used to calculate crack propagation within the contact stress field. The problem of determining the cycles required to generate an initial crack and what to choose as an initial crack size is unresolved as it is in non-fretting fatigue.

Fatigue life analysis of cracked gas receiver of emergency cut-off system in gas gathering station

NASA Astrophysics Data System (ADS)

Hu, Junzhi; Zhou, Jiyong; Li, Siyuan

2017-06-01

Small-scale air compressor and gas receiver are used as the driving gas of the emergency cut-off system in gas gathering station. Operation of block valve is ensured by starting and stopping compressor automatically. The frequent start-stop of compressor and the pressure fluctuation pose a threat to the service life of gas receiver, and then affect normal operation of the emergency cut-off system and security of gas gathering station. In this paper, the fatigue life of a pressure vessel with axial semi-elliptical surface crack in the inner wall is analyzed under the varying pressure by means of the theory of fracture mechanics. The influences of the amplitude of pressure fluctuation and the initial crack size on the residual life of gas receiver are discussed. It provides a basis for setting the working parameters of gas receiver of emergency cut-off system and determining the maintenance cycle.

The Influence of Porosity on Fatigue Crack Initiation in Additively Manufactured Titanium Components.

PubMed

Tammas-Williams, S; Withers, P J; Todd, I; Prangnell, P B

2017-08-04

Without post-manufacture HIPing the fatigue life of electron beam melting (EBM) additively manufactured parts is currently dominated by the presence of porosity, exhibiting large amounts of scatter. Here we have shown that the size and location of these defects is crucial in determining the fatigue life of EBM Ti-6Al-4V samples. X-ray computed tomography has been used to characterise all the pores in fatigue samples prior to testing and to follow the initiation and growth of fatigue cracks. This shows that the initiation stage comprises a large fraction of life (>70%). In these samples the initiating defect was often some way from being the largest (merely within the top 35% of large defects). Using various ranking strategies including a range of parameters, we found that when the proximity to the surface and the pore aspect ratio were included the actual initiating defect was within the top 3% of defects ranked most harmful. This lays the basis for considering how the deposition parameters can be optimised to ensure that the distribution of pores is tailored to the distribution of applied stresses in additively manufactured parts to maximise the fatigue life for a given loading cycle.

Mechanics of tidally driven fractures in Europa's ice shell and implications for seismic and radar profiling

NASA Astrophysics Data System (ADS)

Lee, S.; Pappalardo, R. T.; Makris, N. C.

2005-12-01

Among Europa's surface features, cycloidal cracks are probably the most important for proving the existence of a subsurface liquid ocean. This is because (1) there is strong evidence that they are caused by tidally induced stress [1], and (2) this stress likely only approaches the ice failure strength if an ocean is present. There are a number of outstanding issues, however, in quantitatively explaining cycloidal cracks. First, current estimates of the pure diurnal tidal stress necessary to cause cycloidal cracks even in the presence of an ocean [1,2] is well below the typical stress known to cause tensile failure in natural terrestrial ice [3]. Second, models of ridge formation suggest that cycloidal cracks penetrate through the entire brittle-ice layer [1,4], but current models limit the depth of tidally induced surface cracks to be less than 100 m even in the presence of an ocean [1,5]. Third, the 3-km/h crack propagation speed determined by [1] is three orders of magnitude lower than the roughly 2-km/s speed at which cracks are known to propagate in ice. Our goal is to quantitatively address these issues in a unified manner. To do this, a fracture mechanics model is developed for the initiation and propagation of a crack through an ice layer of finite thickness in the presence of gravitational overburden and porosity. It is shown that Europa's ice shell may be highly porous and salt-rich. This implies that the strength of Europa's outer ice shell may be sufficiently low to make the crack initiation strengths arrived at by current kinematic models [1,2] highly plausible, even though they are much lower than those typically measured for terrestrial ice. A model is developed for the stress intensity factor at a crack tip in an ice shell with finite thickness, gravitational overburden, and depth-dependent porosity. This leads to the conclusion that cycloids are generated as a sequence of discrete and near instantaneous fracture events, each of which penetrates through the entire brittle layer with horizontal length on the order of the brittle layer thickness. This mechanism yields an apparent propagation speed that is consistent with the 3 km/h crack propagation speed necessary to generate cycloids in current kinematic models [1,2]. An implication of this model is that the level of seismic activity should be higher by orders of magnitude in the presence of an ocean. High correlation is then expected between the level of seismic activity and the tidal period in the presence but not in the absence of an ocean. The cracks associated with cycloids that fully penetrate the brittle layer should be at least 106 times more energetic than the shallow, roughly 100-m deep, surface cracks. We show that this greatly improves the signal-to-noise ratio for the type of seismic profiling discussed in [6] if fully penetrating cracks are used as sources of opportunity. Although Europa's ice is likely highly porous, the size of vacuous pores is likely on the order of a millimeter. Since the pore size is at least three orders of magnitude smaller than the ice-penetrating radar wavelength, our calculations show that porosity-induced scattering should not be significant. [1] Hoppa et al. 1999, Science 285. [2] Crawford et al. 2005, LPSC XXXVI #2042. [3] Weeks and Cox 1984, Ocean Sci. Eng. 9. [4] Pappalardo et al. 1999, J. Geophys. Res. 97. [5] Crawford and Stevenson 1988, Icarus 73. [6] Lee et al. 2003, Icarus 165.

Critical Initial Flaw Size Analysis

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Raju, Ivatury S.; Cheston, Derrick J.

2008-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The USS consists of several "tuna can" segments that are approximately 216 inches in diameter, 115 inches tall, and 0.5 inches thick. A 6 inch wide by 1 inch thick flange is welded to the skin and is used to fasten adjacent tuna cans. A schematic of a "tuna can" and the location of the flange-to-skin weld are shown in Figure 1. Gussets (shown in yellow in Figure 1) are welded to the skin and flange every 10 degrees around the circumference of the "tuna can". The flange-to-skin weld is a flux core butt weld with a fillet weld on the inside surface, as illustrated in Figure 2. The welding process may create loss of fusion defects in the weld that could develop into fatigue cracks and jeopardize the structural integrity of the Ares I-X vehicle. The CIFS analysis was conducted to determine the largest crack in the weld region that will not grow to failure within 4 lifetimes, as specified by NASA standard 5001 & 5019 [1].

Buckling and postbuckling of size-dependent cracked microbeams based on a modified couple stress theory

NASA Astrophysics Data System (ADS)

Akbarzadeh Khorshidi, M.; Shariati, M.

2017-07-01

The elastic buckling analysis and the static postbuckling response of the Euler-Bernoulli microbeams containing an open edge crack are studied based on a modified couple stress theory. The cracked section is modeled by a massless elastic rotational spring. This model contains a material length scale parameter and can capture the size effect. The von Kármán nonlinearity is applied to display the postbuckling behavior. Analytical solutions of a critical buckling load and the postbuckling response are presented for simply supported cracked microbeams. This parametric study indicates the effects of the crack location, crack severity, and length scale parameter on the buckling and postbuckling behaviors of cracked microbeams.

Precursor Evolution and Stress Corrosion Cracking Initiation of Cold-Worked Alloy 690 in Simulated Pressurized Water Reactor Primary Water

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhai, Ziqing; Toloczko, Mychailo; Kruska, Karen

Stress corrosion crack initiation of two thermally-treated, cold-worked (CW) alloy 690 (UNS N06690) materials was investigated in 360oC simulated PWR primary water using constant load tensile (CLT) tests and blunt notch compact tension (BNCT) tests equipped with direct current potential drop (DCPD) for in-situ detection of cracking. SCC initiation was not detected by DCPD for either the 21% or 31%CW CLT specimens loaded at their yield stress after ~9,220 hours, however intergranular (IG) precursor damage and isolated surface cracks were observed on the specimens. The two 31%CW BNCT specimens loaded at moderate stress intensity after several cyclic loading ramps showedmore » DCPD-indicated crack initiation after 10,400 hours of exposure at constant stress intensity, which was resulted from significant growth of IG cracks. The 21%CW BNCT specimens only exhibited isolated small IG surface cracks and showed no apparent DCPD change throughout the test. Post-test cross-section examinations revealed many grain boundary (GB) nano-cavities in the bulk of all the CLT and BNCT specimens particularly for the 31%CW materials. Cavities were also found along GBs extending to the surface suggesting an important role in crack nucleation. This paper provides an overview of the evolution of GB cavities and discusses their effects on crack initiation in CW alloy 690.« less

An Investigation of the Sub-Microsecond Features of Dynamic Crack Propagation in PMMA and the Rdx-Based Explosive PBX 9205

NASA Astrophysics Data System (ADS)

Washabaugh, P. D.; Hill, L. G.

2007-12-01

A dynamic crack propagating in a brittle material releases enough thermal energy to produce visible light. The dynamic fracture of even macroscopically amorphous materials becomes unsteady as the crack propagation velocity approaches the material wave-speeds. The heat generated at a crack-tip, especially as it jumps, may be a mechanism to initiate a self-sustaining reaction in an energetic material. Experiments were conducted in specimens to simulate an infinite plate for ˜10 μs. The initial specimens were 152 mm square by 6 mm thick acrylic sheets, and were fabricated to study non-steady near-wave-speed crack propagation. A variant of this specimen embedded a 25 mm×3 mm PBX 9205 pellet to explore the influence of dynamic Mode-I cracks in these materials. The crack was initiated by up to 0.24 g of Detasheet placed along a precursor 50 mm long notch, with a shield to contain the reaction products and prevent propagation along the fractured surfaces. The crack was studied by means of a streak camera and a Fourier-filter of the light reflecting off the newly minted surfaces. The sub-microsecond behavior of holes initiating, preceding and coalescing with the main crack were observed in the PMMA samples. The embedding and mechanical loading of explosives by this technique did not initiate a self-sustaining reaction in preliminary testing.

Initiation and propagation toughness of delamination crack under an impact load

NASA Astrophysics Data System (ADS)

Kumar, Prashant; Kishore, N. N.

1998-10-01

A combined experimental and finite element method is developed to determine the interlaminar dynamic fracture toughness. An interlaminar crack is propagated at very high speed in a double cantilever beam (DCB) specimen made of two steel strips with a precrack. A special fixture is designed to apply impact load to one cantilever and determine the deflection of the cantilever-end, initiation time and crack propagation history. The experimental results are used as input data in a FE code to calculate J-integral by the gradual release of nodal forces to model the propagation of the interlaminar crack. The initiation fracture toughness and propagation fracture toughness are evaluated for interlaminar crack propagating between 850 and 1785 ms. The initiation and propagation toughness were found to vary between 90-200 Jm 2 and 2-13 Jm 2 respectively. The technique is extended to study initiation and propagation toughness of interlaminar crack in unidirectional FRP laminates. 1998 Elsevier Science Ltd.

Dynamic response of fluid inside a penny shaped crack

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hayashi, Kazuo; Seki, Hitoshi

1997-12-31

In order to discuss the method for estimating the geometric characteristics of geothermal reservoir cracks, a theoretical study is performed on the dynamic response of the fluid inside a reservoir crack in a rock mass subjected to a dynamic excitation due to propagation of an elastic wave. As representative models of reservoir cracks, a penny shaped crack and a two-dimensional crack which are connected to a borehole are considered. It is found that the resonance frequency of the fluid motion is dependent on the crack size, the fluid`s viscosity and the permeability of the formation. The intensity of the resonancemore » is dependent on the fluid`s viscosity when the size, the aperture and the permeability are fixed. It is also found that, at a value of the fluid`s viscosity, the resonance of fluid pressure becomes strongest. The optimum value of the fluid`s viscosity is found to be almost perfectly determined by the permeability of the formation. Furthermore, it is revealed that, if the fluid`s viscosity is fixed to be the optimum value, the resonance frequency is almost independent of the permeability and aperture, but is dependent on the size of crack. Inversely speaking, this implies that the size of the reservoir crack can be estimated from the resonance frequency, if the fluid with the above mentioned optimum value of viscosity is employed for hydraulic fracturing.« less

Intermittent crack growth in fatigue

NASA Astrophysics Data System (ADS)

Kokkoniemi, R.; Miksic, A.; Ovaska, M.; Laurson, L.; Alava, M. J.

2017-07-01

Fatigue occurs under cyclic loading at stresses below a material’s static strength limit. We consider fatigue crack growth as a stochastic process and perform crack growth experiments in a metal (copper). We follow optically cracks propagating from initial edge notches. The main interest is in the dynamics of the crack growth—the Paris’ law and the initiation phase prior to that—and especially the intermittency this is discovered to display. How the sampling of the crack advancement, performed at regular intervals, influences such measurement results is analysed by the analogy of planar crack dynamics in slow, driven growth.

The effect of microstructure on 650 C fatigue crack growth in P/M Astroloy

NASA Technical Reports Server (NTRS)

Gayda, J.; Miner, R. V.

1983-01-01

The effect of microstructure on fatigue crack propagation at 650 C has been studied in a P/M nickel-base superalloy, Astroloy. Crack propagation data were obtained in air and vacuum at 20 cpm with a modified compact tension specimen. The rate of crack growth, da/dn, was correlated with the stress intensity range. Key microstructural variables examined were grain size and the distribution and size of the strengthening gamma prime phase. A fine grain size less than 20 microns always promoted rapid, intergranular failure, while a large grain size promoted slower, transgranular failure which decreased as the size and volume fraction of aging gamma prime was manipulated so as to increase alloy strength. The rapid, intergranular mode of failure of the fine grain microstructures was suppressed in vacuum.

Creep fatigue life prediction for engine hot section materials (isotropic)

NASA Technical Reports Server (NTRS)

Moreno, V.

1983-01-01

The Hot Section Technology (HOST) program, creep fatigue life prediction for engine hot section materials (isotropic), is reviewed. The program is aimed at improving the high temperature crack initiation life prediction technology for gas turbine hot section components. Significant results include: (1) cast B1900 and wrought IN 718 selected as the base and alternative materials respectively; (2) fatigue test specimens indicated that measurable surface cracks appear early in the specimen lives, i.e., 15% of total life at 871 C and 50% of life at 538 c; (3) observed crack initiation sites are all surface initiated and are associated with either grain boundary carbides or local porosity, transgrannular cracking is observed at the initiation site for all conditions tested; and (4) an initial evaluation of two life prediction models, representative of macroscopic (Coffin-Mason) and more microscopic (damage rate) approaches, was conducted using limited data generated at 871 C and 538 C. It is found that the microscopic approach provides a more accurate regression of the data used to determine crack initiation model constants, but overpredicts the effect of strain rate on crack initiation life for the conditions tested.

Evolution of the fracture process zone in high-strength concrete under different loading rates

NASA Astrophysics Data System (ADS)

Yu, R. C.; Zhang, X.; Ruiz, G.; Tarifa, M.; Cámara, M.

2010-06-01

For cementitious materials, the inelastic zone around a crack tip is termed as fracture process zone (FPZ) and dominated by complicated mechanism, such as microcracking, crack deflection, bridging, crack face friction, crack tip blunting by voids, crack branching, and so on. Due to the length of the FPZ is related with the characteristic length of the cementitious materials, the size, extent and location of the FPZ has been the object of countless research efforts for several decades. For instance, Cedolin et al. [1] have used an optical method based on the moiré interferometry to determine FPZ in concrete. Castro-Montero et al. [2] have applied the method of holographic interferometry to mortar to study the extension of the FPZ. The advantage of the interferometry method is that the complete FPZ can be directly observed on the surface of the sample. Swartz et al. [3] has adopted the dye penetration technique to illustrate the changing patterns observed as the crack progress from the tensile side to the compression side of the beam. Moreover, acoustic emission (AE) is also an experimental technique well suited for monitoring fracture process. Haidar et al. [4] and Maji et al. [5] have studied the relation between acoustic emission characteristics and the properties of the FPZ. Compared with the extensive research on properties of the FPZ under quasi-static loading conditions, much less information is available on its dynamic characterization, especially for high-strength concrete (HSC). This paper presents the very recent results of an experimental program aimed at disclosing the loading rate effect on the size and velocity of the (FPZ) in HSC. Eighteen three-point bending specimens were conducted under a wide range of loading rates from from 10-4 mm/s to 103 mm/s using either a servo-hydraulic machine or a self-designed drop-weight impact device. The beam dimensions were 100 mm 100 mm in cross section, and 420 mm in length. The initial notch-depth ratio was approximately 0.5, and the span was fixed at 300 mm during the tests. Four strain gauges mounted along the ligament of the specimen were used to measure the FPZ size. Surprisingly, the FPZ size remains almost constant (around 20 mm) when the loading rate varies seven orders of magnitude. This is clearly different from NSC, in which the FPZ size actually decreased with loading rate.

In situ nanoindentation study of plastic Co-deformation in Al-TiN nanocomposites

DOE PAGES

Li, N.; Wang, H.; Misra, A.; ...

2014-10-16

We performed in situ indentation in a transmission electron microscope on Al-TiN multilayers with individual layer thicknesses of 50 nm, 5 nm and 2.7 nm to explore the effect of length scales on the plastic co-deformability of a metal and a ceramic. At 50 nm, plasticity was confined to the Al layers with easy initiation of cracks in the TiN layers. At 5 nm and below, cracking in TiN was suppressed and post mortem measurements indicated a reduction in layer thickness in both layers. Our results demonstrate the profound size effect in enhancing plastic co-deformability in nanoscale metal-ceramic multilayers.

Ares I-X USS Material Testing

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Smith, Stephen W.; Raju, Ivatury S.

2008-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). Material characterization tests were conducted to quantify the material behavior for use in the CIFS analyses. Fatigue crack growth rate, Charpy impact, and fracture tests were conducted on the parent and welded A516 Grade 70 steel. The crack growth rate tests confirmed that the material behaved in agreement with literature data and that a salt water environment would not significantly degrade the fatigue resistance. The Charpy impact tests confirmed that the fracture resistance of the material did not have a significant reduction for the expected operational temperatures of the vehicle.

Effects of microrolling parameters on the microstructure and deformation behavior of pure copper

NASA Astrophysics Data System (ADS)

Jing, Yi; Zhang, Hong-mei; Wu, Hao; Li, Lian-jie; Jia, Hong-bin; Jiang, Zheng-yi

2018-01-01

Microrolling experiments and uniaxial tensile tests of pure copper under different annealing conditions were carried out in this paper. The effects of grain size and reduction on non-uniform deformation, edge cracking, and microstructure were studied. The experimental results showed that the side deformation became more non-uniform, resulting in substantial edge bulge, and the uneven spread increased with increasing grain size and reduction level. When the reduction level reached 80% and the grain size was 65 μm, slight edge cracks occurred. When the grain size was 200 μm, the edge cracks became wider and deeper. No edge cracks occurred when the grain size was 200 μm and the reduction level was less than 60%; edge cracks occurred when the reduction level was increased to 80%. As the reduction level increased, the grains were gradually elongated and appeared as a sheet-like structure along the rolling direction; a fine lamellar structure was obtained when the grain size was 20 μm and the reduction level was less than 60%.

Gear fatigue crack prognosis using embedded model, gear dynamic model and fracture mechanics

NASA Astrophysics Data System (ADS)

Li, C. James; Lee, Hyungdae

2005-07-01

This paper presents a model-based method that predicts remaining useful life of a gear with a fatigue crack. The method consists of an embedded model to identify gear meshing stiffness from measured gear torsional vibration, an inverse method to estimate crack size from the estimated meshing stiffness; a gear dynamic model to simulate gear meshing dynamics and determine the dynamic load on the cracked tooth; and a fast crack propagation model to forecast the remaining useful life based on the estimated crack size and dynamic load. The fast crack propagation model was established to avoid repeated calculations of FEM and facilitate field deployment of the proposed method. Experimental studies were conducted to validate and demonstrate the feasibility of the proposed method for prognosis of a cracked gear.

Fracture mechanisms of glass particles under dynamic compression

DOE Office of Scientific and Technical Information (OSTI.GOV)

Parab, Niranjan D.; Guo, Zherui; Hudspeth, Matthew C.

2017-08-01

In this study, dynamic fracture mechanisms of single and contacting spherical glass particles were observed using high speed synchrotron X-ray phase contrast imaging. A modified Kolsky bar setup was used to apply controlled dynamic compressive loading on the soda-lime glass particles. Four different configurations of particle arrangements with one, two, three, and five particles were studied. In single particle experiments, cracking initiated near the contact area between the particle and the platen, subsequently fragmenting the particle in many small sub-particles. In multi-particle experiments, a crack was observed to initiate from the point just outside the contact area between two particles.more » The initiated crack propagated at an angle to the horizontal loading direction, resulting in separation of a fragment. However, this fragment separation did not affect the ability of the particle to withstand further contact loading. On further compression, large number of cracks initiated in the particle with the highest number of particle-particle contacts near one of the particle-particle contacts. The initiated cracks roughly followed the lines joining the contact points. Subsequently, the initiated cracks along with the newly developed sub-cracks bifurcated rapidly as they propagated through the particle and fractured the particle explosively into many small fragments, leaving the other particles nearly intact.« less

Effect of glide path and apical preparation size on the incidence of apical crack during the canal preparation using Reciproc, WaveOne, and ProTaper Next systems in curved root canals: A stereomicroscope study.

PubMed

Topçuoğlu, Hüseyin Sinan; Düzgün, Salih; Akpek, Firdevs; Topçuoğlu, Gamze

2016-11-01

This study evaluated the effect of creating a glide path and apical preparation size on the incidence of apical cracks during canal preparation in mandibular molar teeth with curved canals. One hundred and forty extracted teeth were used. The teeth were randomly assigned to one control group or six experimental groups (n = 20 per group) for canal preparation. No preparation was performed on teeth in the control group. In three of the six experimental groups, a glide path was not created; a glide path was created on the curved mesial canals of all teeth in the remaining three experimental groups. All teeth in experimental groups were then instrumented with the following systems: Reciproc, WaveOne (WO), and ProTaper Next (PTN). Digital images of the apical root surfaces of these teeth were recorded before preparation, after instrumentation with size 25 files, and after instrumentation with size 40 files. The images were then inspected for the presence of any new apical cracks and propagation. There was no significant difference between the experimental groups during canal preparation using size 25 files (p > 0.05). Reciproc and WO caused more new apical cracks than did PTN during canal preparation using size 40 files (p < 0.05). However, canal preparation using size 40 files did not cause propagation of existing cracks (p > 0.05). Performing a glide path prior to canal preparation did not change the incidence of apical crack during preparation. Additionally, increasing apical preparation size may increase the incidence of apical crack during canal preparation. SCANNING 38:585-590, 2016. © 2016 Wiley Periodicals, Inc. © Wiley Periodicals, Inc.

Application of Fracture Mechanics to Specify the Proof Load Factor for Clamp Band Systems of Launch Vehicles

NASA Astrophysics Data System (ADS)

Singaravelu, J.; Sundaresan, S.; Nageswara Rao, B.

2013-04-01

This article presents a methodology for evaluation of the proof load factor (PLF) for clamp band system (CBS) made of M250 Maraging steel following fracture mechanics principles.CBS is most widely used as a structural element and as a separation system. Using Taguchi's design of experiments and the response surface method (RSM) the compact tension specimens were tested to establish an empirical relation for the failure load ( P max) in terms of the ultimate strength, width, thickness, and initial crack length. The test results of P max closely matched with the developed RSM empirical relation. Crack growth rates of the maraging steel in different environments were examined. Fracture strength (σf) of center surface cracks and through-crack tension specimens are evaluated utilizing the fracture toughness ( K IC). Stress induced in merman band at flight loading conditions is evaluated to estimate the higher load factor and PLF. Statistical safety factor and reliability assessments were made for the specified flaw sizes useful in the development of fracture control plan for CBS of launch vehicles.

Mesh Convergence Requirements for Composite Damage Models

NASA Technical Reports Server (NTRS)

Davila, Carlos G.

2016-01-01

The ability of the finite element method to accurately represent the response of objects with intricate geometry and loading renders the finite element method as an extremely versatile analysis technique for structural analysis. Finite element analysis is routinely used in industry to calculate deflections, stress concentrations, natural frequencies, buckling loads, and much more. The method works by discretizing complex problems into smaller, simpler approximations that are valid over small uniform domains. For common analyses, the maximum size of the elements that can be used is often be determined by experience. However, to verify the quality of a solution, analyses with several levels of mesh refinement should be performed to ensure that the solution has converged. In recent years, the finite element method has been used to calculate the resistance of structures, and in particular that of composite structures. A number of techniques such as cohesive zone modeling, the virtual crack closure technique, and continuum damage modeling have emerged that can be used to predict cracking, delaminations, fiber failure, and other composite damage modes that lead to structural collapse. However, damage models present mesh refinement requirements that are not well understood. In this presentation, we examine different mesh refinement issues related to the representation of damage in composite materials. Damage process zone sizes and their corresponding mesh requirements will be discussed. The difficulties of modeling discontinuities and the associated need for regularization techniques will be illustrated, and some unexpected element size constraints will be presented. Finally, some of the difficulties in constructing models of composite structures capable of predicting transverse matrix cracking will be discussed. It will be shown that to predict the initiation and propagation of transverse matrix cracks, their density, and their saturation may require models that are significantly more refined than those that have been contemplated in the past.

Analysis of crack propagation as an energy absorption mechanism in metal matrix composites

NASA Technical Reports Server (NTRS)

Adams, D. F.; Murphy, D. P.

1981-01-01

The crack initiation and crack propagation capability was extended to the previously developed generalized plane strain, finite element micromechanics analysis. Also, an axisymmetric analysis was developed, which contains all of the general features of the plane analysis, including elastoplastic material behavior, temperature-dependent material properties, and crack propagation. These analyses were used to generate various example problems demonstrating the inelastic response of, and crack initiation and propagation in, a boron/aluminum composite.

Three-dimensional CTOA and constraint effects during stable tearing in a thin-sheet material

NASA Technical Reports Server (NTRS)

Dawicke, D. S.; Newman, J. C., Jr.; Bigelow, C. A.

1995-01-01

A small strain theory, three-dimensional elastic-plastic finite element analysis was used to simulate fracture in thin sheet 2024-T3 aluminum alloy in the T-L orientation. Both straight and tunneled cracks were modeled. The tunneled crack front shapes as a function of applied stress were obtained from the fracture surface of tested specimens. The stable crack growth behavior was measured at the specimen surface as a function of applied stress. The fracture simulation modeled the crack tunneling and extension as a function of applied stress. The results indicated that the global constraint factor, alpha(sub g), initially dropped during stable crack growth. After peak applied stress was achieved, alpha(sub g) began to increase slightly. The effect of crack front shape on alpha(sub g) was small, but the crack front shape did greatly influence the local constraint and through-thickness crack-tip opening angle (CTOA) behavior. The surface values of CTOA for the tunneled crack front model agreed well with experimental measurements, showing the same initial decrease from high values during the initial 3mm of crack growth at the specimen's surface. At the same time, the interior CTOA values increased from low angles. After the initial stable tearing region, the CTOA was constant through the thickness. The three-dimensional analysis appears to confirm the potential of CTOA as a two-dimensional fracture criterion.

Eddy Current Testing and Sizing of Deep Cracks in a Thick Structure

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, H.; Endo, H.; Uchimoto, T.

2004-02-26

Due to the skin effect of eddy current testing, target of ECT restricts to thin structure such as steam generator tubes with 1.27mm thickness. Detecting and sizing of a deep crack in a thick structure remains a problem. In this paper, an ECT probe is presented to solve this problem with the help of numerical analysis. The parameters such as frequency, coil size etc. are discussed. The inverse problem of crack sizing is solved by applying a fast simulator of ECT based on an edge based finite element method and steepest descent method, and reconstructed results of 5, 10 andmore » 15mm depth cracks from experimental signals are shown.« less

Microstructural examination of fatigue crack tip in high strength steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fukuoka, C.; Yoshizawa, H.; Nakagawa, Y.G.

1993-10-01

Fatigue tests were performed to examine how microstructural conditioning influences crack initiation and propagation in SA508 class 3 low-carbon steel. A 3-mm-long crack was introduced in compact tension (CT) fatigue test specimens under four different loads in order to obtain crack tip plastic zones at different stress intensity factor ranges, [Delta]K = 18, 36, 54, and 72 MPa[radical]m. The microstructure of the plastic zones around the crack tip were examined by transmission electron microscopy (TEM) and selected area electron diffraction (SAD). Micro-orientation of the dislocation cells in the plastic zones of all of the CT samples increased to 4 degmore » from the level of an as-received sample. Four-point bending fatigue tests were performed for plate shape samples with a large cyclic strain range. The SAD value of the bending samples was also 4 deg in the damaged area where cracks already initiated at an early stage of the fatigue process. These test results indicate that the microstructural conditioning is a prerequisite for the fatigue crack initiation and propagation in SA508. These observations may lead to better understanding of how fatigue initiation processes transit to cracks.« less

Cyclic plasticity models and application in fatigue analysis

NASA Technical Reports Server (NTRS)

Kalev, I.

1981-01-01

An analytical procedure for prediction of the cyclic plasticity effects on both the structural fatigue life to crack initiation and the rate of crack growth is presented. The crack initiation criterion is based on the Coffin-Manson formulae extended for multiaxial stress state and for inclusion of the mean stress effect. This criterion is also applied for the accumulated damage ahead of the existing crack tip which is assumed to be related to the crack growth rate. Three cyclic plasticity models, based on the concept of combination of several yield surfaces, are employed for computing the crack growth rate of a crack plane stress panel under several cyclic loading conditions.

Self-Healing Nanotextured Vascular-like Materials: Mode I Crack Propagation.

PubMed

Lee, Min Wook; Sett, Soumyadip; An, Seongpil; Yoon, Sam S; Yarin, Alexander L

2017-08-16

Here, we investigate crack propagation initiated from an initial notch in a self-healing material. The crack propagation in the core-shell nanofiber mats formed by coelectrospinning and the composites reinforced by them is in focus. All samples are observed from the crack initiation until complete failure. Due to the short-time experiments done on purpose, the resin and cure released from the cores of the core-shell nanofibers could not achieve a complete curing and stop crack growth, especially given the fact that no heating was used. The aim is to elucidate their effect on the rate of crack propagation. The crack propagation speed in polyacrylonitrile (PAN)-resin-cure nanofiber mats (with PAN being the polymer in the shell) was remarkably lower than that in the corresponding monolithic PAN nanofiber mat, down to 10%. The nanofiber mats were also encased in polydimethylsiloxane (PDMS) matrix to form composites. The crack shape and propagation in the composite samples were studied experimentally and analyzed theoretically, and the theoretical results revealed agreement with the experimental data.

Healing of Fatigue Crack in 1045 Steel by Using Eddy Current Treatment

PubMed Central

Yang, Chuan; Xu, Wenchen; Guo, Bin; Shan, Debin; Zhang, Jian

2016-01-01

In order to investigate the methods to heal fatigue cracks in metals, tubular specimens of 1045 steel with axial and radial fatigue cracks were treated under the eddy current. The optical microscope was employed to examine the change of fatigue cracks of specimens before and after the eddy current treatment. The results show that the fatigue cracks along the axial direction of the specimen could be healed effectively in the fatigue crack initiation zone and the crack tip zone under the eddy current treatment, and the healing could occur within a very short time. The voltage breakdown and the transient thermal compressive stress caused by the detouring of eddy current around the fatigue crack were the main factors contributing to the healing in the fatigue crack initiation zone and the crack tip zone, respectively. Eddy current treatment may be a novel and effective method for crack healing. PMID:28773761

Healing of Fatigue Crack in 1045 Steel by Using Eddy Current Treatment.

PubMed

Yang, Chuan; Xu, Wenchen; Guo, Bin; Shan, Debin; Zhang, Jian

2016-07-29

In order to investigate the methods to heal fatigue cracks in metals, tubular specimens of 1045 steel with axial and radial fatigue cracks were treated under the eddy current. The optical microscope was employed to examine the change of fatigue cracks of specimens before and after the eddy current treatment. The results show that the fatigue cracks along the axial direction of the specimen could be healed effectively in the fatigue crack initiation zone and the crack tip zone under the eddy current treatment, and the healing could occur within a very short time. The voltage breakdown and the transient thermal compressive stress caused by the detouring of eddy current around the fatigue crack were the main factors contributing to the healing in the fatigue crack initiation zone and the crack tip zone, respectively. Eddy current treatment may be a novel and effective method for crack healing.

The epidemiology of physical attack and rape among crack-using women.

PubMed

Falck, R S; Wang, J; Carlson, R G; Siegal, H A

2001-02-01

This prospective study examines the epidemiology of physical attack and rape among a sample of 171 not-in-treatment, crack-cocaine using women. Since initiating crack use, 62% of the women reported suffering a physical attack. The annual rate of victimization by physical attack was 45%. Overall, more than half of the victims sought medical care subsequent to an attack. The prevalence of rape since crack use was initiated was 32%, and the annual rate was 11%. Among those women having been raped since they initiated crack use, 83% reported they were high on crack when the crime occurred as were an estimated 57% of the perpetrators. Logistic regression analyses showed that duration of crack use, arrest for prostitution, and some college education were predictors of having experienced a physical attack. Duration of crack use and a history of prostitution were predictors of suffering a rape. Drug abuse treatment programs must be sensitive to high levels of violence victimization experienced by crack-cocaine using women. Screening women for victimization, and treating the problems that emanate from it, may help make drug abuse treatment more effective.

Effect of Speed (Centrifugal Load) on Gear Crack Propagation Direction

NASA Technical Reports Server (NTRS)

Lewicki, David G.

2001-01-01

The effect of rotational speed (centrifugal force) on gear crack propagation direction was explored. Gears were analyzed using finite element analysis and linear elastic fracture mechanics. The analysis was validated with crack propagation experiments performed in a spur gear fatigue rig. The effects of speed, rim thickness, and initial crack location on gear crack propagation direction were investigated. Crack paths from the finite element method correlated well with those deduced from gear experiments. For the test gear with a backup ratio (rim thickness divided by tooth height) of nib = 0.5, cracks initiating in the tooth fillet propagated to rim fractures when run at a speed of 10,000 rpm and became tooth fractures for speeds slower than 10,000 rpm for both the experiments and anal sis. From additional analysis, speed had little effect on crack propagation direction except when initial crack locations were near the tooth/rim fracture transition point for a given backup ratio. When at that point, higher speeds tended to promote rim fracture while lower speeds (or neglecting centrifugal force) produced tooth fractures.

Microstructural examination of

NASA Astrophysics Data System (ADS)

Fukuoka, C.; Yoshizawa, H.; Nakagawa, Y. G.; Lapides, M. E.

1993-10-01

Fatigue tests were performed to examine how microstructural conditioning influences crack initiation and propagation in SA508 class 3 low-carbon steel. A 3-mm-long crack was introduced in compact tension (CT) fatigue test specimens under four different loads in order to obtain crack tip plastic zones at different stress intensity factor ranges, ΔK = 18, 36, 54, and 72 MPa√m. The microstructure of the plastic zones around the crack tip were examined by trans- mission electron microscopy (TEM) and selected area electron diffraction (SAD). Micro- orientation of the dislocation cells in the plastic zones of all of the CT samples increased to 4 deg from the level of an as-received sample. Four-point bending fatigue tests were performed for plate shape samples with a large cyclic strain range. The SAD value of the bending samples was also 4 deg in the damaged area where cracks already initiated at an early stage of the fatigue process. These test results indicate that the microstructural conditioning is a prerequisite for the fatigue crack initiation and propagation in SA508. These observations may lead to better under- standing of how fatigue initiation processes transit to cracks.

Investigation of Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears

NASA Technical Reports Server (NTRS)

Handschuh, Robert F.; Krantz, Timothy L.; Lerch, Bradley A.; Burke, Christopher S.

2007-01-01

An investigation of the low-cycle bending fatigue of spur gears made from AISI 9310 gear steel was completed. Tests were conducted using the single-tooth bending method to achieve crack initiation and propagation. Tests were conducted on spur gears in a fatigue test machine using a dedicated gear test fixture. Test loads were applied at the highest point of single tooth contact. Gear bending stresses for a given testing load were calculated using a linear-elastic finite element model. Test data were accumulated from 1/4 cycle to several thousand cycles depending on the test stress level. The relationship of stress and cycles for crack initiation was found to be semi-logarithmic. The relationship of stress and cycles for crack propagation was found to be linear. For the range of loads investigated, the crack propagation phase is related to the level of load being applied. Very high loads have comparable crack initiation and propagation times whereas lower loads can have a much smaller number of cycles for crack propagation cycles as compared to crack initiation.

Investigation of Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears

NASA Technical Reports Server (NTRS)

Handschuh, Robert F.; Krantz, Timothy L.; Lerch, Bradley A.; Burke, Christopher S.

2007-01-01

An investigation of the low-cycle bending fatigue of spur gears made from AISI 9310 gear steel was completed. Tests were conducted using the single-tooth bending method to achieve crack initiation and propagation. Tests were conducted on spur gears in a fatigue test machine using a dedicated gear test fixture. Test loads were applied at the highest point of single tooth contact. Gear bending stresses for a given testing load were calculated using a linear-elastic finite element model. Test data were accumulated from 1/4 cycle to several thousand cycles depending on the test stress level. The relationship of stress and cycles for crack initiation was found to be semilogarithmic. The relationship of stress and cycles for crack propagation was found to be linear. For the range of loads investigated, the crack propagation phase is related to the level of load being applied. Very high loads have comparable crack initiation and propagation times whereas lower loads can have a much smaller number of cycles for crack propagation cycles as compared to crack initiation.

Detection of Steel Fatigue Cracks with Strain Sensing Sheets Based on Large Area Electronics

PubMed Central

Yao, Yao; Glisic, Branko

2015-01-01

Reliable early-stage damage detection requires continuous monitoring over large areas of structure, and with sensors of high spatial resolution. Technologies based on Large Area Electronics (LAE) can enable direct sensing and can be scaled to the level required for Structural Health Monitoring (SHM) of civil structures and infrastructure. Sensing sheets based on LAE contain dense arrangements of thin-film strain sensors, associated electronics and various control circuits deposited and integrated on a flexible polyimide substrate that can cover large areas of structures. This paper presents the development stage of a prototype strain sensing sheet based on LAE for crack detection and localization. Two types of sensing-sheet arrangements with size 6 × 6 inch (152 × 152 mm) were designed and manufactured, one with a very dense arrangement of sensors and the other with a less dense arrangement of sensors. The sensing sheets were bonded to steel plates, which had a notch on the boundary, so the fatigue cracks could be generated under cyclic loading. The sensors within the sensing sheet that were close to the notch tip successfully detected the initialization of fatigue crack and localized the damage on the plate. The sensors that were away from the crack successfully detected the propagation of fatigue cracks based on the time history of the measured strain. The results of the tests have validated the general principles of the proposed sensing sheets for crack detection and identified advantages and challenges of the two tested designs. PMID:25853407

The effect of microstructure on the tensile and fatigue behavior of Ti-22Al-23Nb in air and vacuum

NASA Astrophysics Data System (ADS)

Luetjering, Stephanie

Titanium aluminide alloys containing the ordered orthorhombic (O) phase, based on Ti2AlNb, exhibit high specific strengths at elevated temperature along with good room temperature tensile ductility and fracture toughness values. They are thus considered as potential materials for aerospace applications both in their monolithic form and as matrices in metal matrix composites. Microstructure/property relationships have been studied to a great extend with regard to tensile and creep properties. However, only little is known in the key areas of fatigue crack initiation, fatigue crack propagation and fatigue life. The main objective of this work therefore is to get a comprehensive understanding of the effects of microstructural parameters (such as volume fraction of the individual phases, their size and distribution) on the cyclic properties of O-based titanium aluminides. Furthermore, the performance of these alloys in aggressive environments, a critical issue for this alloy class, is being addressed. Tensile, isothermal fatigue, and fatigue crack growth (FCG) tests were conducted at 20°C and 540°C both in lab air and vacuum (pressure ≤ 1 x 10-6 torr) on three microstructural conditions of a representative O-based titanium alloy, Ti-22Al-23Nb. Results indicate a strong effect of microstructure on tensile and FCG properties, whereas only a slight influence of microstructure on the fatigue life is evident. The O phase contributes mainly to the material's yield stress. The tensile elongation is predominantly influenced by the beta phase volume fraction. The observed effect of microstructure on the FCG behavior is attributed to crack closure, crack front geometry and crystallographic texture. Environmental effects on the fatigue life are pronounced at elevated temperature and high applied stress amplitudes only. These conditions lead to premature crack initiation at the specimen's surface for testing in air, whereas testing in vacuum results in subsurface crack nucleation and an extended fatigue life of about two orders of magnitude. The FCG behavior is influenced by the environment at both 20°C and 540°C, proposing fatigue crack growth mechanisms enhanced by hydrogen embrittlement.

Fracture of a Brittle-Particle Ductile Matrix Composite with Applications to a Coating System

NASA Astrophysics Data System (ADS)

Bianculli, Steven J.

In material systems consisting of hard second phase particles in a ductile matrix, failure initiating from cracking of the second phase particles is an important failure mechanism. This dissertation applies the principles of fracture mechanics to consider this problem, first from the standpoint of fracture of the particles, and then the onset of crack propagation from fractured particles. This research was inspired by the observation of the failure mechanism of a commercial zinc-based anti-corrosion coating and the analysis was initially approached as coatings problem. As the work progressed it became evident that failure mechanism was relevant to a broad range of composite material systems and research approach was generalized to consider failure of a system consisting of ellipsoidal second phase particles in a ductile matrix. The starting point for the analysis is the classical Eshelby Problem, which considered stress transfer from the matrix to an ellipsoidal inclusion. The particle fracture problem is approached by considering cracks within particles and how they are affected by the particle/matrix interface, the difference in properties between the particle and matrix, and by particle shape. These effects are mapped out for a wide range of material combinations. The trends developed show that, although the particle fracture problem is very complex, the potential for fracture among a range of particle shapes can, for certain ranges in particle shape, be considered easily on the basis of the Eshelby Stress alone. Additionally, the evaluation of cracks near the curved particle/matrix interface adds to the existing body of work of cracks approaching bi-material interfaces in layered material systems. The onset of crack propagation from fractured particles is then considered as a function of particle shape and mismatch in material properties between the particle and matrix. This behavior is mapped out for a wide range of material combinations. The final section of this dissertation qualitatively considers an approach to determine critical particle sizes, below which crack propagation will not occur for a coating system that exhibited stable cracks in an interfacial layer between the coating and substrate.

Three Dimensional Constraint Effects on the Estimated (Delta)CTOD during the Numerical Simulation of Different Fatigue Threshold Testing Techniques

NASA Technical Reports Server (NTRS)

Seshadri, Banavara R.; Smith, Stephen W.

2007-01-01

Variation in constraint through the thickness of a specimen effects the cyclic crack-tip-opening displacement (DELTA CTOD). DELTA CTOD is a valuable measure of crack growth behavior, indicating closure development, constraint variations and load history effects. Fatigue loading with a continual load reduction was used to simulate the load history associated with fatigue crack growth threshold measurements. The constraint effect on the estimated DELTA CTOD is studied by carrying out three-dimensional elastic-plastic finite element simulations. The analysis involves numerical simulation of different standard fatigue threshold test schemes to determine how each test scheme affects DELTA CTOD. The American Society for Testing and Materials (ASTM) prescribes standard load reduction procedures for threshold testing using either the constant stress ratio (R) or constant maximum stress intensity (K(sub max)) methods. Different specimen types defined in the standard, namely the compact tension, C(T), and middle cracked tension, M(T), specimens were used in this simulation. The threshold simulations were conducted with different initial K(sub max) values to study its effect on estimated DELTA CTOD. During each simulation, the DELTA CTOD was estimated at every load increment during the load reduction procedure. Previous numerical simulation results indicate that the constant R load reduction method generates a plastic wake resulting in remote crack closure during unloading. Upon reloading, this remote contact location was observed to remain in contact well after the crack tip was fully open. The final region to open is located at the point at which the load reduction was initiated and at the free surface of the specimen. However, simulations carried out using the constant Kmax load reduction procedure did not indicate remote crack closure. Previous analysis results using various starting K(sub max) values and different load reduction rates have indicated DELTA CTOD is independent of specimen size. A study of the effect of specimen thickness and geometry on the measured DELTA CTOD for various load reduction procedures and its implication in the estimation of fatigue crack growth threshold values is discussed.

Evidence that abnormal grain growth precedes fatigue crack initiation in nanocrystalline Ni-Fe

DOE Office of Scientific and Technical Information (OSTI.GOV)

Furnish, Timothy A.; Bufford, Daniel C.; Ren, Fang

Prior studies on the high-cycle fatigue behavior of nanocrystalline metals have shown that fatigue fracture is associated with abnormal grain growth (AGG). However, those previous studies have been unable to determine if AGG precedes fatigue crack initiation, or vice-versa. The present study shows that AGG indeed occurs prior to crack formation in nanocrystalline Ni-Fe by using a recently developed synchrotron X-ray diffraction modality that has been adapted for in-situ analysis. The technique allows fatigue tests to be interrupted at the initial signs of the AGG process, and subsequent microscopy reveals the precursor damage state preceding crack initiation.

Evidence that abnormal grain growth precedes fatigue crack initiation in nanocrystalline Ni-Fe

DOE PAGES

Furnish, Timothy A.; Bufford, Daniel C.; Ren, Fang; ...

2018-09-06

Prior studies on the high-cycle fatigue behavior of nanocrystalline metals have shown that fatigue fracture is associated with abnormal grain growth (AGG). However, those previous studies have been unable to determine if AGG precedes fatigue crack initiation, or vice-versa. The present study shows that AGG indeed occurs prior to crack formation in nanocrystalline Ni-Fe by using a recently developed synchrotron X-ray diffraction modality that has been adapted for in-situ analysis. The technique allows fatigue tests to be interrupted at the initial signs of the AGG process, and subsequent microscopy reveals the precursor damage state preceding crack initiation.

Microstructural studies on failure mechanisms in thermo-mechanical fatigue of repaired DS R80 and IN 738 Superalloys

NASA Astrophysics Data System (ADS)

Abrokwah, Emmanuel Otchere

Directionally solidified Rene 80 (DS R80) and polycrystalline Inconel 738(IN 738) Superalloys were tested in thermo-mechanical fatigue (TMF) over the temperature range of 500-900°C and plastic strain range from 0.1 to 0.8% using a DSI Gleeble thermal simulator. Thermo-mechanical testing was carried out on the parent material (baseline) in the conventional solution treated and aged condition (STA), as well as gas tungsten arc welded (GTAW) with an IN-738 filler, followed by solution treatment and ageing. Comparison of the baseline alloy microstructure with that of the welded and heat treated alloy showed that varying crack initiation mechanisms, notably oxidation by stress assisted grain boundary oxidation, grain boundary MC carbides fatigue crack initiation, fatigue crack initiation from sample surfaces, crack initiation from weld defects and creep deformation were operating, leading to different “weakest link” and failure initiation points. The observations from this study show that the repaired samples had extra crack initiation sites not present in the baseline, which accounted for their occasional poor fatigue life. These defects include lack of fusion between the weld and the base metal, fusion zone cracking, and heat affected zone microfissures.

Role of transient water pressure in quarrying: A subglacial experiment using acoustic emissions

USGS Publications Warehouse

Cohen, D.; Hooyer, T.S.; Iverson, N.R.; Thomason, J.F.; Jackson, M.

2006-01-01

Probably the most important mechanism of glacial erosion is quarrying: the growth and coalescence of cracks in subglacial bedrock and dislodgement of resultant rock fragments. Although evidence indicates that erosion rates depend on sliding speed, rates of crack growth in bedrock may be enhanced by changing stresses on the bed caused by fluctuating basal water pressure in zones of ice-bed separation. To study quarrying in real time, a granite step, 12 cm high with a crack in its stoss surface, was installed at the bed of Engabreen, Norway. Acoustic emission sensors monitored crack growth events in the step as ice slid over it. Vertical stresses, water pressure, and cavity height in the lee of the step were also measured. Water was pumped to the lee of the step several times over 8 days. Pumping initially caused opening of a leeward cavity, which then closed after pumping was stopped and water pressure decreased. During cavity closure, acoustic emissions emanating mostly from the vicinity of the base of the crack in the step increased dramatically. With repeated pump tests this crack grew with time until the step's lee surface was quarried. Our experiments indicate that fluctuating water pressure caused stress thresholds required for crack growth to be exceeded. Natural basal water pressure fluctuations should also concentrate stresses on rock steps, increasing rates of crack growth. Stress changes on the bed due to water pressure fluctuations will increase in magnitude and duration with cavity size, which may help explain the effect of sliding speed on erosion rates. Copyright 2006 by the American Geophysical Union.

Diagnosis of retrofit fatigue crack re-initiation and growth in steel-girder bridges for proactive repair and emergency planning.

DOT National Transportation Integrated Search

2014-07-01

This report presents a vibration : - : based damage : - : detection methodology that is capable of effectively capturing crack growth : near connections and crack re : - : initiation of retrofitted connections. The proposed damage detection algorithm...

Dynamic Torsional and Cyclic Fracture Behavior of ProFile Rotary Instruments at Continuous or Reciprocating Rotation as Visualized with High-speed Digital Video Imaging.

PubMed

Tokita, Daisuke; Ebihara, Arata; Miyara, Kana; Okiji, Takashi

2017-08-01

This study examined the dynamic fracture behavior of nickel-titanium rotary instruments in torsional or cyclic loading at continuous or reciprocating rotation by means of high-speed digital video imaging. The ProFile instruments (size 30, 0.06 taper; Dentsply Maillefer, Ballaigues, Switzerland) were categorized into 4 groups (n = 7 in each group) as follows: torsional/continuous (TC), torsional/reciprocating (TR), cyclic/continuous (CC), and cyclic/reciprocating (CR). Torsional loading was performed by rotating the instruments by holding the tip with a vise. For cyclic loading, a custom-made device with a 38° curvature was used. Dynamic fracture behavior was observed with a high-speed camera. The time to fracture was recorded, and the fractured surface was examined with scanning electron microscopy. The TC group initially exhibited necking of the file followed by the development of an initial crack line. The TR group demonstrated opening and closing of a crack according to its rotation in the cutting and noncutting directions, respectively. The CC group separated without any detectable signs of deformation. In the CR group, initial crack formation was recognized in 5 of 7 samples. The reciprocating rotation exhibited a longer time to fracture in both torsional and cyclic fatigue testing (P < .05). The scanning electron microscopic images showed a severely deformed surface in the TR group. The dynamic fracture behavior of NiTi rotary instruments, as visualized with high-speed digital video imaging, varied between the different modes of rotation and different fatigue testing. Reciprocating rotation induced a slower crack propagation and conferred higher fatigue resistance than continuous rotation in both torsional and cyclic loads. Copyright © 2017 American Association of Endodontists. Published by Elsevier Inc. All rights reserved.

Stress corrosion cracking and corrosion fatigue characterisation of MgZn1Ca0.3 (ZX10) in a simulated physiological environment.

PubMed

Jafari, Sajjad; Raman, R K Singh; Davies, Chris H J; Hofstetter, Joelle; Uggowitzer, Peter J; Löffler, Jörg F

2017-01-01

Magnesium (Mg) alloys have attracted great attention as potential materials for biodegradable implants. It is essential that an implant material possesses adequate resistance to cracking/fracture under the simultaneous actions of corrosion and mechanical stresses, i.e., stress corrosion cracking (SCC) and/or corrosion fatigue (CF). This study investigates the deformation behaviour of a newly developed high-strength low-alloy Mg alloy, MgZn1Ca0.3 (ZX10), processed at two different extrusion temperatures of 325 and 400°C (named E325 and E400, respectively), under slow strain tensile and cyclic tension-compression loadings in air and modified simulated body fluid (m-SBF). Extrusion resulted in a bimodal grain size distribution with recrystallised grain sizes of 1.2 μm ± 0.8 μm and 7 ± 5 μm for E325 and E400, respectively. E325 possessed superior tensile and fatigue properties to E400 when tested in air. This is mainly attributed to a grain-boundary strengthening mechanism. However, both E325 and E400 were found to be susceptible to SCC at a strain rate of 3.1×10 -7 s -1 in m-SBF. Moreover, both E325 and E400 showed similar fatigue strength when tested in m-SBF. This is explained on the basis of crack initiation from localised corrosion following tests in m-SBF. Crown Copyright © 2016. Published by Elsevier Ltd. All rights reserved.

Crystallographic Analysis of Fatigue Crack Initiation Behavior in Coarse-Grained Magnesium Alloy Under Tension-Tension Loading Cycles

NASA Astrophysics Data System (ADS)

Tamada, Kazuhiro; Kakiuchi, Toshifumi; Uematsu, Yoshihiko

2017-07-01

Plane bending fatigue tests are conducted to investigate fatigue crack initiation mechanisms in coarse-grained magnesium alloy, AZ31, under the stress ratios R = -1 and 0.1. The initial crystallographic structures are analyzed by an electron backscatter diffraction method. The slip or twin operation during fatigue tests is identified from the line angle analyses based on Euler angles of the grains. Under the stress ratio R = -1, relatively thick tension twin bands are formed in coarse grains. Subsequently, compression twin or secondary pyramidal slip operates within the tension twin band, resulting in the fatigue crack initiation. On the other hand, under R = 0.1 with tension-tension loading cycles, twin bands are formed on the specimen surface, but the angles of those bands do not correspond to tension twins. Misorientation analyses of c-axes in the matrix grain and twin band reveal that double twins are activated. Under R = 0.1, fatigue crack initiates along the double twin boundaries. The different manners of fatigue crack initiation at R = -1 and 0.1 are related to the asymmetricity of twining under tension and compression loadings. The fatigue strengths under different stress ratios cannot be estimated by the modified Goodman diagram due to the effect of stress ratio on crack initiation mechanisms.

The Influence on Microstructure and Microtexture on Fatigue Crack Initiation and Growth in Alpha + Beta Titanium

DTIC Science & Technology

2011-10-01

crack growth, microstructure, EBSD, fractography 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT: SAR NUMBER OF PAGES 6 19a...differences in thermomechanical processing routes have been correlated with variations in fatigue life through the use of quantitative fractography ...Keywords: fatigue, crack initiation, crack growth, microstructure, EBSD, fractography 1. Introduction Two-phase titanium alloys have the unique

Damage Accumulation in SiC/SiC Composites with 3D Architectures

NASA Technical Reports Server (NTRS)

Morscher, Gregory N.; Yun, Hee-Mann; DiCarlo, James A.

2003-01-01

The formation and propagation of multiple matrix cracks in relatively dense ceramic matrix composites when subjected to increasing tensile stress is necessary for high strength and tough composites. However, the occurrence of matrix cracks at low stresses may limit the usefulness of some non-oxide composite systems when subjected to oxidizing environments for long times at stresses sufficient to cause matrix cracking. For SiC fiber-reinforced composites with two-dimensional woven architectures and chemically vapor infiltrated (CVI) SiC matrix and melt-infiltrated (MI) Si/SiC matrix composites, the matrix cracking behavior has been fairly well characterized for different fiber-types and woven architectures. It was found that the occurrence, degree, and growth of matrix cracks depends on the material properties of the composite constituents as well as other physical properties of the composite or architecture, e.g., matrix porosity and size of the fiber bundle. In this study, matrix cracking in SiC fiber reinforced, melt-infiltrated SiC composites with a 3D orthogonal architecture was determined for specimens tested in tension at room temperature. Acoustic emission (AE) was used to monitor the matrix cracking activity, which was later confirmed by microscopic examination of specimens that had failed. The determination of the exact location of AE demonstrated that initial cracking occurred in the matrix rich regions when a large z-direction fiber bundle was used. For specimens with large z-direction fiber tows, the earliest matrix cracking could occur at half the stress for standard 2D woven composites with similar constituents. Damage accumulation in 3D architecture composites will be compared to damage accumulation in 2D architecture composites and discussed with respect to modeling composite stress-strain behavior and use of these composites at elevated temperatures.

Crack networks in damaged glass

NASA Astrophysics Data System (ADS)

Mallet, Celine; Fortin, Jerome; Gueguen, Yves

2013-04-01

We investigate how cracks develop and propagate in synthetic glass samples. Cracks are introduced in glass by a thermal shock of 300oC. Crack network is documented from optical and electronic microscopy on these samples that have been submitted to a thermal shock only. Samples are cylinder of 80 mm length and 40 mm diameter. Sections were cut along the cylinder axis and perpendicular to it. Using SEM, crack lengths and apertures can be measured. Optical microscopy allows to get the crack distribution over the entire sample. The sample average crack length is 3 mm. The average aperture is 6 ± 3μm. There is however a clear difference between the sample core, where the crack network has approximatively a transverse isotrope symmetry and the outer ring, where cracks are smaller and more numerous. By measuring before and after the thermal treatment the radial P and S wave velocities in room conditions, we can determine the total crack density which is 0.24. Thermally cracked samples, as described above, were submitted to creep tests. Constant axial stress and lateral stress were applied. Several experiments were performed at different stress values. Samples are saturated for 48 hours (to get an homogeneous pore fluid distribution), the axial stress is increased up to 80% of the sample strength. Stress step tests were performed in order to get creep data. The evolution of strain (axial and radial strain) is measured using strain gages, gap sensors (for the global axial strain) and pore volume change (for the volumetric strain). Creep data are interpreted as evidence of sub-critical crack growth in the cracked glass samples. The above microstructural observations are used, together with a crack propagation model, to account for the creep behavior. Assuming that (i) the observed volumetric strain rate is due to crack propagation and (ii) crack aspect ratio is constant we calculate the creep rate. We obtain some value on the crack propagation during a 24 hours of constant stress test. At each of these test, crack propagate of 0.3 to 0.4 mm. From the initial average crack length of 3 mm, the crack reach the size of 5.8 mm at the end of a complete creep test (with 8 constant stress step of 24 hours).

Factors controlling the size of graphene oxide sheets produced via the graphite oxide route.

PubMed

Pan, Shuyang; Aksay, Ilhan A

2011-05-24

We have studied the effect of the oxidation path and the mechanical energy input on the size of graphene oxide sheets derived from graphite oxide. The cross-planar oxidation of graphite from the (0002) plane results in periodic cracking of the uppermost graphene oxide layer, limiting its lateral dimension to less than 30 μm. We use an energy balance between the elastic strain energy associated with the undulation of graphene oxide sheets at the hydroxyl and epoxy sites, the crack formation energy, and the interaction energy between graphene layers to determine the cell size of the cracks. As the effective crack propagation rate in the cross-planar direction is an order of magnitude smaller than the edge-to-center oxidation rate, graphene oxide single sheets larger than those defined by the periodic cracking cell size are produced depending on the aspect ratio of the graphite particles. We also demonstrate that external energy input from hydrodynamic drag created by fluid motion or sonication, further reduces the size of the graphene oxide sheets through tensile stress buildup in the sheets.

Fatigue Crack Length Sizing Using a Novel Flexible Eddy Current Sensor Array.

PubMed

Xie, Ruifang; Chen, Dixiang; Pan, Mengchun; Tian, Wugang; Wu, Xuezhong; Zhou, Weihong; Tang, Ying

2015-12-21

The eddy current probe, which is flexible, array typed, highly sensitive and capable of quantitative inspection is one practical requirement in nondestructive testing and also a research hotspot. A novel flexible planar eddy current sensor array for the inspection of microcrack presentation in critical parts of airplanes is developed in this paper. Both exciting and sensing coils are etched on polyimide films using a flexible printed circuit board technique, thus conforming the sensor to complex geometric structures. In order to serve the needs of condition-based maintenance (CBM), the proposed sensor array is comprised of 64 elements. Its spatial resolution is only 0.8 mm, and it is not only sensitive to shallow microcracks, but also capable of sizing the length of fatigue cracks. The details and advantages of our sensor design are introduced. The working principal and the crack responses are analyzed by finite element simulation, with which a crack length sizing algorithm is proposed. Experiments based on standard specimens are implemented to verify the validity of our simulation and the efficiency of the crack length sizing algorithm. Experimental results show that the sensor array is sensitive to microcracks, and is capable of crack length sizing with an accuracy within ±0.2 mm.

Fatigue Crack Length Sizing Using a Novel Flexible Eddy Current Sensor Array

PubMed Central

Xie, Ruifang; Chen, Dixiang; Pan, Mengchun; Tian, Wugang; Wu, Xuezhong; Zhou, Weihong; Tang, Ying

2015-01-01

The eddy current probe, which is flexible, array typed, highly sensitive and capable of quantitative inspection is one practical requirement in nondestructive testing and also a research hotspot. A novel flexible planar eddy current sensor array for the inspection of microcrack presentation in critical parts of airplanes is developed in this paper. Both exciting and sensing coils are etched on polyimide films using a flexible printed circuit board technique, thus conforming the sensor to complex geometric structures. In order to serve the needs of condition-based maintenance (CBM), the proposed sensor array is comprised of 64 elements. Its spatial resolution is only 0.8 mm, and it is not only sensitive to shallow microcracks, but also capable of sizing the length of fatigue cracks. The details and advantages of our sensor design are introduced. The working principal and the crack responses are analyzed by finite element simulation, with which a crack length sizing algorithm is proposed. Experiments based on standard specimens are implemented to verify the validity of our simulation and the efficiency of the crack length sizing algorithm. Experimental results show that the sensor array is sensitive to microcracks, and is capable of crack length sizing with an accuracy within ±0.2 mm. PMID:26703608

Extreme Toughening of Soft Materials with Liquid Metal.

PubMed

Kazem, Navid; Bartlett, Michael D; Majidi, Carmel

2018-05-01

Soft and tough materials are critical for engineering applications in medical devices, stretchable and wearable electronics, and soft robotics. Toughness in synthetic materials is mostly accomplished by increasing energy dissipation near the crack tip with various energy dissipation techniques. However, bio-materials exhibit extreme toughness by combining multi-scale energy dissipation with the ability to deflect and blunt an advancing crack tip. Here, we demonstrate a synthetic materials architecture that also exhibits multi-modal toughening, whereby embedding a suspension of micron sized and highly deformable liquid metal (LM) droplets inside a soft elastomer, the fracture energy dramatically increases by up to 50x (from 250 ± 50 J m -2 to 11,900 ± 2600 J m -2 ) over an unfilled polymer. For some LM-embedded elastomer (LMEE) compositions, the toughness is measured to be 33,500 ± 4300 J m -2 , which far exceeds the highest value previously reported for a soft elastic material. This extreme toughening is achieved by (i) increasing energy dissipation, (ii) adaptive crack movement, and (iii) effective elimination of the crack tip. Such properties arise from the deformability of the LM inclusions during loading, providing a new mechanism to not only prevent crack initiation, but also resist the propagation of existing tears for ultra tough, soft materials. © 2018 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

A review of the effect of a/W ratio on fracture toughness (I) —Experimental investigation in EPFM

NASA Astrophysics Data System (ADS)

Li, Qing-Fen; Zheng, Wei; Shu, Hai-Sheng

2005-03-01

Many experimental investigations have previously been performed and recently done on different shipbuilding structural steels where the specimens size and crack depth/specimen width ( a/W) were varied. A series of interesting results have been gained. It is worthwhile to have a review on the effect of a/W ratio on fracture toughness, and further theoretical analysis is necessary. In this paper, experimental work in elasticplastic fracture mechanics (EPFM) was discussed. Tests had been carried out on 10 kinds of strength steels. Results showed that J i and δ1 values increased with decreasing a/W when a/W<0.3 for three-point bend specimens and that shallow crack specimens which have less constrained flow field give markedly higher values of toughness than deeply notched specimens. However, for a/W>0.3, the toughness was found to be independent of a/W. Slip line field analysis shows that for shallow cracks, the hydrostatic stress is lower than that from standard deeply cracked bend specimen which develops a high level of crack tip constraint, provides a lower bound estimate of toughness, and will ensure an unduly conservative approach when applied to structure defects especially if initiation values of COD/ J-integral are used.

Evaluation of Crack Arrest Toughness ( K IA) of P91 Steel in Various Cold Worked and Thermally Aged Conditions

NASA Astrophysics Data System (ADS)

Sathyanarayanan, S.; Moitra, A.; Sasikala, G.; Bhaduri, A. K.

2015-02-01

K IA is increasingly being regarded as a characteristic fracture toughness below which cleavage fracture does not occur. Its evaluation from small-sized Charpy specimens would be advantageous for applications in power plant industries. In this study, K IA has been evaluated for P91 steel in various cold worked and thermally aged conditions. Evaluation of K IA requires determination of crack arrest load( P arrest) and crack arrest length( a arrest). The main challenge is in the determination of a arrest due to the non-availability of standard methodologies and the absence of unequivocal microstructural signatures on the fracture surface in this steel to identify crack arrest. a arrest has been determined using the analytical Key- Curve methodology which has proven successful for this steel in unaged condition. The applicability of the Key- Curve method is validated by the good agreement of the determined final crack length with that measured optically on unbroken specimens of N&T and subsequently 15% cold-worked P91 steel which had been previously aged at 650 °C for 5000 h. Mean K IA varies from 47.46 MPa√m (NT steel aged at 600 °C for 5000 h) to 69.85 MPa√m(NT + 15% cw steel aged at 650 °C for 10000 h) for the various cold worked and aged datasets. K IA is found to be an average property unlike initiation toughness ( K Jd) which shows statistical scatter. Mean K IA is found to be in reasonable agreement with the lower bound values of cleavage initiation toughness ( K Jd) for the datasets in this study.

Quantitative Detection of Cracks in Steel Using Eddy Current Pulsed Thermography.

PubMed

Shi, Zhanqun; Xu, Xiaoyu; Ma, Jiaojiao; Zhen, Dong; Zhang, Hao

2018-04-02

Small cracks are common defects in steel and often lead to catastrophic accidents in industrial applications. Various nondestructive testing methods have been investigated for crack detection; however, most current methods focus on qualitative crack identification and image processing. In this study, eddy current pulsed thermography (ECPT) was applied for quantitative crack detection based on derivative analysis of temperature variation. The effects of the incentive parameters on the temperature variation were analyzed in the simulation study. The crack profile and position are identified in the thermal image based on the Canny edge detection algorithm. Then, one or more trajectories are determined through the crack profile in order to determine the crack boundary through its temperature distribution. The slope curve along the trajectory is obtained. Finally, quantitative analysis of the crack sizes was performed by analyzing the features of the slope curves. The experimental verification showed that the crack sizes could be quantitatively detected with errors of less than 1%. Therefore, the proposed ECPT method was demonstrated to be a feasible and effective nondestructive approach for quantitative crack detection.

Exploring How Weathering Related Stresses and Subcritical Crack Growth May Influence the Size of Sediment Produced From Different Rock Types.

NASA Astrophysics Data System (ADS)

Eppes, M. C.; Hallet, B.; Hancock, G. S.; Mackenzie-Helnwein, P.; Keanini, R.

2016-12-01

The formation and diminution of rock debris, sediment and soil at and near Earth's surface is driven in large part by in situ, non-transport related, rock cracking. Given the relatively low magnitude stresses that arise in surface and near-surface settings, this production and diminution of granular material is likely strongly influenced and/or driven by subcritical crack growth (Eppes et al., 2016), cracking that occurs under stress loading conditions much lower than a rock's strength as typically measured in the laboratory under rapid loading. Despite a relatively sound understanding of subcritical crack growth through engineering and geophysical studies, its geomorphic and sedimentologic implications have only been minimally explored. Here, based on existing studies, we formulate several hypotheses to predict how weathering-induced stresses combined with the subcritical crack growth properties of rock may influence sediment size distribution. For example, subcritical crack growth velocity (v) can be described by v = CKIn where KI is the mode I (simple opening mode) stress intensity factor, a function of tensile stress at the crack tip and crack length; C is a rock- and environment-dependent constant; and n is material constant, the subcritical crack growth index. Fracture length and spacing in rock is strongly dependent on n, where higher n values result in fewer, more distally spaced cracks (e.g. Olsen, 1993). Thus, coarser sediment might be expected from rocks with higher n values. Weathering-related stresses such as thermal stresses and mineral hydration, however, can disproportionally stress boundaries between minerals with contrasting thermal or chemical properties and orientation, resulting in granular disintegration. Thus, rocks with properties favorable to inducing these stresses might produce sediment whose size is reflective of its constituent grains. We begin to test these hypotheses through a detailed examination of crack and rock characteristics in outcrops of granite, sandstone, and quartzite found in Shenandoah National Park, Virginia. Preliminary results reveal that many observed cracking characteristics are consistent with our hypotheses linking subcritical crack growth, weathering stresses and the production of different sized sediment from different rock types.

A structural health monitoring fastener for tracking fatigue crack growth in bolted metallic joints

NASA Astrophysics Data System (ADS)

Rakow, Alexi Schroder

Fatigue cracks initiating at fastener hole locations in metallic components are among the most common form of airframe damage. The fastener hole site has been surveyed as the second leading initiation site for fatigue related accidents of fixed wing aircraft. Current methods for inspecting airframes for these cracks are manual, whereby inspectors rely on non-destructive inspection equipment or hand-held probes to scan over areas of a structure. Use of this equipment often demands disassembly of the vehicle to search appropriate hole locations for cracks, which elevates the complexity and cost of these maintenance inspections. Improved reliability, safety, and reduced cost of such maintenance can be realized by the permanent integration of sensors with a structure to detect this damage. Such an integrated system of sensors would form a structural health monitoring (SHM) system. In this study, an Additive, Interleaved, Multi-layer Electromagnetic (AIME) sensor was developed and integrated with the shank of a fastener to form a SHM Fastener, a new SHM technology targeted at detection of fastener hole cracks. The major advantages of the SHM Fastener are its installation, which does not require joint layer disassembly, its capability to detect inner layer cracks, and its capability to operate in a continuous autonomous mode. Two methods for fabricating the proposed SHM Fastener were studied. The first option consisted of a thin flexible printed circuit film that was bonded around a thin metallic sleeve placed around the fastener shank. The second option consisted of coating sensor materials directly to the shank of a part in an effort to increase the durability of the sensor under severe loading conditions. Both analytical and numerical models were developed to characterize the capability of the sensors and provide a design tool for the sensor layout. A diagnostic technique for crack growth monitoring was developed to complete the SHM system, which consists of the sensor, data acquisition hardware, algorithm, and diagnostic display. The AIME sensor design, SHM Fastener, and complete SHM system are presented along with experimental results from a series of single-layer and bolted double lap joint aluminum laboratory specimens to validate the capability of these sensors to monitor metallic joints for fastener hole cracks. Fatigue cracks were successfully tracked to over 0.7 inches from the fastener hole in these tests. Sensor output obtained from single-layer fatigue specimens was compared with analytical predictions for fatigue crack growth versus cycle number showing a good correlation in trend between sensor output and predicted crack size.

Brittle fracture in structural steels: perspectives at different size-scales.

PubMed

Knott, John

2015-03-28

This paper describes characteristics of transgranular cleavage fracture in structural steel, viewed at different size-scales. Initially, consideration is given to structures and the service duty to which they are exposed at the macroscale, highlighting failure by plastic collapse and failure by brittle fracture. This is followed by sections describing the use of fracture mechanics and materials testing in carrying-out assessments of structural integrity. Attention then focuses on the microscale, explaining how values of the local fracture stress in notched bars or of fracture toughness in pre-cracked test-pieces are related to features of the microstructure: carbide thicknesses in wrought material; the sizes of oxide/silicate inclusions in weld metals. Effects of a microstructure that is 'heterogeneous' at the mesoscale are treated briefly, with respect to the extraction of test-pieces from thick sections and to extrapolations of data to low failure probabilities. The values of local fracture stress may be used to infer a local 'work-of-fracture' that is found experimentally to be a few times greater than that of two free surfaces. Reasons for this are discussed in the conclusion section on nano-scale events. It is suggested that, ahead of a sharp crack, it is necessary to increase the compliance by a cooperative movement of atoms (involving extra work) to allow the crack-tip bond to displace sufficiently for the energy of attraction between the atoms to reduce to zero. © 2015 The Author(s) Published by the Royal Society. All rights reserved.

A finite element model on effects of impact load and cavitation on fatigue crack propagation in mechanical bileaflet aortic heart valve.

PubMed

Mohammadi, H; Klassen, R J; Wan, W-K

2008-10-01

Pyrolytic carbon mechanical heart valves (MHVs) are widely used to replace dysfunctional and failed heart valves. As the human heart beats around 40 million times per year, fatigue is the prime mechanism of mechanical failure. In this study, a finite element approach is implemented to develop a model for fatigue analysis of MHVs due to the impact force between the leaflet and the stent and cavitation in the aortic position. A two-step method to predict crack propagation in the leaflets of MHVs has been developed. Stress intensity factors (SIFs) are computed at a small initiated crack located on the leaflet edge (the worst case) using the boundary element method (BEM). Static analysis of the crack is performed to analyse the stress distribution around the front crack zone when the crack is opened; this is followed by a dynamic crack analysis to consider crack propagation using the finite element approach. Two factors are taken into account in the calculation of the SIFs: first, the effect of microjet formation due to cavitation in the vicinity of leaflets, resulting in water hammer pressure; second, the effect of the impact force between the leaflet and the stent of the MHVs, both in the closing phase. The critical initial crack length, the SIFs, the water hammer pressure, and the maximum jet velocity due to cavitation have been calculated. With an initial crack length of 35 microm, the fatigue life of the heart valve is greater than 60 years (i.e. about 2.2 x 10(9) cycles) and, with an initial crack length of 170 microm, the fatigue life of the heart valve would be around 2.5 years (i.e. about 9.1 x 10(7) cycles). For an initial crack length greater than 170 microm, there is catastrophic failure and fatigue cracking no longer occurs. A finite element model of fatigue analysis using Patran command language (PCL custom code) in MSC software can be used to evaluate the useful lifespan of MHVs. Similar methodologies can be extended to other medical devices under cyclic loads.

Research notes : keeping steel bars anchored in cracked girders.

DOT National Transportation Integrated Search

2011-01-01

Researchers at Oregon State University fabricated large-size reinforced concrete beams each with an intentional crack made by positioning a plastic sheet in the formwork when the beams were cast. By maintaining control over crack location, crack angl...

Crack propagation in teeth: a comparison of perimortem and postmortem behavior of dental materials and cracks.

PubMed

Hughes, Cris E; White, Crystal A

2009-03-01

This study presents a new method for understanding postmortem heat-induced crack propagation patterns in teeth. The results demonstrate that patterns of postmortem heat-induced crack propagation differ from perimortem and antemortem trauma-induced crack propagation patterns. Dental material of the postmortem tooth undergoes dehydration leading to a shrinking and more brittle dentin material and a weaker dentin-enamel junction. Dentin intertubule tensile stresses are amplified by the presence of the pulp cavity, and initiates crack propagation from the internal dentin, through the dentin-enamel junction and lastly the enamel. In contrast, in vivo perimortem and antemortem trauma-induced crack propagation initiates cracking from the external surface of the enamel toward the dentin-enamel junction where the majority of the energy of the crack is dissipated, eliminating the crack's progress into the dentin. These unique patterns of crack propagation can be used to differentiate postmortem taphonomy-induced damage from antemortem and perimortem trauma in teeth.

Crack Initiation and Growth in Rigid Polymeric Closed-Cell Foam Cryogenic Applications

NASA Technical Reports Server (NTRS)

Sayyah, Tarek; Steeve, Brian; Wells, Doug

2006-01-01

Cryogenic vessels, such as the Space Shuttle External Tank, are often insulated with closed-cell foam because of its low thermal conductivity. The coefficient of thermal expansion mismatch between the foam and metallic substrate places the foam under a biaxial tension gradient through the foam thickness. The total foam thickness affects the slope of the stress gradient and is considered a significant contributor to the initiation of subsurface cracks. Rigid polymeric foams are brittle in nature and any subsurface cracks tend to propagate a finite distance toward the surface. This presentation investigates the relationship between foam thickness and crack initiation and subsequent crack growth, using linear elastic fracture mechanics, in a rigid polymeric closed-cell foam through analysis and comparison with experimental results.

Prediction Of Critical Crack Sizes In Solar Cells

NASA Technical Reports Server (NTRS)

Chen, Chern P.

1989-01-01

Report presents theoretical analysis of cracking in Si and GaAs solar photovoltaic cells subjected to bending or twisting. Analysis also extended to predict critical sizes for cracks in Ge substrate coated with thin film of GaAs. Analysis leads to general conclusions. Approach and results of study useful in development of guidelines for acceptance or rejection of slightly flawed cells during manufacture.

Simulation of Low Velocity Impact Induced Inter- and Intra-Laminar Damage of Composite Beams Based on XFEM

NASA Astrophysics Data System (ADS)

Sun, Wei; Guan, Zhidong; Li, Zengshan

2017-12-01

In this paper, the Inter-Fiber Fracture (IFF) criterion of Puck failure theory based on the eXtended Finite Element Method (XFEM) was implemented in ABAQUS code to predict the intra-laminar crack initiation of unidirectional (UD) composite laminate. The transverse crack path in the matrix can be simulated accurately by the presented method. After the crack initiation, the propagation of the crack is simulated by Cohesive Zoom Model (CZM), in which the displacement discontinuities and stress concentration caused by matrix crack is introduced into the finite element (FE) model. Combined with the usage of the enriched element interface, which can be used to simulate the inter-laminar delamination crack, the Low Velocity Impact (LVI) induced damage of UD composite laminate beam with a typical stacking of composite laminates [05/903]S is studied. A complete crack initiation and propagation process was simulated and the numerical results obtained by the XFEM are consistent with the experimental results.

Cross-validated detection of crack initiation in aerospace materials

NASA Astrophysics Data System (ADS)

Vanniamparambil, Prashanth A.; Cuadra, Jefferson; Guclu, Utku; Bartoli, Ivan; Kontsos, Antonios

2014-03-01

A cross-validated nondestructive evaluation approach was employed to in situ detect the onset of damage in an Aluminum alloy compact tension specimen. The approach consisted of the coordinated use primarily the acoustic emission, combined with the infrared thermography and digital image correlation methods. Both tensile loads were applied and the specimen was continuously monitored using the nondestructive approach. Crack initiation was witnessed visually and was confirmed by the characteristic load drop accompanying the ductile fracture process. The full field deformation map provided by the nondestructive approach validated the formation of a pronounced plasticity zone near the crack tip. At the time of crack initiation, a burst in the temperature field ahead of the crack tip as well as a sudden increase of the acoustic recordings were observed. Although such experiments have been attempted and reported before in the literature, the presented approach provides for the first time a cross-validated nondestructive dataset that can be used for quantitative analyses of the crack initiation information content. It further allows future development of automated procedures for real-time identification of damage precursors including the rarely explored crack incubation stage in fatigue conditions.

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

NASA Technical Reports Server (NTRS)

Bonacuse, Peter J.; Kantzos, Pete T.; Barrie, Robert; Telesman, Jack; Ghosn, Louis J.; Gabb, Timothy P.

2004-01-01

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Characterization of fatigue crack initiation and propagation in Ti-6Al-4V with electrical potential drop technique

NASA Technical Reports Server (NTRS)

Kalluri, Sreeramesh; Telesman, Jack

1988-01-01

Electrical potential methods have been used in the past primarily to monitor crack length in long crack specimens subjected to fatigue loading. An attempt was made to develop test procedures for monitoring the fatigue crack initiation and the growth of short fatigue cracks in a turbine disk alloy with the electrical potential drop technique (EPDT). In addition, the EPDT was also applied to monitor the fatigue crack growth in long crack specimens of the same alloy. The resolution of the EPDT for different specimen geometries was determined. Factors influencing the EPDT are identified and the applicability of EPDT in implementing damage tolerant design concepts for turbine disk materials is discussed. The experimental procedure adopted and the results obtained is discussed. No substantial differences were observed between the fatigue crack growth data of short and long crack specimens.

Fatigue crack detection and identification by the elastic wave propagation method

NASA Astrophysics Data System (ADS)

Stawiarski, Adam; Barski, Marek; Pająk, Piotr

2017-05-01

In this paper the elastic wave propagation phenomenon was used to detect the initiation of the fatigue damage in isotropic plate with a circular hole. The safety and reliability of structures mostly depend on the effectiveness of the monitoring methods. The Structural Health Monitoring (SHM) system based on the active pitch-catch measurement technique was proposed. The piezoelectric (PZT) elements was used as an actuators and sensors in the multipoint measuring system. The comparison of the intact and defected structures has been used by damage detection algorithm. One part of the SHM system has been responsible for detection of the fatigue crack initiation. The second part observed the evolution of the damage growth and assess the size of the defect. The numerical results of the wave propagation phenomenon has been used to present the effectiveness and accuracy of the proposed method. The preliminary experimental analysis has been carried out during the tension test of the aluminum plate with a circular hole to determine the efficiency of the measurement technique.

FASTRAN II - FATIGUE CRACK GROWTH STRUCTURAL ANALYSIS (UNIX VERSION)

NASA Technical Reports Server (NTRS)

Newman, J. C.

1994-01-01

Predictions of fatigue crack growth behavior can be made with the Fatigue Crack Growth Structural Analysis (FASTRAN II) computer program. As cyclic loads are applied to a selected crack configuration with an initial crack size, FASTRAN II predicts crack growth as a function of cyclic load history until either a desired crack size is reached or failure occurs. FASTRAN II is based on plasticity-induced crack-closure behavior of cracks in metallic materials and accounts for load-interaction effects, such as retardation and acceleration, under variable-amplitude loading. The closure model is based on the Dugdale model with modifications to allow plastically deformed material to be left along the crack surfaces as the crack grows. Plane stress and plane strain conditions, as well as conditions between these two, can be simulated in FASTRAN II by using a constraint factor on tensile yielding at the crack front to approximately account for three-dimensional stress states. FASTRAN II contains seventeen predefined crack configurations (standard laboratory fatigue crack growth rate specimens and many common crack configurations found in structures); and the user can define one additional crack configuration. The baseline crack growth rate properties (effective stress-intensity factor against crack growth rate) may be given in either equation or tabular form. For three-dimensional crack configurations, such as surface cracks or corner cracks at holes or notches, the fatigue crack growth rate properties may be different in the crack depth and crack length directions. Final failure of the cracked structure can be modelled with fracture toughness properties using either linear-elastic fracture mechanics (brittle materials), a two-parameter fracture criterion (brittle to ductile materials), or plastic collapse (extremely ductile materials). The crack configurations in FASTRAN II can be subjected to either constant-amplitude, variable-amplitude or spectrum loading. The applied loads may be either tensile or compressive. Several standardized aircraft flight-load histories, such as TWIST, Mini-TWIST, FALSTAFF, Inverted FALSTAFF, Felix and Gaussian, are included as options. FASTRAN II also includes two other methods that will help the user input spectrum load histories. The two methods are: (1) a list of stress points, and (2) a flight-by-flight history of stress points. Examples are provided in the user manual. Developed as a research program, FASTRAN II has successfully predicted crack growth in many metallic materials under various aircraft spectrum loading. A computer program DKEFF which is a part of the FASTRAN II package was also developed to analyze crack growth rate data from laboratory specimens to obtain the effective stress-intensity factor against crack growth rate relations used in FASTRAN II. FASTRAN II is written in standard FORTRAN 77. It has been successfully compiled and implemented on Sun4 series computers running SunOS and on IBM PC compatibles running MS-DOS using the Lahey F77L FORTRAN compiler. Sample input and output data are included with the FASTRAN II package. The UNIX version requires 660K of RAM for execution. The standard distribution medium for the UNIX version (LAR-14865) is a .25 inch streaming magnetic tape cartridge in UNIX tar format. It is also available on a 3.5 inch diskette in UNIX tar format. The standard distribution medium for the MS-DOS version (LAR-14944) is a 5.25 inch 360K MS-DOS format diskette. The contents of the diskette are compressed using the PKWARE archiving tools. The utility to unarchive the files, PKUNZIP.EXE, is included. The program was developed in 1984 and revised in 1992. Sun4 and SunOS are trademarks of Sun Microsystems, Inc. IBM PC is a trademark of International Business Machines Corp. MS-DOS is a trademark of Microsoft, Inc. F77L is a trademark of the Lahey Computer Systems, Inc. UNIX is a registered trademark of AT&T Bell Laboratories. PKWARE and PKUNZIP are trademarks of PKWare, Inc.

FASTRAN II - FATIGUE CRACK GROWTH STRUCTURAL ANALYSIS (IBM PC VERSION)

NASA Technical Reports Server (NTRS)

Newman, J. C.

1994-01-01

Predictions of fatigue crack growth behavior can be made with the Fatigue Crack Growth Structural Analysis (FASTRAN II) computer program. As cyclic loads are applied to a selected crack configuration with an initial crack size, FASTRAN II predicts crack growth as a function of cyclic load history until either a desired crack size is reached or failure occurs. FASTRAN II is based on plasticity-induced crack-closure behavior of cracks in metallic materials and accounts for load-interaction effects, such as retardation and acceleration, under variable-amplitude loading. The closure model is based on the Dugdale model with modifications to allow plastically deformed material to be left along the crack surfaces as the crack grows. Plane stress and plane strain conditions, as well as conditions between these two, can be simulated in FASTRAN II by using a constraint factor on tensile yielding at the crack front to approximately account for three-dimensional stress states. FASTRAN II contains seventeen predefined crack configurations (standard laboratory fatigue crack growth rate specimens and many common crack configurations found in structures); and the user can define one additional crack configuration. The baseline crack growth rate properties (effective stress-intensity factor against crack growth rate) may be given in either equation or tabular form. For three-dimensional crack configurations, such as surface cracks or corner cracks at holes or notches, the fatigue crack growth rate properties may be different in the crack depth and crack length directions. Final failure of the cracked structure can be modelled with fracture toughness properties using either linear-elastic fracture mechanics (brittle materials), a two-parameter fracture criterion (brittle to ductile materials), or plastic collapse (extremely ductile materials). The crack configurations in FASTRAN II can be subjected to either constant-amplitude, variable-amplitude or spectrum loading. The applied loads may be either tensile or compressive. Several standardized aircraft flight-load histories, such as TWIST, Mini-TWIST, FALSTAFF, Inverted FALSTAFF, Felix and Gaussian, are included as options. FASTRAN II also includes two other methods that will help the user input spectrum load histories. The two methods are: (1) a list of stress points, and (2) a flight-by-flight history of stress points. Examples are provided in the user manual. Developed as a research program, FASTRAN II has successfully predicted crack growth in many metallic materials under various aircraft spectrum loading. A computer program DKEFF which is a part of the FASTRAN II package was also developed to analyze crack growth rate data from laboratory specimens to obtain the effective stress-intensity factor against crack growth rate relations used in FASTRAN II. FASTRAN II is written in standard FORTRAN 77. It has been successfully compiled and implemented on Sun4 series computers running SunOS and on IBM PC compatibles running MS-DOS using the Lahey F77L FORTRAN compiler. Sample input and output data are included with the FASTRAN II package. The UNIX version requires 660K of RAM for execution. The standard distribution medium for the UNIX version (LAR-14865) is a .25 inch streaming magnetic tape cartridge in UNIX tar format. It is also available on a 3.5 inch diskette in UNIX tar format. The standard distribution medium for the MS-DOS version (LAR-14944) is a 5.25 inch 360K MS-DOS format diskette. The contents of the diskette are compressed using the PKWARE archiving tools. The utility to unarchive the files, PKUNZIP.EXE, is included. The program was developed in 1984 and revised in 1992. Sun4 and SunOS are trademarks of Sun Microsystems, Inc. IBM PC is a trademark of International Business Machines Corp. MS-DOS is a trademark of Microsoft, Inc. F77L is a trademark of the Lahey Computer Systems, Inc. UNIX is a registered trademark of AT&T Bell Laboratories. PKWARE and PKUNZIP are trademarks of PKWare, Inc.

Finite element model study of the effect of corner rounding on detectability of corner cracks using bolt hole eddy current

NASA Astrophysics Data System (ADS)

Underhill, P. R.; Krause, T. W.

2017-02-01

Recent work has shown that the detectability of corner cracks in bolt-holes is compromised when rounding of corners arises, as might occur during bolt-hole removal. Probability of Detection (POD) studies normally require a large number of samples of both fatigue cracks and electric discharge machined notches. In the particular instance of rounding of bolt-hole corners the generation of such a large set of samples representing the full spectrum of potential rounding would be prohibitive. In this paper, the application of Finite Element Method (FEM) modeling is used to supplement the study of detection of cracks forming at the rounded corners of bolt-holes. FEM models show that rounding of the corner of the bolt-hole reduces the size of the response to a corner crack to a greater extent than can be accounted for by loss of crack area. This reduced sensitivity can be ascribed to a lower concentration of eddy currents at the rounded corner surface and greater lift-off of pick-up coils relative to that of a straight-edge corner. A rounding with a radius of 0.4 mm (.016 inch) showed a 20% reduction in the strength of the crack signal. Assuming linearity of the crack signal with crack size, this would suggest an increase in the minimum detectable size by 25%.

Stable tearing behavior of a thin-sheet material with multiple cracks

NASA Technical Reports Server (NTRS)

Dawicke, D. S.; Newman, J. C., Jr.; Sutton, M. A.; Amstutz, B. E.

1994-01-01

Fracture tests were conducted on 2.3mm thick, 305mm wide sheets of 2024-T3 aluminum alloy with 1-5 collinear cracks. The cracks were introduced (crack history) into the specimens by three methods: (1) saw cutting; (2) fatigue precracking at a low stress range; and (3) fatigue precracking at a high stress range. For the single crack tests, the initial crack history influenced the stress required for the onset of stable crack growth and the first 10mm of crack growth. The effect on failure stress was about 4 percent or less. For the multiple crack tests, the initial crack history was shown to cause differences of more than 20 percent in the link-up stress and 13 percent in failure stress. An elastic-plastic finite element analysis employing the Crack Tip Opening Angle (CTOA) fracture criterion was used to predict the fracture behavior of the single and multiple crack tests. The numerical predictions were within 7 percent of the observed link-up and failure stress in all the tests.

Influence of crack history on the stable tearing behavior of a thin-sheet material with multiple cracks

NASA Technical Reports Server (NTRS)

Dawicke, D. S.; Newman, J. C., Jr.; Sutton, M. A.; Amstutz, B. E.

1994-01-01

Fracture tests were conducted on 2.3mm thick, 305mm wide sheets of 2024-T3 aluminum alloy with from one to five collinear cracks. The cracks were introduced (crack history) into the specimens by three methods: saw cutting, fatigue precracking at a low stress range, and fatigue precracking at a high stress range. For the single crack tests, the initial crack history influenced the stress required for the onset of stable crack growth and the first 10mm of crack growth. The effect on failure stress was about 4 percent or less. For the multiple crack tests, the initial crack history was shown to cause differences of more than 20 percent in the link-up stress and 13 percent in failure stress. An elastic-plastic finite element analysis employing the CTOA fracture criterion was used to predict the fracture behavior of the single and multiple crack tests. The numerical predictions were within 7 percent of the observed link-up and failure stress in all the tests.

Eddy current standards - Cracks versus notches

NASA Astrophysics Data System (ADS)

Hagemaier, D. J.; Collingwood, M. R.; Nguyen, K. H.

1992-10-01

Eddy current tests aimed at evaluating cracks and electron-discharge machined (EDM) notches in 7075-T6 aluminum specimens are described. A comparison of the shape and amplitude of recordings made from both transverse and longitudinal scans of small EDM notches and fatigue cracks showd almost identical results. The signal amplitude and phase angle increased with an increase of EDM notch and crak size. It is concluded that equivalent eddy current results obtained from similar-size surface cracks and notches in aluminum can be used to establish a desired sensitivity level for inspection.

The Dugdale model for the compact specimen

NASA Technical Reports Server (NTRS)

Mall, S.; Newman, J. C., Jr.

1983-01-01

Plastic zone size and crack tip opening displacement (CTOD) equations were developed. Boundary collocation analyses were used to analyze the compact specimen subjected to various loading conditions (pin loads, concentrated forces, and uniform pressure acting on the crack surface). Stress intensity factor and crack surface displacement equations for some of these loadings were developed and used to obtain the Dugdale model. The results from the equations for plastic zone size and CTOD agreed well with numerical values calculated by Terada for crack length to width ratios greater than 0.4.

In-situ observations of crack initiation and growth at notches in cast Ti-48Al-2Cr-2Nb

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pollock, T.M.; Muraleedharan, K.; Mumm, D.R.

1996-12-01

Gamma titanium aluminide alloys have recently received a great deal of attention due to their demonstrated potential for application in aircraft engines. Although a number of studies have been conducted on the fracture behavior of these alloys under conditions where relatively long pre-existing cracks are present, there is little information on the early stages of crack initiation and growth. The objective of the study reported here was to observe the initial development of cracks at the scale of the microstructure. To confine the process of interest to well-defined regions, notched specimens were utilized. Observations regarding the initiation, growth and themore » influence of environment on failure are discussed.« less

Stress-Dependent Matrix Cracking in 2D Woven SiC-Fiber Reinforced Melt-Infiltrated SiC Matrix Composites

NASA Technical Reports Server (NTRS)

Morscher, Gregory N.

2003-01-01

The matrix cracking of a variety of SiC/SiC composites has been characterized for a wide range of constituent variation. These composites were fabricated by the 2-dimensional lay-up of 0/90 five-harness satin fabric consisting of Sylramic fiber tows that were then chemical vapor infiltrated (CVI) with BN, CVI with SiC, slurry infiltrated with SiC particles followed by molten infiltration of Si. The composites varied in number of plies, the number of tows per length, thickness, and the size of the tows. This resulted in composites with a fiber volume fraction in the loading direction that ranged from 0.12 to 0.20. Matrix cracking was monitored with modal acoustic emission in order to estimate the stress-dependent distribution of matrix cracks. It was found that the general matrix crack properties of this system could be fairly well characterized by assuming that no matrix cracks originated in the load-bearing fiber, interphase, chemical vapor infiltrated Sic tow-minicomposites, i.e., all matrix cracks originate in the 90 degree tow-minicomposites or the large unreinforced Sic-Si matrix regions. Also, it was determined that the larger tow size composites had a much narrower stress range for matrix cracking compared to the standard tow size composites.

Detection and monitoring of shear crack growth using S-P conversion of seismic waves

NASA Astrophysics Data System (ADS)

Modiriasari, A.; Bobet, A.; Pyrak-Nolte, L. J.

2017-12-01

A diagnostic method for monitoring shear crack initiation, propagation, and coalescence in rock is key for the detection of major rupture events, such as slip along a fault. Active ultrasonic monitoring was used in this study to determine the precursory signatures to shear crack initiation in pre-cracked rock. Prismatic specimens of Indiana limestone (203x2101x638x1 mm) with two pre-existing parallel flaws were subjected to uniaxial compression. The flaws were cut through the thickness of the specimen using a scroll saw. The length of the flaws was 19.05 mm and had an inclination angle with respect to the loading direction of 30o. Shear wave transducers were placed on each side of the specimen, with polarization parallel to the loading direction. The shear waves, given the geometry of the flaws, were normally incident to the shear crack forming between the two flaws during loading. Shear crack initiation and propagation was detected on the specimen surface using digital image correlation (DIC), while initiation inside the rock was monitored by measuring full waveforms of the transmitted and reflected shear (S) waves across the specimen. Prior to the detection of a shear crack on the specimen surface using DIC, transmitted S waves were converted to compressional (P) waves. The emergence of converted S-P wave occurs because of the presence of oriented microcracks inside the rock. The microcracks coalesce and form the shear crack observed on the specimen surface. Up to crack coalescence, the amplitude of the converted waves increased with shear crack propagation. However, the amplitude of the transmitted shear waves between the two flaws did not change with shear crack initiation and propagation. This is in agreement with the conversion of elastic waves (P- to S-wave or S- to P-wave) observed by Nakagawa et al., (2000) for normal incident waves. Elastic wave conversions are attributed to the formation of an array of oriented microcracks that dilate under shear stress, which causes energy partitioning into P, S, and P-to-S or S-to-P waves. This finding provides a diagnostic method for detecting shear crack initiation and growth using seismic wave conversions. Acknowledgments: This material is based upon work supported by the National Science Foundation, Geomechanics and Geotechnical Systems Program (award No. CMMI-1162082).

High Temperature Mechanical Behavior of Polycrystalline Alumina from Mixed Nanometer and Micrometer Powders

NASA Technical Reports Server (NTRS)

Goldsby, Jon C.

2001-01-01

Sintered aluminum oxide materials were formed using commercial methods from mechanically mixed powders of nano-and micrometer alumina. The powders were consolidated at 1500 and 1600 C with 3.2 and 7.2 ksi applied stress in argon. The conventional micrometer sized powders failed to consolidate. While 100 percent nanometer-sized alumina and its mixture with the micrometer powders achieved less than 99 percent density. Preliminary high temperature creep behavior indicates no super-plastic strains. However high strains (less than 0.65 percent) were generated in the nanometer powder, due to cracks and linked voids initiated by cavitation.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Qiusheng, Y., E-mail: qsyan@gdut.edu.cn; Senkai, C., E-mail: senkite@sina.com; Jisheng, P., E-mail: panjisheng@gdut.edu.cn

Different machining processes were used in the single crystal SiC wafer machining. SEM was used to observe the surface morphology and a cross-sectional cleavages microscopy method was used for subsurface cracks detection. Surface and subsurface cracks characteristics of single crystal SiC wafer in abrasive machining were analysed. The results show that the surface and subsurface cracks system of single crystal SiC wafer in abrasive machining including radial crack, lateral crack and the median crack. In lapping process, material removal is dominated by brittle removal. Lots of chipping pits were found on the lapping surface. With the particle size becomes smaller,more » the surface roughness and subsurface crack depth decreases. When the particle size was changed to 1.5µm, the surface roughness Ra was reduced to 24.0nm and the maximum subsurface crack was 1.2µm. The efficiency of grinding is higher than lapping. Plastic removal can be achieved by changing the process parameters. Material removal was mostly in brittle fracture when grinding with 325# diamond wheel. Plow scratches and chipping pits were found on the ground surface. The surface roughness Ra was 17.7nm and maximum subsurface crack depth was 5.8 µm. When grinding with 8000# diamond wheel, the material removal was in plastic flow. Plastic scratches were found on the surface. A smooth surface of roughness Ra 2.5nm without any subsurface cracks was obtained. Atomic scale removal was possible in cluster magnetorheological finishing with diamond abrasive size of 0.5 µm. A super smooth surface eventually obtained with a roughness of Ra 0.4nm without any subsurface crack.« less

Fatigue behavior of ultrafine grained medium Carbon steel processed by severe plastic deformation

NASA Astrophysics Data System (ADS)

Ruffing, C.; Ivanisenko, Yu; Kerscher, E.

2014-08-01

The endurance limit of materials has been observed to be significantly increased in materials with an ultrafine grained microstructure [1, 2]. As this effect, however, has not yet been investigated in steels, fatigue experiments of an unalloyed medium carbon steel with a carbon content of 0.45 wt.-%, which was treated by high pressure torsion (HPT) [3-5] at elevated temperature were carried out. The treatments were applied to discs which had different initial carbide morphologies and showed an increase of hardness after HPT by a factor of 1.75 - 3.2 compared to the initial states, whereby the amount of increase depends on the initial carbide morphology. The maximum hardness achieved was 810 HV. The discs were cut into fatigue specimens in the form of bars of the size of 4 mm x 1 mm x 600 gm. Until a hardness of 500 HV the endurance limits correspond linearly with the hardness. This is no longer the case at higher hardness values, where inherent and process-initiated flaws lead to lower fatigue limits. The maximum endurance limit exceeded 1050 MPa in 4-point-micro-bending and at a load ratio of R = 0.1. Fractography revealed different crack initiation sites like pre cracks and shear bands [6, 7] resulting from HPT or fisheye fractures initiated from non-metallic inclusions.

Surface and subsurface cracks characteristics of single crystal SiC wafer in surface machining

NASA Astrophysics Data System (ADS)

Qiusheng, Y.; Senkai, C.; Jisheng, P.

2015-03-01

Different machining processes were used in the single crystal SiC wafer machining. SEM was used to observe the surface morphology and a cross-sectional cleavages microscopy method was used for subsurface cracks detection. Surface and subsurface cracks characteristics of single crystal SiC wafer in abrasive machining were analysed. The results show that the surface and subsurface cracks system of single crystal SiC wafer in abrasive machining including radial crack, lateral crack and the median crack. In lapping process, material removal is dominated by brittle removal. Lots of chipping pits were found on the lapping surface. With the particle size becomes smaller, the surface roughness and subsurface crack depth decreases. When the particle size was changed to 1.5µm, the surface roughness Ra was reduced to 24.0nm and the maximum subsurface crack was 1.2µm. The efficiency of grinding is higher than lapping. Plastic removal can be achieved by changing the process parameters. Material removal was mostly in brittle fracture when grinding with 325# diamond wheel. Plow scratches and chipping pits were found on the ground surface. The surface roughness Ra was 17.7nm and maximum subsurface crack depth was 5.8 µm. When grinding with 8000# diamond wheel, the material removal was in plastic flow. Plastic scratches were found on the surface. A smooth surface of roughness Ra 2.5nm without any subsurface cracks was obtained. Atomic scale removal was possible in cluster magnetorheological finishing with diamond abrasive size of 0.5 µm. A super smooth surface eventually obtained with a roughness of Ra 0.4nm without any subsurface crack.

Characterization of cracking behavior using posttest fractographic analysis

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kobayashi, T.; Shockey, D.A.

A determination of time to initiation of stress corrosion cracking in structures and test specimens is important for performing structural failure analysis and for setting inspection intervals. Yet it is seldom possible to establish how much of a component's lifetime represents the time to initiation of fracture and how much represents postinitiation crack growth. This exploratory research project was undertaken to examine the feasibility of determining crack initiation times and crack growth rates from posttest examination of fracture surfaces of constant-extension-rate-test (CERT) specimens by using the fracture reconstruction applying surface topography analysis (FRASTA) technique. The specimens used in this studymore » were Type 304 stainless steel fractured in several boiling water reactor (BWR) aqueous environments. 2 refs., 25 figs., 2 tabs.« less

Eddy-current inversion in the thin-skin limit: Determination of depth and opening for a long crack

NASA Astrophysics Data System (ADS)

Burke, S. K.

1994-09-01

A method for crack size determination using eddy-current nondestructive evaluation is presented for the case of a plate containing an infinitely long crack of uniform depth and uniform crack opening. The approach is based on the approximate solution to Maxwell's equations for nonmagnetic conductors in the limit of small skin depth and relies on least-squares polynomial fits to a normalized coil impedance function as a function of skin depth. The method is straightforward to implement and is relatively insensitive to both systematic and random errors. The procedure requires the computation of two functions: a normalizing function, which depends both on the coil parameters and the skin depth, and a crack-depth function which depends only on the coil parameters in addition to the crack depth. The practical perfomance of the method was tested using a set of simulated cracks in the form of electro-discharge machined slots in aluminum alloy plates. The crack depths and crack opening deduced from the eddy-current measurements agree with the actual crack dimensions to within 10% or better. Recommendations concerning the optimum conditions for crack sizing are also made.

Non-Destructive Evaluation of Depth of Surface Cracks Using Ultrasonic Frequency Analysis

PubMed Central

Her, Shiuh-Chuan; Lin, Sheng-Tung

2014-01-01

Ultrasonic is one of the most common uses of a non-destructive evaluation method for crack detection and characterization. The effectiveness of the acoustic-ultrasound Structural Health Monitoring (SHM) technique for the determination of the depth of the surface crack was presented. A method for ultrasonic sizing of surface cracks combined with the time domain and frequency spectrum was adopted. The ultrasonic frequency spectrum was obtained by Fourier transform technique. A series of test specimens with various depths of surface crack ranging from 1 mm to 8 mm was fabricated. The depth of the surface crack was evaluated using the pulse-echo technique. In this work, three different longitudinal waves with frequencies of 2.25 MHz, 5 MHz and 10 MHz were employed to investigate the effect of frequency on the sizing detection of surface cracks. Reasonable accuracies were achieved with measurement errors less than 7%. PMID:25225875

Diffraction-based study of fatigue crack initiation and propagation in aerospace aluminum alloys

NASA Astrophysics Data System (ADS)

Gupta, Vipul K.

The crack initiation sites and microstructure-sensitive growth of small fatigue cracks are experimentally characterized in two precipitation-hardened aluminum alloys, 7075-T651 and 7050-T7451, stressed in ambient temperature moist-air (warm-humid) and -50°C dry N2 (cold-dry) environmental conditions. Backscattered electron imaging (BSE) and energy dispersive spectroscopy (EDS) of the fracture surfaces showed that Fe-Cu rich constituent particle clusters are the most common initiation sites within both alloys stressed in either environment. The crack growth within each alloy, on average, was observed to be slowed in the cold-dry environment than in the warm-humid environment, but only at longer crack lengths. Although no overwhelming effects of grain boundaries and grain orientations on small-crack growth were observed, crack growth data showed local fluctuations within individual grains. These observations are understood as crack propagation through the underlying substructure at the crack surface and frequent interaction with low/high-angle grain and subgrain boundaries, during cyclic loading, and, are further attributed to periodic changes in crack propagation path and multiple occurrences of crack-branching observed in the current study. SEM-based stereology in combination with electron backscattered diffraction (EBSD) established fatigue crack surface crystallography within the region from ˜1 to 50 mum of crack initiating particle clusters. Fatigue crack facets were parallel to a wide variety of crystallographic planes, with pole orientations distributed broadly across the irreducible stereographic triangle between the {001} and {101}-poles within both warm-humid and cold-dry environments. The results indicate environmentally affected fatigue cracking in both cases, given the similarity between the observed morphology and crystallography with that of a variety of aerospace aluminum alloys cracked in the presence of moist-air. There was no evidence of crystallographic {111} slip-plane cracking typical of the Stage I crack growth mode observed in single crystals and high purity polycrystals of face centered cubic metals, and which has presently been assumed for the present materials within fatigue crack initiation models. Rather, the facets tend to have near-Mode I spatial orientation, which is another indicator of the importance of environmentally affected fatigue damage. The results provide a physical basis to develop microstructurally-based next generation multi-stage fatigue (MSF) models that should include a new crack decohesion criteria based upon environmental fatigue cracking mechanisms. EBSD study of small-cracks in alloy 7050-T7451, stressed in warm-humid environment, showed that crack-path orientation changes and crack-branching occurred at both low/high-angle grain and subgrain boundaries. Single surface trace analysis suggests that the crack-path differs substantially from crystallographic slip-planes. EBSD-based observations of small-crack propagation through subgrain structure, either formed by cyclic plastic strain accumulation or pre-existing (typical of unrecrystallized grain structure in the present materials), suggest that subgrain structure plays a crucial role in small fatigue crack propagation. As mentioned earlier, local fluctuations in small-crack growth rates appear to be caused by frequent interaction with subgrain boundaries, and multiple occurrences of crack-branching and crack-path orientation changes at low/high-angle grain and subgrain boundaries. The aforementioned deviation from low-index {001}/{101}-planes and the occurrence of high-index cracking planes observed by EBSD/Stereology, in this study and others, are interpreted as trans-subgranular decohesion or inter-subgranular cracking, due to trapped hydrogen. In summary, the results provide a firmer experimental foundation for, and clearer understanding of, the mechanisms of environmental fatigue cracking of aluminum alloys, especially the role of inter-subgranular cracking, which had previously been advanced based upon fracture surface observations alone.

Development of flaw acceptance criteria for aging management of spent nuclear fuel multiple-purpose canisters

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lam, P.; Sindelar, R.

2015-03-09

A typical multipurpose canister (MPC) is made of austenitic stainless steel and is loaded with spent nuclear fuel assemblies. The canister may be subject to service-induced degradation when it is exposed to aggressive atmospheric environments during a possibly long-term storage period if the permanent repository is yet to be identified and readied. Because heat treatment for stress relief is not required for the construction of an MPC, stress corrosion cracking may be initiated on the canister surface in the welds or in the heat affected zone. An acceptance criteria methodology is being developed for flaw disposition should the crack-like defectsmore » be detected by periodic In-service Inspection. The first-order instability flaw sizes has been determined with bounding flaw configurations, that is, through-wall axial or circumferential cracks, and part-through-wall long axial flaw or 360° circumferential crack. The procedure recommended by the American Petroleum Institute (API) 579 Fitness-for-Service code (Second Edition) is used to estimate the instability crack length or depth by implementing the failure assessment diagram (FAD) methodology. The welding residual stresses are mostly unknown and are therefore estimated with the API 579 procedure. It is demonstrated in this paper that the residual stress has significant impact on the instability length or depth of the crack. The findings will limit the applicability of the flaw tolerance obtained from limit load approach where residual stress is ignored and only ligament yielding is considered.« less

Development of flaw acceptance criteria for aging management of spent nuclear fuel multi-purpose canisters

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lam, Poh -Sang; Sindelar, Robert L.

2015-03-09

A typical multipurpose canister (MPC) is made of austenitic stainless steel and is loaded with spent nuclear fuel assemblies. The canister may be subject to service-induced degradation when it is exposed to aggressive atmospheric environments during a possibly long-term storage period if the permanent repository is yet to be identified and readied. Because heat treatment for stress relief is not required for the construction of an MPC, stress corrosion cracking may be initiated on the canister surface in the welds or in the heat affected zone. An acceptance criteria methodology is being developed for flaw disposition should the crack-like defectsmore » be detected by periodic in-service Inspection. The first-order instability flaw sizes has been determined with bounding flaw configurations, that is, through-wall axial or circumferential cracks, and part-through-wall long axial flaw or 360° circumferential crack. The procedure recommended by the American Petroleum Institute (API) 579 Fitness-for-Service code (Second Edition) is used to estimate the instability crack length or depth by implementing the failure assessment diagram (FAD) methodology. The welding residual stresses are mostly unknown and are therefore estimated with the API 579 procedure. It is demonstrated in this paper that the residual stress has significant impact on the instability length or depth of the crack. The findings will limit the applicability of the flaw tolerance obtained from limit load approach where residual stress is ignored and only ligament yielding is considered.« less

Small Crack Growth and Fatigue Life Predictions for High-Strength Aluminium Alloys. Part 1; Experimental and Fracture Mechanics Analysis

NASA Technical Reports Server (NTRS)

Wu, X. R.; Newman, J. C.; Zhao, W.; Swain, M. H.; Ding, C. F.; Phillips, E. P.

1998-01-01

The small crack effect was investigated in two high-strength aluminium alloys: 7075-T6 bare and LC9cs clad alloy. Both experimental and analytical investigations were conducted to study crack initiation and growth of small cracks. In the experimental program, fatigue tests, small crack and large crack tests A,ere conducted under constant amplitude and Mini-TWIST spectrum loading conditions. A pronounced small crack effect was observed in both materials, especially for the negative stress ratios. For all loading conditions, most of the fatigue life of the SENT specimens was shown to be crack propagation from initial material defects or from the cladding layer. In the analysis program, three-dimensional finite element and A weight function methods were used to determine stress intensity factors and to develop SIF equations for surface and corner cracks at the notch in the SENT specimens. A plastisity-induced crack-closure model was used to correlate small and large crack data, and to make fatigue life predictions, Predicted crack-growth rates and fatigue lives agreed well with experiments. A total fatigue life prediction method for the aluminum alloys was developed and demonstrated using the crack-closure model.

Effect of Stress Ratio and Loading Frequency on the Corrosion Fatigue Behavior of Smooth Steel Wire in Different Solutions

PubMed Central

Wang, Songquan; Zhang, Dekun; Hu, Ningning; Zhang, Jialu

2016-01-01

In this work, the effects of loading condition and corrosion solution on the corrosion fatigue behavior of smooth steel wire were discussed. The results of polarization curves and weight loss curves showed that the corrosion of steel wire in acid solution was more severe than that in neutral and alkaline solutions. With the extension of immersion time in acid solution, the cathodic reaction of steel wire gradually changed from the reduction of hydrogen ion to the reduction of oxygen, but was always the reduction of hydrogen ion in neutral and alkaline solutions. The corrosion kinetic parameters and equivalent circuits of steel wires were also obtained by simulating the Nyquist diagrams. In corrosion fatigue test, the effect of stress ratio and loading frequency on the crack initiation mechanism was emphasized. The strong corrosivity of acid solution could accelerate the nucleation of crack tip. The initiation mechanism of crack under different conditions was summarized according to the side and fracture surface morphologies. For the crack initiation mechanism of anodic dissolution, the stronger the corrosivity of solution was, the more easily the fatigue crack source formed, while, for the crack initiation mechanism of deformation activation, the lower stress ratio and higher frequency would accelerate the generation of corrosion fatigue crack source. PMID:28773869

Comparison of Intralaminar and Interlaminar Mode-I Fracture Toughness of Unidirectional IM7/8552 Graphite/Epoxy Composite

NASA Technical Reports Server (NTRS)

Czabaj, Michael W.; Ratcliffe, James

2012-01-01

The intralaminar and interlaminar mode-I fracture-toughness of a unidirectional IM7/8552 graphite/epoxy composite were measured using compact tension (CT) and double cantilever beam (DCB) test specimens, respectively. Two starter crack geometries were considered for both the CT and DCB specimen configurations. In the first case, starter cracks were produced by 12.5 micron thick, Teflon film inserts. In the second case, considerably sharper starter cracks were produced by fatigue precracking. For each specimen configuration, use of the Teflon film starter cracks resulted in initially unstable crack growth and artificially high initiation fracture-toughness values. Conversely, specimens with fatigue precracks exhibited stable growth onset and lower initiation fracture toughness. For CT and DCB specimens with fatigue precracks, the intralaminar and interlaminar initiation fracture toughnesses were approximately equal. However, during propagation, the CT specimens exhibited more extensive fiber bridging, and rapidly increasing R-curve behavior as compared to the DCB specimens. Observations of initiation and propagation of intralaminar and interlaminar fracture, and the measurements of fracture toughness, were supported by fractographic analysis using scanning electron microscopy.

Counter-intuitive experimental evidence on the initiation of radical crack in ceramic thin films at the atomic scale

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhuang, Chunqiang, E-mail: chunqiang.zhuang@bjut.edu.cn; Li, Zhipeng; Lin, Songsheng

2015-10-15

The basic issue related to radial crack in ceramic thin films has received considerable attention due to the fact that the radial crack plays an important role in evaluating the toughness properties of ceramic materials. In this work, an atomic-scale new experimental evidence is clearly presented to reveal the counter-intuitive initiation, the nucleation and the propagation mechanism of the radial crack in Al-Cr-N ceramic thin films.

Fatigue and fracture: Overview

NASA Technical Reports Server (NTRS)

Halford, G. R.

1984-01-01

A brief overview of the status of the fatigue and fracture programs is given. The programs involve the development of appropriate analytic material behavior models for cyclic stress-strain-temperature-time/cyclic crack initiation, and cyclic crack propagation. The underlying thrust of these programs is the development and verification of workable engineering methods for the calculation, in advance of service, of the local cyclic stress-strain response at the critical life governing location in hot section compounds, and the resultant crack initiation and crack growth lifetimes.

Damage Mechanisms and Controlled Crack Propagation in a Hot Pressed Silicon Nitride Ceramic. Ph.D. Thesis - Northwestern Univ., 1993

NASA Technical Reports Server (NTRS)

Calomino, Anthony Martin

1994-01-01

The subcritical growth of cracks from pre-existing flaws in ceramics can severely affect the structural reliability of a material. The ability to directly observe subcritical crack growth and rigorously analyze its influence on fracture behavior is important for an accurate assessment of material performance. A Mode I fracture specimen and loading method has been developed which permits the observation of stable, subcritical crack extension in monolithic and toughened ceramics. The test specimen and procedure has demonstrated its ability to generate and stably propagate sharp, through-thickness cracks in brittle high modulus materials. Crack growth for an aluminum oxide ceramic was observed to be continuously stable throughout testing. Conversely, the fracture behavior of a silicon nitride ceramic exhibited crack growth as a series of subcritical extensions which are interrupted by dynamic propagation. Dynamic initiation and arrest fracture resistance measurements for the silicon nitride averaged 67 and 48 J/sq m, respectively. The dynamic initiation event was observed to be sudden and explosive. Increments of subcritical crack growth contributed to a 40 percent increase in fracture resistance before dynamic initiation. Subcritical crack growth visibly marked the fracture surface with an increase in surface roughness. Increments of subcritical crack growth loosen ceramic material near the fracture surface and the fracture debris is easily removed by a replication technique. Fracture debris is viewed as evidence that both crack bridging and subsurface microcracking may be some of the mechanisms contributing to the increase in fracture resistance. A Statistical Fracture Mechanics model specifically developed to address subcritical crack growth and fracture reliability is used together with a damaged zone of material at the crack tip to model experimental results. A Monte Carlo simulation of the actual experiments was used to establish a set of modeling input parameters. It was demonstrated that a single critical parameter does not characterize the conditions required for dynamic initiation. Experimental measurements for critical crack lengths, and the energy release rates exhibit significant scatter. The resulting output of the model produces good agreement with both the average values and scatter of experimental measurements.

Probability of failure prediction for step-stress fatigue under sine or random stress

NASA Technical Reports Server (NTRS)

Lambert, R. G.

1979-01-01

A previously proposed cumulative fatigue damage law is extended to predict the probability of failure or fatigue life for structural materials with S-N fatigue curves represented as a scatterband of failure points. The proposed law applies to structures subjected to sinusoidal or random stresses and includes the effect of initial crack (i.e., flaw) sizes. The corrected cycle ratio damage function is shown to have physical significance.

Inhibitory Control and Impulsivity Levels in Women Crack Users.

PubMed

Hess, Adriana Raquel Binsfeld; Menezes, Carolina B; de Almeida, Rosa Maria Martins

2018-05-12

investigate impulsivity levels and inhibitory control in women crack users and explore the relationships between impulsivity and inhibitory control. 52 healthy women (M = 32.83 years; SD = 9.54) and 46 crack cocaine users (M = 31.02 years; SD = 7.73), in abstinence, performed the assessment protocol included a Sociodemographic Data Questionnaire, Mini-Mental State Examination (MMSE), a GO/No-Go Task and the Barratt Impulsiveness Scale-11 (BIS-11). It was a quantitative research with cross-sectional design and control group. crack group showed higher levels of impulsivity in all domains when compared to the control group (crack group M = 76.39, SD = 11.39, control group M = 58.53, SD = 10.76, p <.01). Participants from the crack group presented a significantly higher total reaction time in the Go-NoGo task (F(1,93) = 9.93, p =.002; effect size =.09, observed power =.87) and significantly more commission (F(1,93) = 7.20, p =.009; effect size =.07, observed power =.75) and omission errors (F(1,93) = 6.04, p =.01; effect size =.06, observed power =.68), in Go/NoGo Task. Groups did also significantly differ on total standard deviations suggesting that variability in total reaction time was significantly greater in the crack group. Results showed that only in the crack group there were significant correlations between Go-NoGo parameters and Barratt Impulsiveness Scale. Our findings are consistent that impulsivity and inhibitory control are closely linked to crack use in women. Future studies should consider to evaluate crack users in different withdrawal times, controlling the impact of abstinence time in the variables studied.

Dynamics of a fluid-driven crack in three dimensions by the finite difference method

NASA Astrophysics Data System (ADS)

Chouet, Bernard

1986-12-01

The finite difference method is applied to the study of the dynamics of a three-dimensional fluid-filled crack excited into resonance by the sudden failure of a small barrier of area ΔS on the crack surface. The impulse response of the crack is examined for various ratios of crack width to crack length and for several values of the crack stiffness C = (b/μ)(L/d), where b is the bulk modulus of the fluid, μ is the rigidity of the solid, and L and d are the crack length and crack thickness, respectively. The motion of the crack is characterized by distinct time scales representing the duration of brittle failure and the periods of acoustic resonance in the lateral and longitudinal dimensions of the source. The rupture has a duration proportional to the area of crack expansion and is the trigger responsible for the excitation of the crack into resonance; the resonant periods are proportional to the crack stiffness and to the width and length of the crack. The crack wave sustaining the resonance is analogous to the tube wave propagating in a fluid-filled borehole. It is dispersive, showing a phase velocity that decreases with increasing wavelength. Its wave speed is always lower than the acoustic velocity of the fluid and shows a strong dependence on the crack stiffness, decreasing as the stiffness increases. The initial motion of the crack surface is an opening, and the radiated far-field compressional wave starts with a strong but brief compression which has a duration proportional to the crack stiffness and size of the rupture area; the amplitude of this pulse increases with the area of rupture but decreases with increasing stiffness. Flow into the newly created cavity triggers a pressure drop in the fluid, which produces a partial collapse of the wall propagated over the crack surface at the speed of the crack wave. The collapse of the crack surface generates a weak long-period component of dilatation following the compressional first motion in the far-field P wave train; the dilatational component is clearer in the signal from stiffer cracks when seen in the direction of the rupture. The energy loss by radiation is stronger for high frequencies, resulting in a progressive enrichment of the crack response in lower frequencies over the duration of resonance. These source characteristics translate into a far-field signature that is marked by a high-frequency content near its onset and dominated by a longer-period component in its coda. The source duration shows a strong dependence on the fluid viscosity and associated viscous damping at the crack wall.

Multiscale Modeling of Damage Processes in Aluminum Alloys: Grain-Scale Mechanisms

NASA Technical Reports Server (NTRS)

Hochhalter, J. D.; Veilleux, M. G.; Bozek, J. E.; Glaessgen, E. H.; Ingraffea, A. R.

2008-01-01

This paper has two goals related to the development of a physically-grounded methodology for modeling the initial stages of fatigue crack growth in an aluminum alloy. The aluminum alloy, AA 7075-T651, is susceptible to fatigue cracking that nucleates from cracked second phase iron-bearing particles. Thus, the first goal of the paper is to validate an existing framework for the prediction of the conditions under which the particles crack. The observed statistics of particle cracking (defined as incubation for this alloy) must be accurately predicted to simulate the stochastic nature of microstructurally small fatigue crack (MSFC) formation. Also, only by simulating incubation of damage in a statistically accurate manner can subsequent stages of crack growth be accurately predicted. To maintain fidelity and computational efficiency, a filtering procedure was developed to eliminate particles that were unlikely to crack. The particle filter considers the distributions of particle sizes and shapes, grain texture, and the configuration of the surrounding grains. This filter helps substantially reduce the number of particles that need to be included in the microstructural models and forms the basis of the future work on the subsequent stages of MSFC, crack nucleation and microstructurally small crack propagation. A physics-based approach to simulating fracture should ultimately begin at nanometer length scale, in which atomistic simulation is used to predict the fundamental damage mechanisms of MSFC. These mechanisms include dislocation formation and interaction, interstitial void formation, and atomic diffusion. However, atomistic simulations quickly become computationally intractable as the system size increases, especially when directly linking to the already large microstructural models. Therefore, the second goal of this paper is to propose a method that will incorporate atomistic simulation and small-scale experimental characterization into the existing multiscale framework. At the microscale, the nanoscale mechanics are represented within cohesive zones where appropriate, i.e. where the mechanics observed at the nanoscale can be represented as occurring on a plane such as at grain boundaries or slip planes at a crack front. Important advancements that are yet to be made include: 1. an increased fidelity in cohesive zone modeling; 2. a means to understand how atomistic simulation scales with time; 3. a new experimental methodology for generating empirical models for CZMs and emerging materials; and 4. a validation of simulations of the damage processes at the nano-micro scale. With ever-increasing computer power, the long-term ability to employ atomistic simulation for the prognosis of structural components will not be limited by computation power, but by our lack of knowledge in incorporating atomistic models into simulations of MSFC into a multiscale framework.

The fatigue response of the aluminium-lithium alloy, 8090

NASA Technical Reports Server (NTRS)

Birt, M. J.; Beevers, C. J.

1989-01-01

The fatigue response of an Al-Li-Cu-Mg-Zr (8090) alloy has been studied at room temperature. The initiation and growth of small and long cracks has been examined at R = 0.1 and at a frequency of 100 Hz. Initiation was observed to occur dominantly at sub-grain boundaries. The growth of the small cracks was crystallographic in character and exhibited little evidence of retardation or arrest at the grain boundaries. The long crack data showed the alloy to have a high resistance to fatigue crack growth with underaging providing the optimum heat treatment for fatigue crack growth resistance. In general, this can be attributed to high levels of crack closure which resulted from the presence of extensive microstructurally related asperities.

Natural Fatigue Crack Initiation and Detection in High Quality Spur Gears

DTIC Science & Technology

2012-06-01

Natural Fatigue Crack Initiation and Detection in High Quality Spur Gears by David “Blake” Stringer, Ph.D., Kelsen E. LaBerge, Ph.D., Cory...0383 June 2012 Natural Fatigue Crack Initiation and Detection in High Quality Spur Gears David “Blake” Stringer and Ph.D., Kelsen E. LaBerge...Quality Spur Gears 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) David “Blake” Stringer, Ph.D., Kelsen E

Online Bridge Crack Monitoring with Smart Film

PubMed Central

Wang, Shuliang; Li, Xingxing; Zhou, Zhixiang; Zhang, Xu; Yang, Guang; Qiu, Minfeng

2013-01-01

Smart film crack monitoring method, which can be used for detecting initiation, length, width, shape, location, and propagation of cracks on real bridges, is proposed. Firstly, the fabrication of the smart film is developed. Then the feasibility of the method is analyzed and verified by the mechanical sensing character of the smart film under the two conditions of normal strain and crack initiation. Meanwhile, the coupling interference between parallel enameled wires of the smart film is discussed, and then low-frequency detecting signal and the custom communication protocol are used to decrease interference. On this basis, crack monitoring system with smart film is designed, where the collected crack data is sent to the remote monitoring center and the cracks are simulated and recurred. Finally, the monitoring system is applied to six bridges, and the effects are discussed. PMID:24489496

Cortical bone fracture analysis using XFEM - case study.

PubMed

Idkaidek, Ashraf; Jasiuk, Iwona

2017-04-01

We aim to achieve an accurate simulation of human cortical bone fracture using the extended finite element method within a commercial finite element software abaqus. A two-dimensional unit cell model of cortical bone is built based on a microscopy image of the mid-diaphysis of tibia of a 70-year-old human male donor. Each phase of this model, an interstitial bone, a cement line, and an osteon, are considered linear elastic and isotropic with material properties obtained by nanoindentation, taken from literature. The effect of using fracture analysis methods (cohesive segment approach versus linear elastic fracture mechanics approach), finite element type, and boundary conditions (traction, displacement, and mixed) on cortical bone crack initiation and propagation are studied. In this study cohesive segment damage evolution for a traction separation law based on energy and displacement is used. In addition, effects of the increment size and mesh density on analysis results are investigated. We find that both cohesive segment and linear elastic fracture mechanics approaches within the extended finite element method can effectively simulate cortical bone fracture. Mesh density and simulation increment size can influence analysis results when employing either approach, and using finer mesh and/or smaller increment size does not always provide more accurate results. Both approaches provide close but not identical results, and crack propagation speed is found to be slower when using the cohesive segment approach. Also, using reduced integration elements along with the cohesive segment approach decreases crack propagation speed compared with using full integration elements. Copyright © 2016 John Wiley & Sons, Ltd. Copyright © 2016 John Wiley & Sons, Ltd.

Laser-induced damage and fracture in fused silica vacuum windows

NASA Astrophysics Data System (ADS)

Campbell, John H.; Hurst, Patricia A.; Heggins, Dwight D.; Steele, William A.; Bumpas, Stanley E.

1997-05-01

Laser induced damage, that initiates catastrophic fracture, has been observed in large, fused silica lenses that also serve as vacuum barriers in high-fluence positions on the Nova and Beamlet lasers. In nearly all cases damage occurs on the vacuum side of the lens. The damage can lead to catastrophic crack growth if the flaw size exceeds the critical flaw size for SiO2. If the elastic stored energy in the lens in high enough, the lens will fracture into many pieces resulting in an implosion. The consequences of such an implosion can be severe, particularly for large vacuum systems. Three parameters control the degree of fracture in the vacuum barrier window: (1) the elastic stored energy, (2) the ratio of the window thickness to flaw depth and (3) secondary crack propagation. Fracture experiments have ben carried our on 15-cm diameter fused silica windows that contain surface flaws caused by laser damage. The results of these experiments, combined with data from window failures on Beamlet and Nova have been sued to develop design criteria for a 'fail-safe' lens. Specifically the window must be made thick enough such that the peak tensile stress is less than 500 psi and the corresponding ratio of the thickness to critical flaw size is less than 6. Under these conditions a properly mounted window, upon failure, will break into only tow pieces and will not implode. One caveat to these design criteria is that the air leak through the window before secondary crack growth occurs. Finite element stress calculations of a window before and immediately following fracture into two pieces show that the elastic stored energy is redistributed if the fragments 'lock' in place and thereby bridge the opening. In such cases, the peak stresses at the flaw site can increase leading to further crack growth.

Damage, crack growth and fracture characteristics of nuclear grade graphite using the Double Torsion technique

NASA Astrophysics Data System (ADS)

Becker, T. H.; Marrow, T. J.; Tait, R. B.

2011-07-01

The crack initiation and propagation characteristics of two medium grained polygranular graphites, nuclear block graphite (NBG10) and Gilsocarbon (GCMB grade) graphite, have been studied using the Double Torsion (DT) technique. The DT technique allows stable crack propagation and easy crack tip observation of such brittle materials. The linear elastic fracture mechanics (LEFM) methodology of the DT technique was adapted for elastic-plastic fracture mechanics (EPFM) in conjunction with a methodology for directly calculating the J-integral from in-plane displacement fields (JMAN) to account for the non-linearity of graphite deformation. The full field surface displacement measurement techniques of electronic speckle pattern interferometry (ESPI) and digital image correlation (DIC) were used to observe and measure crack initiation and propagation. Significant micro-cracking in the fracture process zone (FPZ) was observed as well as crack bridging in the wake of the crack tip. The R-curve behaviour was measured to determine the critical J-integral for crack propagation in both materials. Micro-cracks tended to nucleate at pores, causing deflection of the crack path. Rising R-curve behaviour was observed, which is attributed to the formation of the FPZ, while crack bridging and distributed micro-cracks are responsible for the increase in fracture resistance. Each contributes around 50% of the irreversible energy dissipation in both graphites.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhai, Ziqing; Kruska, Karen; Toloczko, Mychailo B.

Stress corrosion crack initiation of two thermally-treated, cold-worked (CW) alloy 690 materials was investigated in 360oC simulated PWR primary water using constant load tensile (CLT) tests and blunt notch compact tension (BNCT) tests equipped with direct current potential drop (DCPD) for in-situ detection of cracking. SCC initiation was not detected by DCPD for the 21% and 31%CW CLT specimens loaded at their yield stress after ~9,220 h, however intergranular (IG) precursor damage and isolated surface cracks were observed on the specimens. The two 31%CW BNCT specimens loaded at moderate stress intensity after several cyclic loading ramps showed DCPD-indicated crack initiationmore » after 10,400h exposure at constant stress intensity, which resulted from significant growth of IG cracks. The 21%CW BNCT specimens only exhibited isolated small IG surface cracks and showed no apparent DCPD change throughout the test. Interestingly, post-test cross-section examinations revealed many grain boundary (GB) nano-cavities in the bulk of all the CLT and BNCT specimens particularly for the 31%CW materials. Cavities were also found along GBs extending to the surface suggesting an important role in crack nucleation. This paper provides an overview of the evolution of GB cavities and will discuss their effects on crack initiation in CW alloy 690.« less

A two scale analysis of tight sandstones

NASA Astrophysics Data System (ADS)

Adler, P. M.; Davy, C. A.; Song, Y.; Troadec, D.; Hauss, G.; Skoczylas, F.

2015-12-01

Tight sandstones have a low porosity and a very small permeability K. Available models for K do not compare well with measurements. These sandstones are made of SiO_2 grains, with a typical size of several hundreds of micron. These grains are separated by a network of micro-cracks, with sizes ranging between microns down to tens of nm. Therefore, the structure can be schematized by Voronoi polyhedra separated by plane and permeable polygonal micro-cracks. Our goal is to estimate K based on a two scale analysis and to compare the results to measurements. For a particular sample [2], local measurements on several scales include FIB/SEM [3], CMT and 2D SEM. FIB/SEM is selected because the peak pore size given by Mercury Intrusion Porosimetry is of 350nm. FIB/SEM imaging (with 50 nm voxel size) identifies an individual crack of 180nm average opening, whereas CMT provides a connected porosity (individual crack) for 60 nm voxel size, of 4 micron average opening. Numerical modelling is performed by combining the micro-crack network scale (given by 2D SEM) and the 3D micro-crack scale (given by either FIB/SEM or CMT). Estimates of the micro-crack density are derived from 2D SEM trace maps by counting the intersections with scanlines, the surface density of traces, and the number of fracture intersections. K is deduced by using a semi empirical formula valid for identical, isotropic and uniformly distributed fractures [1]. This value is proportional to the micro-crack transmissivity sigma. Sigma is determined by solving the Stokes equation in the micro-cracks measured by FIB/SEM or CMT. K is obtained by combining the two previous results. Good correlation with measured values on centimetric plugs is found when using sigma from CMT data. The results are discussed and further research is proposed. [1] Adler et al, Fractured porous media, Oxford Univ. Press, 2012. [2] Duan et al, Int. J. Rock Mech. Mining Sci., 65, p75, 2014. [3] Song et al, Marine and Petroleum Eng., 65, p63, 2015.

Structural and leakage integrity of tubes affected by circumferential cracking

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hernalsteen, P.

1997-02-01

In this paper the author deals with the notion that circumferential cracks are generally considered unacceptable. He argues for the need to differentiate two facets of such cracks: the issue of the size and growth rate of a crack; and the issue of the structural strength and leakage potential of the tube in the presence of the crack. In this paper the author tries to show that the second point is not a major concern for such cracks. The paper presents data on the structural strength or burst pressure characteristics of steam generator tubes derived from models and data basesmore » of experimental work. He also presents a leak rate model, and compares the performance of circumferential and axial cracks as far as burst strength and leak rate. The final conclusion is that subject to improvement in NDE capabilities (sizing, detection, growth), that Steam Generator Defect Specific Management can be used to allow circumferentially degraded tubes to remain in service.« less

Hydrogen-Induced Delayed Cracking in TRIP-Aided Lean-Alloyed Ferritic-Austenitic Stainless Steels.

PubMed

Papula, Suvi; Sarikka, Teemu; Anttila, Severi; Talonen, Juho; Virkkunen, Iikka; Hänninen, Hannu

2017-06-03

Susceptibility of three lean-alloyed ferritic-austenitic stainless steels to hydrogen-induced delayed cracking was examined, concentrating on internal hydrogen contained in the materials after production operations. The aim was to study the role of strain-induced austenite to martensite transformation in the delayed cracking susceptibility. According to the conducted deep drawing tests and constant load tensile testing, the studied materials seem not to be particularly susceptible to delayed cracking. Delayed cracks were only occasionally initiated in two of the materials at high local stress levels. However, if a delayed crack initiated in a highly stressed location, strain-induced martensite transformation decreased the crack arrest tendency of the austenite phase in a duplex microstructure. According to electron microscopy examination and electron backscattering diffraction analysis, the fracture mode was predominantly cleavage, and cracks propagated along the body-centered cubic (BCC) phases ferrite and α'-martensite. The BCC crystal structure enables fast diffusion of hydrogen to the crack tip area. No delayed cracking was observed in the stainless steel that had high austenite stability. Thus, it can be concluded that the presence of α'-martensite increases the hydrogen-induced cracking susceptibility.

Hydrogen-Induced Delayed Cracking in TRIP-Aided Lean-Alloyed Ferritic-Austenitic Stainless Steels

PubMed Central

Papula, Suvi; Sarikka, Teemu; Anttila, Severi; Talonen, Juho; Virkkunen, Iikka; Hänninen, Hannu

2017-01-01

Susceptibility of three lean-alloyed ferritic-austenitic stainless steels to hydrogen-induced delayed cracking was examined, concentrating on internal hydrogen contained in the materials after production operations. The aim was to study the role of strain-induced austenite to martensite transformation in the delayed cracking susceptibility. According to the conducted deep drawing tests and constant load tensile testing, the studied materials seem not to be particularly susceptible to delayed cracking. Delayed cracks were only occasionally initiated in two of the materials at high local stress levels. However, if a delayed crack initiated in a highly stressed location, strain-induced martensite transformation decreased the crack arrest tendency of the austenite phase in a duplex microstructure. According to electron microscopy examination and electron backscattering diffraction analysis, the fracture mode was predominantly cleavage, and cracks propagated along the body-centered cubic (BCC) phases ferrite and α’-martensite. The BCC crystal structure enables fast diffusion of hydrogen to the crack tip area. No delayed cracking was observed in the stainless steel that had high austenite stability. Thus, it can be concluded that the presence of α’-martensite increases the hydrogen-induced cracking susceptibility. PMID:28772975

Thermal fatigue behaviour for a 316 L type steel

NASA Astrophysics Data System (ADS)

Fissolo, A.; Marini, B.; Nais, G.; Wident, P.

1996-10-01

This paper deals with initiation and growth of cracks produced by thermal fatigue loadings on 316 L steel, which is a reference material for the first wall of the next fusion reactor ITER. Two types of facilities have been built. As for true components, thermal cycles have been repeatedly applied on the surface of the specimen. The first is mainly concerned with initiation, which is detected with a light microscope. The second allows one to determine the propagation of a single crack. Crack initiation is analyzed using the French RCC-MR code procedure, and the strain-controlled isothermal fatigue curves. To predict crack growth, a model previously proposed by Haigh and Skelton is applied. This is based on determination of effective stress intensity factors, which takes into account both plastic strain and crack closure phenomena. It is shown that estimations obtained with such methodologies are in good agreement with experimental data.

NASA-Langley Research Center's participation in a round-robin comparison between some current crack-propagation prediction methods

NASA Technical Reports Server (NTRS)

Hudson, C. M.; Lewis, P. E.

1979-01-01

A round-robin study was conducted which evaluated and compared different methods currently in practice for predicting crack growth in surface-cracked specimens. This report describes the prediction methods used by the Fracture Mechanics Engineering Section, at NASA-Langley Research Center, and presents a comparison between predicted crack growth and crack growth observed in laboratory experiments. For tests at higher stress levels, the correlation between predicted and experimentally determined crack growth was generally quite good. For tests at lower stress levels, the predicted number of cycles to reach a given crack length was consistently higher than the experimentally determined number of cycles. This consistent overestimation of the number of cycles could have resulted from a lack of definition of crack-growth data at low values of the stress intensity range. Generally, the predicted critical flaw sizes were smaller than the experimentally determined critical flaw sizes. This underestimation probably resulted from using plane-strain fracture toughness values to predict failure rather than the more appropriate values based on maximum load.

Path (un)predictability of two interacting cracks in polycarbonate sheets using Digital Image Correlation.

PubMed

Koivisto, J; Dalbe, M-J; Alava, M J; Santucci, S

2016-08-31

Crack propagation is tracked here with Digital Image Correlation analysis in the test case of two cracks propagating in opposite directions in polycarbonate, a material with high ductility and a large Fracture Process Zone (FPZ). Depending on the initial distances between the two crack tips, one may observe different complex crack paths with in particular a regime where the two cracks repel each other prior to being attracted. We show by strain field analysis how this can be understood according to the principle of local symmetry: the propagation is to the direction where the local shear - mode KII in fracture mechanics language - is zero. Thus the interactions exhibited by the cracks arise from symmetry, from the initial geometry, and from the material properties which induce the FPZ. This complexity makes any long-range prediction of the path(s) impossible.

Crack orientation and depth estimation in a low-pressure turbine disc using a phased array ultrasonic transducer and an artificial neural network.

PubMed

Yang, Xiaoxia; Chen, Shili; Jin, Shijiu; Chang, Wenshuang

2013-09-13

Stress corrosion cracks (SCC) in low-pressure steam turbine discs are serious hidden dangers to production safety in the power plants, and knowing the orientation and depth of the initial cracks is essential for the evaluation of the crack growth rate, propagation direction and working life of the turbine disc. In this paper, a method based on phased array ultrasonic transducer and artificial neural network (ANN), is proposed to estimate both the depth and orientation of initial cracks in the turbine discs. Echo signals from cracks with different depths and orientations were collected by a phased array ultrasonic transducer, and the feature vectors were extracted by wavelet packet, fractal technology and peak amplitude methods. The radial basis function (RBF) neural network was investigated and used in this application. The final results demonstrated that the method presented was efficient in crack estimation tasks.

Crack Orientation and Depth Estimation in a Low-Pressure Turbine Disc Using a Phased Array Ultrasonic Transducer and an Artificial Neural Network

PubMed Central

Yang, Xiaoxia; Chen, Shili; Jin, Shijiu; Chang, Wenshuang

2013-01-01

Stress corrosion cracks (SCC) in low-pressure steam turbine discs are serious hidden dangers to production safety in the power plants, and knowing the orientation and depth of the initial cracks is essential for the evaluation of the crack growth rate, propagation direction and working life of the turbine disc. In this paper, a method based on phased array ultrasonic transducer and artificial neural network (ANN), is proposed to estimate both the depth and orientation of initial cracks in the turbine discs. Echo signals from cracks with different depths and orientations were collected by a phased array ultrasonic transducer, and the feature vectors were extracted by wavelet packet, fractal technology and peak amplitude methods. The radial basis function (RBF) neural network was investigated and used in this application. The final results demonstrated that the method presented was efficient in crack estimation tasks. PMID:24064602

Correlation of eddy current responses between fatigue cracks and electrical-discharge-machining notches

NASA Astrophysics Data System (ADS)

Seo, Sukho; Choi, Gyudong; Eom, Tae Jhoun; Lee, Bokwon; Lee, Soo Yeol

2017-07-01

The eddy current responses of Electrical Discharge Machining (EDM) notches and fatigue cracks are directly compared to verify the reliability of eddy current inspection. The fatigue crack growth tests using a constant load range control mode were conducted to obtain a variety of edge crack sizes, ranging from 0.9 to 6.6 mm for Al alloy and from 0.1 to 3 mm for Ti alloy. EDM notch specimens of Al and Ti alloys were accordingly prepared in lengths similar to that of the fatigued specimen. The crack length was determined by optical microscope and scanning electron microscope. The eddy current responses between the EDM and fatigued specimens with varying notch/crack length were examined using probe sensors at (100-500) kHz and (1-2) MHz for Al and Ti alloys, respectively. The results show a significant difference in the eddy current signal between the two specimens, based on the correlation between the eddy current response and notch/crack length. This suggests that eddy current inspection using the EDM reference specimen is inaccurate in determining the precise crack size, unless the eddy current response data base is obtained from a fatigue-cracked specimen.

Simulating the effect of slab features on vapor intrusion of crack entry

PubMed Central

Yao, Yijun; Pennell, Kelly G.; Suuberg, Eric M.

2012-01-01

In vapor intrusion screening models, a most widely employed assumption in simulating the entry of contaminant into a building is that of a crack in the building foundation slab. Some modelers employed a perimeter crack hypothesis while others chose not to identify the crack type. However, few studies have systematically investigated the influence on vapor intrusion predictions of slab crack features, such as the shape and distribution of slab cracks and related to this overall building foundation footprint size. In this paper, predictions from a three-dimensional model of vapor intrusion are used to compare the contaminant mass flow rates into buildings with different foundation slab crack features. The simulations show that the contaminant mass flow rate into the building does not change much for different assumed slab crack shapes and locations, and the foundation footprint size does not play a significant role in determining contaminant mass flow rate through a unit area of crack. Moreover, the simulation helped reveal the distribution of subslab contaminant soil vapor concentration beneath the foundation, and the results suggest that in most cases involving no biodegradation, the variation in subslab concentration should not exceed an order of magnitude, and is often significantly less than this. PMID:23359620

RSRM TP-H1148 Main Grain Propellant Crack Initiation Evaluation

NASA Technical Reports Server (NTRS)

Earnest, Todd E.

2005-01-01

Pressurized TP-HI 148 propellant fracture toughness testing was performed to assess the potential for initiation of visually undetectable cracks in the RSRM forward segment transition region during motor ignition. Two separate test specimens were used in this evaluation. Testing was performed in cold-gas and hot-fire environments, and under both static and dynamic pressurization conditions. Analysis of test results demonstrates safety factors against initiation of visually undetectable cracks in excess of 8.0. The Reusable Solid Rocket Motor (RSRM) forward segment is cast with PBAN propellant (TP-HI 148) to form T an 1 1-point star configuration that transitions to a tapered center perforated bore (see Figure 1). The geometry of the transition region between the fin valleys and the bore causes a localized area of high strain during horizontal storage. Updated analyses using worst-case mechanical properties at 40 F and improved modeling techniques indicated a slight reduction in safety margins over previous predictions. Although there is no history of strain induced cracks or flaws in the transition region propellant, a proactive test effort was initiated to better understand the implications of the new analysis, primarily the resistance of TP-H1148 propellant to crack initiation' during RSRM ignition.

Indentation Damage and Crack Repair in Human Enamel*

PubMed Central

Rivera, C.; Arola, D.; Ossa, A.

2013-01-01

Tooth enamel is the hardest and most highly mineralized tissue in the human body. While there have been a number of studies aimed at understanding the hardness and crack growth resistance behavior of this tissue, no study has evaluated if cracks in this tissue undergo repair. In this investigation the crack repair characteristics of young human enamel were evaluated as a function of patient gender and as a function of the distance from the Dentin Enamel Junction (DEJ). Cracks were introduced via microindentation along the prism direction and evaluated as a function of time after the indentation. Microscopic observations indicated that the repair of cracks began immediately after crack initiation and reaches saturation after approximately 48 hours. During this process he crack length decreased up to 10% of the initial length, and the largest degree of reduction occurred in the deep enamel, nearest the DEJ. In addition, it was found that the degree of repair was significantly greater in the enamel of female patients. PMID:23541701

Indentation damage and crack repair in human enamel.

PubMed

Rivera, C; Arola, D; Ossa, A

2013-05-01

Tooth enamel is the hardest and most highly mineralized tissue in the human body. While there have been a number of studies aimed at understanding the hardness and crack growth resistance behavior of this tissue, no study has evaluated if cracks in this tissue undergo repair. In this investigation the crack repair characteristics of young human enamel were evaluated as a function of patient gender and as a function of the distance from the Dentin Enamel Junction (DEJ). Cracks were introduced via microindentation along the prism direction and evaluated as a function of time after the indentation. Microscopic observations indicated that the repair of cracks began immediately after crack initiation and reaches saturation after approximately 48 h. During this process he crack length decreased up to 10% of the initial length, and the largest degree of reduction occurred in the deep enamel, nearest the DEJ. In addition, it was found that the degree of repair was significantly greater in the enamel of female patients. Copyright © 2013 Elsevier Ltd. All rights reserved.

The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe

DOE Office of Scientific and Technical Information (OSTI.GOV)

Furnish, T. A.; Mehta, A.; Van Campen, D.

Conventional structural metals suffer from fatigue-crack initiation through dislocation activity which forms persistent slip bands leading to notch-like extrusions and intrusions. Ultrafine-grained and nanocrystalline metals can potentially exhibit superior fatigue-crack initiation resistance by suppressing these cumulative dislocation activities. Prior studies on these metals have confirmed improved high-cycle fatigue performance. In the case of nano-grained metals, analyses of subsurface crack initiation sites have indicated that the crack nucleation is associated with abnormally large grains. But, these post-mortem analyses have led to only speculation about when abnormal grain growth occurs (e.g., during fatigue, after crack initiation, or during crack growth). In thismore » study, a recently developed synchrotron X-ray diffraction technique was used to detect the onset and progression of abnormal grain growth during stress-controlled fatigue loading. Our study provides the first direct evidence that the grain coarsening is cyclically induced and occurs well before final fatigue failure—our results indicate that the first half of the fatigue life was spent prior to the detectable onset of abnormal grain growth, while the second half was spent coarsening the nanocrystalline structure and cyclically deforming the abnormally large grains until crack initiation. Post-mortem fractography, coupled with cycle-dependent diffraction data, provides the first details regarding the kinetics of this abnormal grain growth process during high-cycle fatigue testing. Finally, precession electron diffraction images collected in a transmission electron microscope after the in situ fatigue experiment also confirm the X-ray evidence that the abnormally large grains contain substantial misorientation gradients and sub-grain boundaries.« less

The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe

DOE PAGES

Furnish, T. A.; Mehta, A.; Van Campen, D.; ...

2016-10-11

Conventional structural metals suffer from fatigue-crack initiation through dislocation activity which forms persistent slip bands leading to notch-like extrusions and intrusions. Ultrafine-grained and nanocrystalline metals can potentially exhibit superior fatigue-crack initiation resistance by suppressing these cumulative dislocation activities. Prior studies on these metals have confirmed improved high-cycle fatigue performance. In the case of nano-grained metals, analyses of subsurface crack initiation sites have indicated that the crack nucleation is associated with abnormally large grains. But, these post-mortem analyses have led to only speculation about when abnormal grain growth occurs (e.g., during fatigue, after crack initiation, or during crack growth). In thismore » study, a recently developed synchrotron X-ray diffraction technique was used to detect the onset and progression of abnormal grain growth during stress-controlled fatigue loading. Our study provides the first direct evidence that the grain coarsening is cyclically induced and occurs well before final fatigue failure—our results indicate that the first half of the fatigue life was spent prior to the detectable onset of abnormal grain growth, while the second half was spent coarsening the nanocrystalline structure and cyclically deforming the abnormally large grains until crack initiation. Post-mortem fractography, coupled with cycle-dependent diffraction data, provides the first details regarding the kinetics of this abnormal grain growth process during high-cycle fatigue testing. Finally, precession electron diffraction images collected in a transmission electron microscope after the in situ fatigue experiment also confirm the X-ray evidence that the abnormally large grains contain substantial misorientation gradients and sub-grain boundaries.« less

An extension of fracture mechanics/technology to larger and smaller cracks/defects

PubMed Central

Abé, Hiroyuki

2009-01-01

Fracture mechanics/technology is a key science and technology for the design and integrity assessment of the engineering structures. However, the conventional fracture mechanics has mostly targeted a limited size of cracks/defects, say of from several hundred microns to several tens of centimeters. The author and his group has tried to extend that limited size and establish a new version of fracture technology for very large cracks used in geothermal energy extraction and for very small cracks/defects or damage often appearing in the combination of mechanical and electronic components of engineering structures. Those new versions are reviewed in this paper. PMID:19907123

An extension of fracture mechanics/technology to larger and smaller cracks/defects.

PubMed

Abé, Hiroyuki

2009-01-01

Fracture mechanics/technology is a key science and technology for the design and integrity assessment of the engineering structures. However, the conventional fracture mechanics has mostly targeted a limited size of cracks/defects, say of from several hundred microns to several tens of centimeters. The author and his group has tried to extend that limited size and establish a new version of fracture technology for very large cracks used in geothermal energy extraction and for very small cracks/defects or damage often appearing in the combination of mechanical and electronic components of engineering structures. Those new versions are reviewed in this paper.

Architectural design of diamond-like carbon coatings for long-lasting joint replacements.

PubMed

Liu, Yujing; Zhao, Xiaoli; Zhang, Lai-Chang; Habibi, Daryoush; Xie, Zonghan

2013-07-01

Surface engineering through the application of super-hard, low-friction coatings as a potential approach for increasing the durability of metal-on-metal replacements is attracting significant attention. In this study innovative design strategies are proposed for the development of diamond-like-carbon (DLC) coatings against the damage caused by wear particles on the joint replacements. Finite element modeling is used to analyze stress distributions induced by wear particles of different sizes in the newly-designed coating in comparison to its conventional monolithic counterpart. The critical roles of architectural design in regulating stress concentrations and suppressing crack initiation within the coatings is elucidated. Notably, the introduction of multilayer structure with graded modulus is effective in modifying the stress field and reducing the magnitude and size of stress concentrations in the DLC diamond-like-carbon coatings. The new design is expected to greatly improve the load-carrying ability of surface coatings on prosthetic implants, in addition to the provision of damage tolerance through crack arrest. Copyright © 2013 Elsevier B.V. All rights reserved.

Solution to the problem of the poor cyclic fatigue resistance of bulk metallic glasses

PubMed Central

Launey, Maximilien E.; Hofmann, Douglas C.; Johnson, William L.; Ritchie, Robert O.

2009-01-01

The recent development of metallic glass-matrix composites represents a particular milestone in engineering materials for structural applications owing to their remarkable combination of strength and toughness. However, metallic glasses are highly susceptible to cyclic fatigue damage, and previous attempts to solve this problem have been largely disappointing. Here, we propose and demonstrate a microstructural design strategy to overcome this limitation by matching the microstructural length scales (of the second phase) to mechanical crack-length scales. Specifically, semisolid processing is used to optimize the volume fraction, morphology, and size of second-phase dendrites to confine any initial deformation (shear banding) to the glassy regions separating dendrite arms having length scales of ≈2 μm, i.e., to less than the critical crack size for failure. Confinement of the damage to such interdendritic regions results in enhancement of fatigue lifetimes and increases the fatigue limit by an order of magnitude, making these “designed” composites as resistant to fatigue damage as high-strength steels and aluminum alloys. These design strategies can be universally applied to any other metallic glass systems. PMID:19289820

A Fatigue Model for Discontinuous Particulate-Reinforced Aluminum Alloy Composite: Influence of Microstructure

NASA Astrophysics Data System (ADS)

McCullough, R. R.; Jordon, J. B.; Brammer, A. T.; Manigandan, K.; Srivatsan, T. S.; Allison, P. G.; Rushing, T. W.

2014-01-01

In this paper, the use of a microstructure-sensitive fatigue model is put forth for the analysis of discontinuously reinforced aluminum alloy metal matrix composite. The fatigue model was used for a ceramic particle-reinforced aluminum alloy deformed under conditions of fully reversed strain control. Experimental results revealed the aluminum alloy to be strongly influenced by volume fraction of the particulate reinforcement phase under conditions of strain-controlled fatigue. The model safely characterizes the evolution of fatigue damage in this aluminum alloy composite into the distinct stages of crack initiation and crack growth culminating in failure. The model is able to capture the specific influence of particle volume fraction, particle size, and nearest neighbor distance in quantifying fatigue life. The model yields good results for correlation of the predicted results with the experimental test results on the fatigue behavior of the chosen aluminum alloy for two different percentages of the ceramic particle reinforcement. Further, the model illustrates that both particle size and volume fraction are key factors that govern fatigue lifetime. This conclusion is well supported by fractographic observations of the cyclically deformed and failed specimens.

Short-crack growth behaviour in an aluminum alloy: An AGARD cooperative test program

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.; Edwards, P. R.

1988-01-01

An AGARD Cooperative Test Program on the growth of short fatigue cracks was conducted to define the significance of the short-crack effect, to compare test results from various laboratories, and to evaluate an existing analytical crack-growth prediction model. The initiation and growth of short fatigue cracks (5 micrometer to 2 mm) from the surface of a semi-circular notch in 2024-T3 aluminum alloy sheet material were monitored under various load histories. The cracks initiated from inclusion particle clusters or voids on the notch surface and generally grew as surface cracks. Tests were conducted under several constant-amplitude (stress ratios of -2, -1, 0, and 0.5) and spectrum (FALSTAFF and Gaussian) loading conditions at 3 stress levels each. Short crack growth was recorded using a plastic-replica technique. Over 250 edge-notched specimens were fatigue tested and nearly 950 cracks monitored by 12 participants from 9 countries. Long crack-growth rate data for cracks greater than 2 mm in length were obtained over a wide range in rates (10 to the -8 to 10 to the -1 mm/cycle) for all constant-amplitude loading conditions. Long crack-growth rate data for the FALSTAFF and Gaussian load sequences were also obtained.

Probabilistic Mesomechanical Fatigue Model

NASA Technical Reports Server (NTRS)

Tryon, Robert G.

1997-01-01

A probabilistic mesomechanical fatigue life model is proposed to link the microstructural material heterogeneities to the statistical scatter in the macrostructural response. The macrostructure is modeled as an ensemble of microelements. Cracks nucleation within the microelements and grow from the microelements to final fracture. Variations of the microelement properties are defined using statistical parameters. A micromechanical slip band decohesion model is used to determine the crack nucleation life and size. A crack tip opening displacement model is used to determine the small crack growth life and size. Paris law is used to determine the long crack growth life. The models are combined in a Monte Carlo simulation to determine the statistical distribution of total fatigue life for the macrostructure. The modeled response is compared to trends in experimental observations from the literature.

Initiation and growth of multiple-site damage in the riveted lap joint of a curved stiffened fuselage panel: An experimental and analytical study

NASA Astrophysics Data System (ADS)

Ahmed, Abubaker Ali

As part of the structural integrity research of the National Aging Aircraft Research Program, a comprehensive study on multiple-site damage (MSD) initiation and growth in a pristine lap-joint fuselage panel has been conducted. The curved stiffened fuselage panel was tested at the Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility located at the Federal Aviation Administration William J. Hughes Technical Center. A strain survey test was conducted to verify proper load application. The panel was then subjected to a fatigue test with constant-amplitude cyclic loading. The applied loading spectrum included underload marker cycles so that crack growth history could be reconstructed from post-test fractographic examinations. Crack formation and growth were monitored via nondestructive and high-magnification visual inspections. Strain gage measurements recorded during the strain survey tests indicated that the inner surface of the skin along the upper rivet row of the lap joint experienced high tensile stresses due to local bending. During the fatigue loading, cracks were detected by eddy-current inspections at multiple rivet holes along the upper rivet row. Through-thickness cracks were detected visually after about 80% of the fatigue life. Once MSD cracks from two adjacent rivet holes linked up, there was a quick deterioration in the structural integrity of the lap joint. The linkup resulted in a 2.87" (72.9-mm) lead fatigue crack that rapidly propagated across 12 rivet holes and crossed over into the next skin bay, at which stage the fatigue test was terminated. A post-fatigue residual strength test was then conducted by loading the panel quasi-statically up to final failure. The panel failed catastrophically when the crack extended instantaneously across three additional bays. Post-test fractographic examinations of the fracture surfaces in the lap joint of the fuselage panel were conducted to characterize subsurface crack initiation and growth. Results showed evidence of fretting damage and crack initiation at multiple locations near the rivet holes along the faying surface of the skin. The subsurface cracks grew significantly along the faying surface before reaching the outer surface of the skin, forming elliptical crack fronts. A finite element model (FE) of the panel was constructed and geometrically-nonlinear analyses conducted to determine strain distribution under the applied loads. The FE model was validated by comparing the analysis results with the strain gage measurements recorded during the strain survey test. The validated FE model was then used to determine stress-intensity factors at the crack tips. Stress-intensity factor results indicated that crack growth in the lap joint was under mixed-mode; however, the opening-mode stress intensity factor was dominant. The stress-intensity factors computed from the FE analysis were used to conduct cycle-by-cycle integration of fatigue crack growth. In the cycle-by-cycle integration, the NASGRO crack growth model was used with its parameters selected to account for the effects of plasticity-induced crack closure and the test environment on crack growth rate. Fatigue crack growth predictions from cycle-by-cycle computation were in good agreement with the experimental measured crack growth data. The results of the study provide key insights into the natural development and growth of MSD cracks in the pristine lap joint. The data provided by the study represent a valuable source for the evaluation and validation of analytical methodologies used for predicting MSD crack initiation and growth.

The reduction in fatigue crack growth resistance of dentin with depth.

PubMed

Ivancik, J; Neerchal, N K; Romberg, E; Arola, D

2011-08-01

The fatigue crack growth resistance of dentin was characterized as a function of depth from the dentino-enamel junction. Compact tension (CT) specimens were prepared from the crowns of third molars in the deep, middle, and peripheral dentin. The microstructure was quantified in terms of the average tubule dimensions and density. Fatigue cracks were grown in-plane with the tubules and characterized in terms of the initiation and growth responses. Deep dentin exhibited the lowest resistance to the initiation of fatigue crack growth, as indicated by the stress intensity threshold (ΔK(th) ≈ 0.8 MPa•m(0.5)) and the highest incremental fatigue crack growth rate (over 1000 times that in peripheral dentin). Cracks in deep dentin underwent incremental extension under cyclic stresses that were 40% lower than those required in peripheral dentin. The average fatigue crack growth rates increased significantly with tubule density, indicating the importance of microstructure on the potential for tooth fracture. Molars with deep restorations are more likely to suffer from the cracked-tooth syndrome, because of the lower fatigue crack growth resistance of deep dentin.

Shear Strength and Cracking Process of Non-persistent Jointed Rocks: An Extensive Experimental Investigation

NASA Astrophysics Data System (ADS)

Asadizadeh, Mostafa; Moosavi, Mahdi; Hossaini, Mohammad Farouq; Masoumi, Hossein

2018-02-01

In this paper, a number of artificial rock specimens with two parallel (stepped and coplanar) non-persistent joints were subjected to direct shearing. The effects of bridge length ( L), bridge angle ( γ), joint roughness coefficient (JRC) and normal stress ( σ n) on shear strength and cracking process of non-persistent jointed rock were studied extensively. The experimental program was designed based on Taguchi method, and the validity of the resulting data was assessed using analysis of variance. The results revealed that σ n and γ have the maximum and minimum effects on shear strength, respectively. Also, increase in L from 10 to 60 mm led to decrease in shear strength where high level of JRC profile and σ n led to the initiation of tensile cracks due to asperity interlocking. Such tensile cracks are known as "interlocking cracks" which normally initiate from the asperity and then propagate toward the specimen boundaries. Finally, the cracking process of specimens was classified into three categories, namely tensile cracking, shear cracking and combination of tension and shear or mixed mode tensile-shear cracking.

MRF, ELSM and STED: tools to study defects in fused silica optics

NASA Astrophysics Data System (ADS)

Catrin, R.; Taroux, D.; Cormont, P.; Maunier, C.; Neauport, J.

2013-11-01

The MegaJoule laser being constructed at the CEA near Bordeaux (France) is designed to focus more than 1 MJ of energy at 351 nm, on a millimetre scale target in the centre of an experiment chamber. The final optic assembly of this system operating at a wavelength of 351 nm is made up of large fused silica optics, working in transmission, that are used to convey and focus the laser beam. Under high fluences (i.e. more than 5 J/cm2 for 3 ns pulses), the limited lifetime of final optical assembly is a major concern for fusion scale laser facilities. Previous works have shown that surface finishing processes applied to manufacture these optical components can leave subsurface cracks (SSD), pollution or similar defects that act as initiators of the laser damage. In this work, we used epi-fluorescent light scanning microscopy (ELSM) and Stimulated Emission Depletion (STED) in confocal mode with fluorescent dye tagging to get a better knowledge of size and depth of these subsurface cracks. Magnetorheological fluid finishing technique (MRF) was also used as a tool to remove these cracks and thus assess depths measured by confocal microscopy. Subsurface cracks with a width of about 120 nm are observed up to ten micrometers below the surface.

Pitting and Stress Corrosion Cracking Susceptibility of Nanostructured Al-Mg Alloys in Natural and Artificial Environments

NASA Astrophysics Data System (ADS)

Sharma, Mala M.; Ziemian, Constance W.

2008-12-01

The stress corrosion cracking (SCC) behavior of two developmental nanocrystalline 5083 alloys with varied composition and processing conditions was studied. The results were compared to a commercial aluminum AA 5083 (H111) alloy. The pitting densities, size and depths, and residual tensile strengths were measured after alternate immersion in artificial seawater and atmospheric exposure under different loading conditions. Optical and scanning electron microscopy (SEM) with EDX was used to analyze the fracture surfaces of failed specimen after removal at selected intervals and tensile testing. One of the nanostructured Al-Mg alloys exhibited significantly superior pitting resistance when compared to conventional microstructured AA 5083. Under conditions where pitting corrosion showed up as local tunnels toward phase inclusions, transgranular cracking was observed, whereas under conditions when pitting corrosion evolved along grain boundaries, intergranular cracking inside the pit was observed. Pit initiation resistance of the nano alloys appears to be better than that of the conventional alloys. However, long-term pit propagation is a concern and warrants further study. The objective of this investigation was to obtain information regarding the role that ultra-fine microstructures play in their degradation in marine environments and to provide insight into the corrosion mechanisms and damage processes of these alloys.

Laser cladding assisted by friction stir processing for preparation of deformed crack-free Ni-Cr-Fe coating with nanostructure

NASA Astrophysics Data System (ADS)

Xie, Siyao; Li, Ruidi; Yuan, Tiechui; Chen, Chao; Zhou, Kechao; Song, Bo; Shi, Yusheng

2018-02-01

Although laser cladding has find its widespread application in surface hardening, this technology has been significantly limited by the solidification crack, which usually initiates along grain boundary due to the brittle precipitation in grain boundary and networks formation during the laser rapid melting/solidification process. This paper proposed a novel laser cladding technology assisted by friction stir processing (FSP) to eliminate the usual metallurgical defects by the thermomechanical coupling effect of FSP with the Ni-Cr-Fe as representative coating material. By the FSP assisted laser cladding, the crack in laser cladding Ni-Cr-Fe coating was eliminated and the coarse networks of laser cladding coating was transformed into dispersed nanoparticles. Moreover, the plastic layers with thicknesses 47-140 μm can be observed, with gradient grain refinement from substrate to the top surface in which grain size reached 300 nm and laser photocoagulation net second phase crushed in the layer. In addition, cracks closed in the plastic zone. The refinement of grain resulted the hardness increased to over 400 HV, much higher than the 300 HV of the laser cladding structure. After FSP, the friction coefficient decreased from 0.6167 to 0.5645 which promoted the wear resistance.

Cohesive stress heterogeneities and the transition from intrinsic ductility to brittleness

NASA Astrophysics Data System (ADS)

Tanguy, D.

2017-11-01

The influence of nanoscale cavities on the fracture of the Σ 33 {554 }[110 ] symmetrical tilt grain boundary is studied by atomistic simulations. The crack crystallography is chosen such that dislocation emission is easy. A transition from a ductile behavior of the tip to a brittle one is obtained for a dense (coverage beyond 15% and intercavity spacing smaller than 4 nm) distribution of small cavities (sizes in-between 1 and 2 nm). The results are in good agreement with recent experiments from the literature. Even at the highest coverage, the character of the crack is highly sensitive to the initial position of the tip and a mixture of ductile and brittle responses is found. This complexity is beyond the usual criterion based on the drop of the work of separation with the amount of damage in the structure. It is shown that a heterogeneous cohesive zone model, with parameters extracted from the simulations and enriched with a criterion for plasticity, can explain the simulations and reproduce the transition. Additional simulations show that outside this range of small sizes and dense packing, which gives essentially a two-dimensional response (either crack opening or infinite straight dislocation emission), dislocation half-loops appear for intercavity spacing starting at about 4 nm. They constitute, together with regions of low coverage/small cavities, efficient obstacles to brittle cracking. These results could be guidelines to designing interfaces more resistant to solute embrittlement, in general. The cohesive zone model is generic. Furthermore, the {554} single crystal was used to determine to which extent the results depend on the details of the core structure versus the cavity distribution. These elements show that the conclusions reached have a generic character.

Prediction and Verification of Ductile Crack Growth from Simulated Defects in Strength Overmatched Butt Welds

NASA Technical Reports Server (NTRS)

Nishioka, Owen S.

1997-01-01

Defects that develop in welds during the fabrication process are frequently manifested as embedded flaws from lack of fusion or lack of penetration. Fracture analyses of welded structures must be able to assess the effect of such defects on the structural integrity of weldments; however, the transferability of R-curves measured in laboratory specimens to defective structural welds has not been fully examined. In the current study, the fracture behavior of an overmatched butt weld containing a simulated buried, lack-of-penetration defect is studied. A specimen designed to simulate pressure vessel butt welds is considered; namely, a center crack panel specimen, of 1.25 inch by 1.25 inch cross section, loaded in tension. The stress-relieved double-V weld has a yield strength 50% higher than that of the plate material, and displays upper shelf fracture behavior at room temperature. Specimens are precracked, loaded monotonically while load-CMOD measurements are made, then stopped and heat tinted to mark the extent of ductile crack growth. These measurements are compared to predictions made using finite element analysis of the specimens using the fracture mechanics code Warp3D, which models void growth using the Gurson-Tvergaard dilitant plasticity formulation within fixed sized computational cells ahead of the crack front. Calibrating data for the finite element analyses, namely cell size and initial material porosities are obtained by matching computational predictions to experimental results from tests of welded compact tension specimens. The R-curves measured in compact tension specimens are compared to those obtained from multi-specimen weld tests, and conclusions as to the transferability of R-curves is discussed.

Oxidation- and Creep-Enhanced Fatigue of Haynes 188 Alloy-Oxide Scale System Under Simulated Pulse Detonation Engine Conditions

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Fox, Dennis S.; Miller, Robert A.

2002-01-01

The development of the pulse detonation engine (PDE) requires robust design of the engine components that are capable of enduring harsh detonation environments. In this study, a high cycle thermal fatigue test rig was developed for evaluating candidate PDE combustor materials using a CO2 laser. The high cycle thermal fatigue behavior of Haynes 188 alloy was investigated under an enhanced pulsed laser test condition of 30 Hz cycle frequency (33 ms pulse period, and 10 ms pulse width including 0.2 ms pulse spike). The temperature swings generated by the laser pulses near the specimen surface were characterized by using one-dimensional finite difference modeling combined with experimental measurements. The temperature swings resulted in significant thermal cyclic stresses in the oxide scale/alloy system, and induced extensive surface cracking. Striations of various sizes were observed at the cracked surfaces and oxide/alloy interfaces under the cyclic stresses. The test results indicated that oxidation and creep-enhanced fatigue at the oxide scale/alloy interface was an important mechanism for the surface crack initiation and propagation under the simulated PDE condition.

Fatigue Life Analysis of Tapered Hybrid Composite Flexbeams

NASA Technical Reports Server (NTRS)

Murri, Gretchen B.; Schaff, Jeffery R.; Dobyns, Alan L.

2002-01-01

Nonlinear-tapered flexbeam laminates from a full-size composite helicopter rotor hub flexbeam were tested under combined constant axial tension and cyclic bending loads. The two different graphite/glass hybrid configurations tested under cyclic loading failed by delamination in the tapered region. A 2-D finite element model was developed which closely approximated the flexbeam geometry, boundary conditions, and loading. The analysis results from two geometrically nonlinear finite element codes, ANSYS and ABAQUS, are presented and compared. Strain energy release rates (G) obtained from the above codes using the virtual crack closure technique (VCCT) at a resin crack location in the flexbeams are presented for both hybrid material types. These results compare well with each other and suggest that the initial delamination growth from the resin crack toward the thick region of the flexbeam is strongly mode II. The peak calculated G values were used with material characterization data to calculate fatigue life curves and compared with test data. A curve relating maximum surface strain to number of loading cycles at delamination onset compared reasonably well with the test results.

Fatigue Crack Initiation Properties of Rail Steels

DOT National Transportation Integrated Search

1982-01-01

Fatigue crack initiation properties of rail-steels were determined experimentally. One new and four used rail steels were investigated. The effects of the following parameters were studied: stress ratio (ratio of minimum to maximum stress in a cycle)...

Estimation of Crack Initiation and Propagation Thresholds of Confined Brittle Coal Specimens Based on Energy Dissipation Theory

NASA Astrophysics Data System (ADS)

Ning, Jianguo; Wang, Jun; Jiang, Jinquan; Hu, Shanchao; Jiang, Lishuai; Liu, Xuesheng

2018-01-01

A new energy-dissipation method to identify crack initiation and propagation thresholds is introduced. Conventional and cyclic loading-unloading triaxial compression tests and acoustic emission experiments were performed for coal specimens from a 980-m deep mine with different confining pressures of 10, 15, 20, 25, 30, and 35 MPa. Stress-strain relations, acoustic emission patterns, and energy evolution characteristics obtained during the triaxial compression tests were analyzed. The majority of the input energy stored in the coal specimens took the form of elastic strain energy. After the elastic-deformation stage, part of the input energy was consumed by stable crack propagation. However, with an increase in stress levels, unstable crack propagation commenced, and the energy dissipation and coal damage were accelerated. The variation in the pre-peak energy-dissipation ratio was consistent with the coal damage. This new method demonstrates that the crack initiation threshold was proportional to the peak stress ( σ p) for ratios that ranged from 0.4351 to 0.4753 σ p, and the crack damage threshold ranged from 0.8087 to 0.8677 σ p.

Refinement of determination of critical thresholds of stress-strain behaviour by using AE data: potential for evaluation of durability of natural stone

NASA Astrophysics Data System (ADS)

Prikryl, Richard; Lokajíček, Tomáš

2017-04-01

According to previous studies, evaluation of stress-strain behaviour (in uniaxial compression) of various rocks appears to be effective tool allowing for prediction of resistance of natural stone to some physical weathering processes. Precise determination of critical thresholds, specifically of 'crack initiation' and 'crack damage' is fundamental issue in this approach. In contrast to 'crack damage stress/strain threshold', which can be easily read from deflection point on volumetric curve, detection of 'crack initiation' is much more difficult. Besides previously proposed mathematical processing of axial stress-strain curve, recording of acoustic emission (AE) data and their processing provide direct measure of various stress/strain thresholds, specifically of 'crack initiation'. This specific parameter is required during successive computation of energetic parameters (mechanical work), that can be stored by a material without formation of new defects (microcracks) due to acting stress. Based on our experimental data, this mechanical work seems to be proportional to the resistance of a material to formation of mode I (tensile) cracks that are responsible for destruction of subsurface below exposed faces of natural stone.

The Merging of Fatigue and Fracture Mechanics Concepts: A Historical Perspective

NASA Technical Reports Server (NTRS)

Newman, James C., Jr.

1997-01-01

The seventh Jerry L. Swedlow Memorial Lecture presents a review of some of the technical developments, that have occurred during the past 40 years, which have led to the merger of fatigue and fracture mechanics concepts. This review is made from the viewpoint of 'crack propagation.' As methods to observe the 'fatigue' process have improved, the formation of fatigue micro-cracks have been observed earlier in life and the measured crack sizes have become smaller. These observations suggest that fatigue damage can now be characterized by 'crack size.' In parallel, the crack-growth analysis methods, using stress-intensity factors, have also improved. But the effects of material inhomogeneities, crack-fracture mechanisms, and nonlinear behavior must now be included in these analyses. The discovery of crack-closure mechanisms, such as plasticity, roughness, and oxide/corrosion/fretting product debris, and the use of the effective stress-intensity factor range, has provided an engineering tool to predict small- and large-crack-growth rate behavior under service loading, conditions. These mechanisms have also provided a rationale for developing, new, damage-tolerant materials. This review suggests that small-crack growth behavior should be viewed as typical behavior, whereas large-crack threshold behavior should be viewed as the anomaly. Small-crack theory has unified 'fatigue' and 'fracture mechanics' concepts; and has bridged the cap between safe-life and durability/damage-tolerance design concepts.

Variations of a global constraint factor in cracked bodies under tension and bending loads

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.; Crews, J. H., Jr.; Bigelow, C. A.; Dawicke, D. S.

1994-01-01

Elastic-plastic finite-element analyses were used to calculate stresses and displacements around a crack in finite-thickness plates for an elastic-perfectly plastic material. Middle- and edge-crack specimens were analyzed under tension and bending loads. Specimens were 1.25 to 20 mm thick with various widths and crack lengths. A global constraint factor alpha(sub g), an averaged normal-stress to flow-stress ratio over the plastic region, was defined to simulate three-dimensional (3D) effects in two-dimensional (2D) models. For crack lengths and uncracked ligament lengths greater than four times the thickness, the global constraint factor was found to be nearly a unique function of a normalized stress-intensity factor (related to plastic-zone size to thickness ratio) from small- to large-scale yielding conditions for various specimen types and thickness. For crack length-to-thickness ratios less than four, the global constraint factor was specimen type, crack length and thickness dependent. Using a 2D strip-yield model and the global constraint factors, plastic-zone sizes and crack-tip displacements agreed reasonably well with the 3D analyses. For a thin sheet aluminum alloy, the critical crack-tip-opening angle during stable tearing was found to be independent of specimen type and crack length for crack length-to-thickness ratios greater than 4.

Computational micromechanics of dynamic compressive loading of a brittle polycrystalline material using a distribution of grain boundary properties

NASA Astrophysics Data System (ADS)

Kraft, R. H.; Molinari, J. F.; Ramesh, K. T.; Warner, D. H.

A two-dimensional finite element model is used to investigate compressive loading of a brittle ceramic. Intergranular cracking in the microstructure is captured explicitly by using a distribution of cohesive interfaces. The addition of confining stress increases the maximum strength and if high enough, can allow the effective material response to reach large strains before failure. Increasing the friction at the grain boundaries also increases the maximum strength until saturation of the strength is approached. Above a transitional strain rate, increasing the rate-of-deformation also increases the strength and as the strain rate increases, fragment sizes of the damaged specimen decrease. The effects of flaws within the specimen were investigated using a random distribution at various initial flaw densities. The model is able to capture an effective modulus change and degradation of strength as the initial flaw density increases. Effects of confinement, friction, and spatial distribution of flaws seem to depend on the crack coalescence and dilatation of the specimen, while strain-rate effects are result of inertial resistance to motion.

A Method for Combining Experimentation and Molecular Dynamics Simulation to Improve Cohesive Zone Models for Metallic Microstructures

NASA Technical Reports Server (NTRS)

Hochhalter, J. D.; Glaessgen, E. H.; Ingraffea, A. R.; Aquino, W. A.

2009-01-01

Fracture processes within a material begin at the nanometer length scale at which the formation, propagation, and interaction of fundamental damage mechanisms occur. Physics-based modeling of these atomic processes quickly becomes computationally intractable as the system size increases. Thus, a multiscale modeling method, based on the aggregation of fundamental damage processes occurring at the nanoscale within a cohesive zone model, is under development and will enable computationally feasible and physically meaningful microscale fracture simulation in polycrystalline metals. This method employs atomistic simulation to provide an optimization loop with an initial prediction of a cohesive zone model (CZM). This initial CZM is then applied at the crack front region within a finite element model. The optimization procedure iterates upon the CZM until the finite element model acceptably reproduces the near-crack-front displacement fields obtained from experimental observation. With this approach, a comparison can be made between the original CZM predicted by atomistic simulation and the converged CZM that is based on experimental observation. Comparison of the two CZMs gives insight into how atomistic simulation scales.

Correlation of microstructure and tempered martensite embrittlement in two 4340 steels

NASA Astrophysics Data System (ADS)

Lee, S.; Lee, D. Y.; Asaro, R. J.

1989-06-01

This study is concerned with a correlation between the microstructure and fracture behavior of two AISI 4340 steels which were vacuum induction melted and then deoxidized with aluminum and titanium additions. This allowed a comparison between microstructures that underwent large increases in grain size and those that did not. When the steels were tempered at 350°C, K Ic and Charpy impact energy plots showed troughs which indicated tempered martensite embrittlement (TME). The TME results of plane strain fracture toughness are interpreted using a simple ductile fracture initiation model based on large strain deformation fields ahead of cracks, suggesting that K Icscales roughly with the square root of the spacing of cementite particles precipitated during the tempering treatment. The trough in Charpy impact energy is found to coincide well with the amount of intergranular fracture and the effect of segregation of phosphorus on the austenite grain boundaries. In addition, cementite particles are of primary importance in initiating the intergranular cracks and, consequently, reducing the Charpy energy. These findings suggest that TME in the two 4340 steels studied can be explained quantitatively using different fracture models.

Power MEMS Development

DTIC Science & Technology

2011-05-01

wafer pair through further processing. Initial cracking issues were identified due to liquid penetration between the wafers during wet processing...free-standing MCD films we needed to address crack formation in the diamond and the Si substrate, which we observed during our initial growths due to...NCD film grown using the heated stage, and finally the thick MCD film grown on the cooled stage. We also found that the control of cracking in the

Hot-Spot Fatigue and Impact Damage Detection on a Helicopter Tailboom

DTIC Science & Technology

2011-09-01

other 14 PZT disks were used as sensors. Among the 28 PZT disks, 16 PZT disks were placed in the two fatigue hot-spot areas to detect cracks initiated...more efficient and effective airframe maintenance, fatigue cracking and impact damage detection technologies were developed and demonstrated on a...SHM system in successfully monitoring fatigue cracks initiated from cyclical loading conditions; detecting, locating and quantifying ballistic

Corrosion and Corrosion-Fatigue Behavior of 7075 Aluminum Alloys Studied by In Situ X-Ray Tomography

NASA Astrophysics Data System (ADS)

Stannard, Tyler

7XXX Aluminum alloys have high strength to weight ratio and low cost. They are used in many critical structural applications including automotive and aerospace components. These applications frequently subject the alloys to static and cyclic loading in service. Additionally, the alloys are often subjected to aggressive corrosive environments such as saltwater spray. These chemical and mechanical exposures have been known to cause premature failure in critical applications. Hence, the microstructural behavior of the alloys under combined chemical attack and mechanical loading must be characterized further. Most studies to date have analyzed the microstructure of the 7XXX alloys using two dimensional (2D) techniques. While 2D studies yield valuable insights about the properties of the alloys, they do not provide sufficiently accurate results because the microstructure is three dimensional and hence its response to external stimuli is also three dimensional (3D). Relevant features of the alloys include the grains, subgrains, intermetallic inclusion particles, and intermetallic precipitate particles. The effects of microstructural features on corrosion pitting and corrosion fatigue of aluminum alloys has primarily been studied using 2D techniques such as scanning electron microscopy (SEM) surface analysis along with post-mortem SEM fracture surface analysis to estimate the corrosion pit size and fatigue crack initiation site. These studies often limited the corrosion-fatigue testing to samples in air or specialized solutions, because samples tested in NaCl solution typically have fracture surfaces covered in corrosion product. Recent technological advancements allow observation of the microstructure, corrosion and crack behavior of aluminum alloys in solution in three dimensions over time (4D). In situ synchrotron X-Ray microtomography was used to analyze the corrosion and cracking behavior of the alloy in four dimensions to elucidate crack initiation at corrosion pits for samples of multiple aging conditions and impurity concentrations. Additionally, chemical reactions between the 3.5 wt% NaCl solution and the crack surfaces were quantified by observing the evolution of hydrogen bubbles from the crack. The effects of the impurity particles and age-hardening particles on the corrosion and fatigue properties were examined in 4D.

Fatigue analysis of multiple site damage at a row of holes in a wide panel

NASA Technical Reports Server (NTRS)

Buhler, Kimberley; Grandt, Alten F., Jr.; Moukawsher, E. J.

1994-01-01

This paper is concerned with predicting the fatigue life of unstiffened panels which contain multiple site damage (MSD). The initial damage consists of through-the-thickness cracks emanating from a row of holes in the center of a finite width panel. A fracture mechanics analysis has been developed to predict the growth, interaction, and coalescence of the various cracks which propagate in the panel. A strain-life analysis incorporating Neuber's rule for notches, and Miner's rule for cumulative damage, is also employed to predict crack initiation for holes without initial cracking. This analysis is compared with the results of a series of fatigue tests on 2024-T3 aluminum panels, and is shown to do an excellent job of predicting the influence of MSD on the fatigue life of nine inch wide specimens. Having established confidence in the ability to analyze the influence of MSD on fatigue life, a parametric study is conducted to examine the influence of various MSD scenarios in an unstiffened panel. The numerical study considered 135 cases in all, with the parametric variables being the applied cyclic stress level, the lead crack geometry, and the number and location of MSD cracks. The numerical analysis provides details for the manner in which lead cracks and MSD cracks grow and coalesce leading to final failure. The results indicate that MSD located adjacent to lead cracks is the most damaging configuration, while for cases without lead cracks, MSD clusters which are not separated by uncracked holes are most damaging.

Distributed deformation ahead of the Cocos-Nazca Rift at the Galapagos triple junction

NASA Astrophysics Data System (ADS)

Smith, Deborah K.; Schouten, Hans; Zhu, Wen-lu; Montési, Laurent G. J.; Cann, Johnson R.

2011-11-01

The Galapagos triple junction is not a simple ridge-ridge-ridge (RRR) triple junction. The Cocos-Nazca Rift (C-N Rift) tip does not meet the East Pacific Rise (EPR). Instead, two secondary rifts form the link: Incipient Rift at 2°40‧N and Dietz Deep volcanic ridge, the southern boundary of the Galapagos microplate (GMP), at 1°10‧N. Recently collected bathymetry data are used to investigate the regional tectonics prior to the establishment of the GMP (∼1.5 Ma). South of C-N Rift a band of northeast-trending cracks cuts EPR-generated abyssal hills. It is a mirror image of a band of cracks previously identified north of C-N Rift on the same age crust. In both areas, the western ends of the cracks terminate against intact abyssal hills suggesting that each crack initiated at the EPR spreading center and cut eastward into pre-existing topography. Each crack formed a short-lived triple junction until it was abandoned and a new crack and triple junction initiated nearby. Between 2.5 and 1.5 Ma, the pattern of cracking is remarkably symmetric about C-N Rift providing support for a crack interaction model in which crack initiation at the EPR axis is controlled by stresses associated with the tip of the westward-propagating C-N Rift. The model also shows that offsets of the EPR axis may explain times when cracking is not symmetric. South of C-N Rift, cracks are observed on seafloor as old as 10.5 Ma suggesting that this triple junction has not been a simple RRR triple junction during that time.

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1997-01-01

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Effect of service exposure on fatigue crack propagation of Inconel 718 turbine disc material at elevated temperatures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jeong, Dae-Ho; Choi, Myung-Je; Goto, Masahiro

In this study, the fatigue crack propagation behavior of Inconel 718 turbine disc with different service times from 0 to 4229 h was investigated at 738 and 823 K. No notable change in microstructural features, other than the increase in grain size, was observed with increasing service time. With increasing service time from 0 to 4229 h, the fatigue crack propagation rates tended to increase, while the ΔK{sub th} value decreased, in low ΔK regime and lower Paris' regime at both testing temperatures. The fractographic observation using a scanning electron microscope suggested that the elevated temperature fatigue crack propagation mechanismmore » of Inconel 718 changed from crystallographic cleavage mechanism to striation mechanism in the low ΔK regime, depending on the grain size. The fatigue crack propagation mechanism is proposed for the crack propagating through small and large grains in the low ΔK regime, and the fatigue crack propagation behavior of Inconel 718 with different service times at elevated temperatures is discussed. - Highlights: • The specimens were prepared from the Inconel 718 turbine disc used for 0 to 4229 h. • FCP rates were measured at 738 and 823 K. • The ΔK{sub th} values decreased with increasing service time. • The FCP behavior showed a strong correlation with the grain size of used turbine disc.« less

Effect of Particle Size Upon Pt/SiO 2 Catalytic Cracking of n-Dodecane Under Supercritical Conditions: in situ SAXS and XANES Studies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lee, Sungwon; Lee, Sungsik; Kumbhalkar, Mrunmayi

The endothermic cracking and dehydrogenation of n-dodecane is investigated over well-defined nanometer size platinum catalysts supported on SiO 2 to study the particle size effects in the catalytic cracking reaction, with simultaneous in situ monitoring of the particle size and oxidation state of the working catalysts by in situ SAXS (small angle X-ray scattering) and XAS (X-ray absorption spectroscopy). The selectivity toward olefins products was found dominant in the 1 nm size platinum catalysts, whereas paraffins are dominant in the 2 nm catalysts. This reveals a strong correlation between catalytic performance and catalyst size as well as the stability ofmore » the nanoparticles in supercritical condition of n-dodecane. The presented results suggest that controlling the size and geometric structure of platinum nanocatalysts could lead to a fundamentally new level of understanding of nanoscale materials by monitoring the catalysts in realistic reaction conditions.« less

Small-crack effects in high-strength aluminum alloys

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.; Wu, X. R.; Venneri, S. L.; Li, C. G.

1994-01-01

The National Aeronautics and Space Administration and the Chinese Aeronautical Establishment participated in a Fatigue and Fracture Mechanics Cooperative Program. The program objectives were to identify and characterize crack initiation and growth of small cracks (10 microns to 2 mm long) in commonly used US and PRC aluminum alloys, to improve fracture mechanics analyses of surface- and corner-crack configurations, and to develop improved life-prediction methods. Fatigue and small-crack tests were performed on single-edgenotch tension (SENT) specimens and large-crack tests were conducted on center-crack tension specimens for constant-amplitude (stress ratios of -1, 0, and 0.5) and Mini-TWIST spectrum loading. The plastic replica method was used to monitor the initiation and growth of small fatigue cracks at the semicircular notch. Crack growth results from each laboratory on 7075-T6 bare and LC9cs clad aluminum alloys agreed well and showed that fatigue life was mostly crack propagation from a material defect (inclusion particles or void) or from the cladding layer. Finite-element and weight-function methods were used to determine stress intensity factors for surface and corner cracks in the SENT specimens. Equations were then developed and used in a crack growth and crack-closure model to correlate small- and large-crack data and to make life predictions for various load histories. The cooperative program produced useful experimental data and efficient analysis methods for improving life predictions. The results should ultimately improve aircraft structural reliability and safety.

Correlating Scatter in Fatigue Life with Fracture Mechanisms in Forged Ti-6242Si Alloy

NASA Astrophysics Data System (ADS)

Sinha, V.; Pilchak, A. L.; Jha, S. K.; Porter, W. J.; John, R.; Larsen, J. M.

2018-04-01

Unlike the quasi-static mechanical properties, such as strength and ductility, fatigue life can vary significantly (by an order of magnitude or more) for nominally identical material and test conditions in many materials, including Ti-alloys. This makes life prediction and management more challenging for components that are subjected to cyclic loading in service. The differences in fracture mechanisms can cause the scatter in fatigue life. In this study, the fatigue fracture mechanisms were investigated in a forged near- α titanium alloy, Ti-6Al-2Sn-4Zr-2Mo-0.1Si, which had been tested under a condition that resulted in life variations by more than an order of magnitude. The crack-initiation and small crack growth processes, including their contributions to fatigue life variability, were elucidated via quantitative characterization of fatigue fracture surfaces. Combining the results from quantitative tilt fractography and electron backscatter diffraction, crystallography of crack-initiating and neighboring facets on the fracture surface was determined. Cracks initiated on the surface for both the shortest and the longest life specimens. The facet plane in the crack-initiating grain was aligned with the basal plane of a primary α grain for both the specimens. The facet planes in grains neighboring the crack-initiating grain were also closely aligned with the basal plane for the shortest life specimen, whereas the facet planes in the neighboring grains were significantly misoriented from the basal plane for the longest life specimen. The difference in the extent of cracking along the basal plane can explain the difference in fatigue life of specimens at the opposite ends of scatter band.

Phase-field study of grain boundary tracking behavior in crack-seal microstructures

NASA Astrophysics Data System (ADS)

Ankit, Kumar; Nestler, Britta; Selzer, Michael; Reichardt, Mathias

2013-12-01

In order to address the growth of crystals in veins, a multiphase-field model is used to capture the dynamics of crystals precipitating from a super-saturated solution. To gain a detailed understanding of the polycrystal growth phenomena in veins, we investigate the influence of various boundary conditions on crystal growth. In particular, we analyze the formation of vein microstructures resulting from the free growth of crystals as well as crack-sealing processes. We define the crystal symmetry by considering the anisotropy in surface energy to simulate crystals with flat facets and sharp corners. The resulting growth competition of crystals with different orientations is studied to deduce a consistent orientation selection rule in the free-growth regime. Using crack-sealing simulations, we correlate the grain boundary tracking behavior depending on the relative rate of crack opening, opening trajectory, initial grain size, and wall roughness. Further, we illustrate how these parameters induce the microstructural transition between blocky (crystals growing anisotropically) to fibrous morphology (isotropic) and formation of grain boundaries. The phase-field simulations of crystals in the free-growth regime (in 2D and 3D) indicate that the growth or consumption of a crystal is dependent on the orientation difference with neighboring crystals. The crack-sealing simulation results (in 2D and 3D) reveal that crystals grow isotropically and grain boundaries track the opening trajectory if the wall roughness is high, opening increments are small, and crystals touch the wall before the next crack increment starts. Further, we find that within the complete crack-seal regime, anisotropy in surface energy results in the formation of curved/oscillating grain boundaries (instead of straight) when the crack-opening velocity is increased and wall roughness is not sufficiently high. Additionally, the overall capability of phase-field method to simulate large-scale polycrystal growth in veins (in 3D) is demonstrated enumerating the main advantages of adopting the novel approach.

The application of an atomistic J-integral to a ductile crack.

PubMed

Zimmerman, Jonathan A; Jones, Reese E

2013-04-17

In this work we apply a Lagrangian kernel-based estimator of continuum fields to atomic data to estimate the J-integral for the emission dislocations from a crack tip. Face-centered cubic (fcc) gold and body-centered cubic (bcc) iron modeled with embedded atom method (EAM) potentials are used as example systems. The results of a single crack with a K-loading compare well to an analytical solution from anisotropic linear elastic fracture mechanics. We also discovered that in the post-emission of dislocations from the crack tip there is a loop size-dependent contribution to the J-integral. For a system with a finite width crack loaded in simple tension, the finite size effects for the systems that were feasible to compute prevented precise agreement with theory. However, our results indicate that there is a trend towards convergence.

A film-rupture model of hydrogen-induced, slow crack growth in alpha-beta titanium

NASA Technical Reports Server (NTRS)

Nelson, H. G.

1975-01-01

The appearance of the terrace like fracture morphology of gaseous hydrogen induced crack growth in acicular alpha-beta titanium alloys is discussed as a function of specimen configuration, magnitude of applied stress intensity, test temperature, and hydrogen pressure. Although the overall appearance of the terrace structure remained essentially unchanged, a distinguishable variation is found in the size of the individual terrace steps, and step size is found to be inversely dependent upon the rate of hydrogen induced slow crack growth. Additionally, this inverse relationship is independent of all the variables investigated. These observations are quantitatively discussed in terms of the formation and growth of a thin hydride film along the alpha-beta boundaries and a qualitative model for hydrogen induced slow crack growth is presented, based on the film-rupture model of stress corrosion cracking.

A total life prediction model for stress concentration sites

NASA Technical Reports Server (NTRS)

Hartman, G. A.; Dawicke, D. S.

1983-01-01

Fatigue crack growth tests were performed on center crack panels and radial crack hole samples. The data were reduced and correlated with the elastic parameter K taking into account finite width and corner crack corrections. The anomalous behavior normally associated with short cracks was not observed. Total life estimates for notches were made by coupling an initiation life estimate with a propagation life estimate.

A total life prediction model for stress concentration sites

NASA Technical Reports Server (NTRS)

Hartman, G. A.; Dawicke, D. S.

1983-01-01

Fatigue crack growth tests were performed on center crack panels and radial crack hole samples. The data were reduced and correlated with the elastic parameter-K taking into account finite width and corner crack corrections. The anomalous behavior normally associated with short cracks was not observed. Total life estimates for notches were made by coupling an initiation life estimate with a propagation life estimate.

Can acoustic emission detect the initiation of fatigue cracks: Application to high-strength light alloys used in aeronautics

NASA Technical Reports Server (NTRS)

Bathias, C.; Brinet, B.; Sertour, G.

1978-01-01

Acoustic emission was used for the detection of fatigue cracking in a number of high-strength light alloys used in aeronautical structures. Among the features studied were: the influence of emission frequency, the effect of surface oxidation, and the influence of grains. It was concluded that acoustic emission is an effective nondestructive technique for evaluating the initiation of fatigue cracking in such materials.

Effect of Hierarchical Microstructures of Lath Martensite on the Transitional Behavior of Fatigue Crack Growth Rate

NASA Astrophysics Data System (ADS)

Yang, Ming; Zhong, Yi; Liang, Yi-long

2018-04-01

In this study, the fatigue-crack growth (FCG) behavior of 20CrMTiH steel with different substructure sizes was investigated. The results showed that coarsen microstructures exhibit excellent growth resistance. Moreover, two transitional behaviors were observed in the FCG curves of all specimens. The first transition point occurs in the near-threshold regime, whereas the second transition point occurs in the Paris regime. A comparison of substructure size to cyclic plastic size showed that the block size is almost equal to cyclic plastic size at ΔKT1, indicating that block size is an effective grain size to control the first transitional behavior of fatigue-crack propagation, whereas the second transitional behavior is related to the packet width or grain size. According to the fracture morphology, the fracture mechanism above and below the transition point responsible for the above phenomenon were distinguished. In addition, two prediction models based on microstructure size were established for lath martensite to evaluate the threshold and stress intensity factor range at the transition point.

Smoke Hazards Resulting from the Burning of Shipboard Paints. Part 3.

DTIC Science & Technology

1987-09-18

pyrolysis begins about 2 mins. after the sample is first exposed to the radiant heat flux. A peak mass loss rate of about 0.4 mg/cm2-s occurs after...the higher local surface tempera- tures associated with the flaming combustion of pyrolysis gases issuing from these cracks. Smoke particle size...combustion in room temperature ventilation air, the mean .’ particle diameters vary between 0.7 and 1.1 /Am during the initial stages of pyrolysis and

Simulating the X-Ray Image Contrast to Set-Up Techniques with Desired Flaw Detectability

NASA Technical Reports Server (NTRS)

Koshti, Ajay M.

2015-01-01

The paper provides simulation data of previous work by the author in developing a model for estimating detectability of crack-like flaws in radiography. The methodology is being developed to help in implementation of NASA Special x-ray radiography qualification, but is generically applicable to radiography. The paper describes a method for characterizing X-ray detector resolution for crack detection. Applicability of ASTM E 2737 resolution requirements to the model are also discussed. The paper describes a model for simulating the detector resolution. A computer calculator application, discussed here, also performs predicted contrast and signal-to-noise ratio calculations. Results of various simulation runs in calculating x-ray flaw size parameter and image contrast for varying input parameters such as crack depth, crack width, part thickness, x-ray angle, part-to-detector distance, part-to-source distance, source sizes, and detector sensitivity and resolution are given as 3D surfaces. These results demonstrate effect of the input parameters on the flaw size parameter and the simulated image contrast of the crack. These simulations demonstrate utility of the flaw size parameter model in setting up x-ray techniques that provide desired flaw detectability in radiography. The method is applicable to film radiography, computed radiography, and digital radiography.

Numerical simulations of microcrack-related damage and ignition behavior of mild-impacted polymer bonded explosives.

PubMed

Yang, Kun; Wu, Yanqing; Huang, Fenglei

2018-08-15

A physical model is developed to describe the viscoelastic-plastic deformation, cracking damage, and ignition behavior of polymer-bonded explosives (PBXs) under mild impact. This model improves on the viscoelastic-statistical crack mechanical model (Visco-SCRAM) in several respects. (i) The proposed model introduces rate-dependent plasticity into the framework which is more suitable for explosives with relatively high binder content. (ii) Damage evolution is calculated by the generalized Griffith instability criterion with the dominant (most unstable) crack size rather than the averaged crack size over all crack orientations. (iii) The fast burning of cracks following ignition and the effects of gaseous products on crack opening are considered. The predicted uniaxial and triaxial stress-strain responses of PBX9501 sample under dynamic compression loading are presented to illustrate the main features of the materials. For an uncovered cylindrical PBX charge impacted by a flat-nosed rod, the simulated results show that a triangular-shaped dead zone is formed beneath the front of the rod. The cracks in the dead zone are stable due to friction-locked stress state, whereas the cracks near the front edges of dead zone become unstable and turn into hotspots due to high-shear effects. Copyright © 2018 Elsevier B.V. All rights reserved.

Applying terahertz technology for nondestructive detection of crack initiation in a film-coated layer on a swelling tablet

PubMed Central

Momose, Wataru; Yoshino, Hiroyuki; Katakawa, Yoshifumi; Yamashita, Kazunari; Imai, Keiji; Sako, Kazuhiro; Kato, Eiji; Irisawa, Akiyoshi; Yonemochi, Etsuo; Terada, Katsuhide

2012-01-01

Here, we describe a nondestructive approach using terahertz wave to detect crack initiation in a film-coated layer on a drug tablet. During scale-up and scale-down of the film coating process, differences in film density and gaps between the film-coated layer and the uncoated tablet were generated due to differences in film coating process parameters, such as the tablet-filling rate in the coating machine, spray pressure, and gas–liquid ratio etc. Tablets using the PEO/PEG formulation were employed as uncoated tablets. We found that heat and humidity caused tablets to swell, thereby breaking the film-coated layer. Using our novel approach with terahertz wave nondestructively detect film surface density (FSD) and interface density differences (IDDs) between the film-coated layer and an uncoated tablet. We also found that a reduced FSD and IDD between the film-coated layer and uncoated tablet increased the risk of crack initiation in the film-coated layer, thereby enabling us to nondestructively predict initiation of cracks in the film-coated layer. Using this method, crack initiation can be nondestructively assessed in swelling tablets after the film coating process without conducting accelerated stability tests, and film coating process parameters during scale-up and scale-down studies can be appropriately established. PMID:25755992

Effect of solution treatment on the fatigue behavior of an as-forged Mg-Zn-Y-Zr alloy

NASA Astrophysics Data System (ADS)

Wang, S. D.; Xu, D. K.; Wang, B. J.; Han, E. H.; Dong, C.

2016-04-01

Through investigating and comparing the fatigue behavior of an as-forged Mg-6.7Zn-1.3Y-0.6Zr (wt.%) alloy before and after solid solution treatment (T4) in laboratory air, the effect of T4 treatment on fatigue crack initiation was disclosed. S-N curves illustrated that the fatigue strength of as-forged samples was 110 MPa, whereas the fatigue strength of T4 samples was only 80 MPa. Observations to fracture surfaces demonstrated that for as-forged samples, fatigue crack initiation sites were covered with a layer of oxide film. However, due to the coarse grain structure and the dissolution of MgZn2 precipitates, the activation and accumulation of {10-12} twins in T4 samples were much easier, resulting in the preferential fatigue crack initiation at cracked twin boundaries (TBs). Surface characterization demonstrated that TB cracking was mainly ascribed to the incompatible plastic deformation in the twinned area and nearby α-Mg matrix.

On fractography of shallow and deep HY-100 cracked bend specimens

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yuan, D.W.; Zarzour, J.F.; Kleinosky, M.J.

1994-12-01

The influence of shallow cracks on the fracture behavior of structural components has been studied extensively in recent years. Finite element analyses have indicated dramatic differences in the crack-tip stress states between shallow and deep cracked bend specimens. In this study, an experimental program was carried out to investigate the fracture behavior of HY-100 steel containing various initial flaw depths. Four a/w ratios ranging from 0.05 to 0.5 were chosen for the notched three-point bend tests. Test results showed that higher fracture toughness values are associated with specimens having shorter surface cracks. Also, fractographic studies indicated that two sets ofmore » dimples are present for a/w = 0.5 specimen, one set of equiaxed dimple for a/w = 0.05 specimen near the crack initiation zone. As the crack grows, increase in the volume fraction of the small dimple were observed. Finally, it showed that the characteristic features of the fracture surfaces can be correlated with the previous numerical predictions.« less

Reliably detectable flaw size for NDE methods that use calibration

NASA Astrophysics Data System (ADS)

Koshti, Ajay M.

2017-04-01

Probability of detection (POD) analysis is used in assessing reliably detectable flaw size in nondestructive evaluation (NDE). MIL-HDBK-1823 and associated mh18232 POD software gives most common methods of POD analysis. In this paper, POD analysis is applied to an NDE method, such as eddy current testing, where calibration is used. NDE calibration standards have known size artificial flaws such as electro-discharge machined (EDM) notches and flat bottom hole (FBH) reflectors which are used to set instrument sensitivity for detection of real flaws. Real flaws such as cracks and crack-like flaws are desired to be detected using these NDE methods. A reliably detectable crack size is required for safe life analysis of fracture critical parts. Therefore, it is important to correlate signal responses from real flaws with signal responses form artificial flaws used in calibration process to determine reliably detectable flaw size.

Reliably Detectable Flaw Size for NDE Methods that Use Calibration

NASA Technical Reports Server (NTRS)

Koshti, Ajay M.

2017-01-01

Probability of detection (POD) analysis is used in assessing reliably detectable flaw size in nondestructive evaluation (NDE). MIL-HDBK-1823 and associated mh1823 POD software gives most common methods of POD analysis. In this paper, POD analysis is applied to an NDE method, such as eddy current testing, where calibration is used. NDE calibration standards have known size artificial flaws such as electro-discharge machined (EDM) notches and flat bottom hole (FBH) reflectors which are used to set instrument sensitivity for detection of real flaws. Real flaws such as cracks and crack-like flaws are desired to be detected using these NDE methods. A reliably detectable crack size is required for safe life analysis of fracture critical parts. Therefore, it is important to correlate signal responses from real flaws with signal responses form artificial flaws used in calibration process to determine reliably detectable flaw size.

Stress corrosion cracking of duplex stainless steels in caustic solutions

NASA Astrophysics Data System (ADS)

Bhattacharya, Ananya

Duplex stainless steels (DSS) with roughly equal amount of austenite and ferrite phases are being used in industries such as petrochemical, nuclear, pulp and paper mills, de-salination plants, marine environments, and others. However, many DSS grades have been reported to undergo corrosion and stress corrosion cracking in some aggressive environments such as chlorides and sulfide-containing caustic solutions. Although stress corrosion cracking of duplex stainless steels in chloride solution has been investigated and well documented in the literature but the SCC mechanisms for DSS in caustic solutions were not known. Microstructural changes during fabrication processes affect the overall SCC susceptibility of these steels in caustic solutions. Other environmental factors, like pH of the solution, temperature, and resulting electrochemical potential also influence the SCC susceptibility of duplex stainless steels. In this study, the role of material and environmental parameters on corrosion and stress corrosion cracking of duplex stainless steels in caustic solutions were investigated. Changes in the DSS microstructure by different annealing and aging treatments were characterized in terms of changes in the ratio of austenite and ferrite phases, phase morphology and intermetallic precipitation using optical micrography, SEM, EDS, XRD, nano-indentation and microhardness methods. These samples were then tested for general and localized corrosion susceptibility and SCC to understand the underlying mechanisms of crack initiation and propagation in DSS in the above-mentioned environments. Results showed that the austenite phase in the DSS is more susceptible to crack initiation and propagation in caustic solutions, which is different from that in the low pH chloride environment where the ferrite phase is the more susceptible phase. This study also showed that microstructural changes in duplex stainless steels due to different heat treatments could affect their SCC susceptibility. Annealed and water quenched specimens were found to be immune to SCC in caustic environment. Aging treatment at 800°C gave rise to sigma and chi precipitates in the DSS. However, these sigma and chi precipitates, known to initiate cracking in DSS in chloride environment did not cause any cracking of DSS in caustic solutions. Aging of DSS at 475°C had resulted in '475°C embrittlement' and caused cracks to initiate in the ferrite phase. This was in contrast to the cracks initiating in the austenite phase in the as-received DSS. Alloy composition and microstructure of DSS as well as solution composition (dissolved ionic species) was also found to affect the electrochemical behavior and passivation of DSS which in turn plays a major role in stress corrosion crack initiation and propagation. Corrosion rates and SCC susceptibility of DSS was found to increase with addition of sulfide to caustic solutions. Corrosion films on DSS, characterized using XRD and X-ray photoelectron spectroscopy, indicated that the metal sulfide compounds were formed along with oxides at the metal surface in the presence of sulfide containing caustic environments. These metal sulfide containing passive films are unstable and hence breaks down under mechanical straining, leading to SCC initiations. The overall results from this study helped in understanding the mechanism of SCC in caustic solutions. Favorable slip systems in the austenite phase of DSS favors slip-induced local film damage thereby initiating a stress corrosion crack. Repeated film repassivation and breaking, followed by crack tip dissolution results in crack propagation in the austenite phase of DSS alloys. Result from this study will have a significant impact in terms of identifying the alloy compositions, fabrication processes, microstructures, and environmental conditions that may be avoided to mitigate corrosion and stress corrosion cracking of DSS in caustic solutions.

Crack surface roughness in three-dimensional random fuse networks

NASA Astrophysics Data System (ADS)

Nukala, Phani Kumar V. V.; Zapperi, Stefano; Šimunović, Srđan

2006-08-01

Using large system sizes with extensive statistical sampling, we analyze the scaling properties of crack roughness and damage profiles in the three-dimensional random fuse model. The analysis of damage profiles indicates that damage accumulates in a diffusive manner up to the peak load, and localization sets in abruptly at the peak load, starting from a uniform damage landscape. The global crack width scales as Wtilde L0.5 and is consistent with the scaling of localization length ξ˜L0.5 used in the data collapse of damage profiles in the postpeak regime. This consistency between the global crack roughness exponent and the postpeak damage profile localization length supports the idea that the postpeak damage profile is predominantly due to the localization produced by the catastrophic failure, which at the same time results in the formation of the final crack. Finally, the crack width distributions can be collapsed for different system sizes and follow a log-normal distribution.

Residual stress and crack initiation in laser clad composite layer with Co-based alloy and WC + NiCr

NASA Astrophysics Data System (ADS)

Lee, Changmin; Park, Hyungkwon; Yoo, Jaehong; Lee, Changhee; Woo, WanChuck; Park, Sunhong

2015-08-01

Although laser cladding process has been widely used to improve the wear and corrosion resistance, there are unwanted cracking issues during and/or after laser cladding. This study investigates the tendency of Co-based WC + NiCr composite layers to cracking during the laser cladding process. Residual stress distributions of the specimen are measured using neutron diffraction and elucidate the correlation between the residual stress and the cracking in three types of cylindrical specimens; (i) no cladding substrate only, (ii) cladding with 100% stellite#6, and (iii) cladding with 55% stellite#6 and 45% technolase40s. The microstructure of the clad layer was composed of Co-based dendrite and brittle eutectic phases at the dendritic boundaries. And WC particles were distributed on the matrix forming intermediate composition region by partial melting of the surface of particles. The overlaid specimen exhibited tensile residual stress, which was accumulated through the beads due to contraction of the coating layer generated by rapid solidification, while the non-clad specimen showed compressive. Also, the specimen overlaid with 55 wt% stellite#6 and 45 wt% technolase40s showed a tensile stress higher than the specimen overlaid with 100% stellite#6 possibly, due to the difference between thermal expansion coefficients of the matrix and WC particles. Such tensile stresses can be potential driving force to provide an easy crack path ways for large brittle fractures combined with the crack initiation sites such as the fractured WC particles, pores and solidification cracks. WC particles directly caused clad cracks by particle fracture under the tensile stress. The pores and solidification cracks also affected as initiation sites and provided an easy crack path ways for large brittle fractures.

Among long-term crack smokers, who avoids and who succumbs to cocaine addiction?

PubMed

Falck, Russel S; Wang, Jichuan; Carlson, Robert G

2008-11-01

Crack cocaine is a highly addictive drug. To learn more about crack addiction, long-term crack smokers who had never met the DSM-IV criteria for lifetime cocaine dependence were compared with those who had. The study sample consisted of crack users (n=172) from the Dayton, Ohio, area who were interviewed periodically over 8 years. Data were collected on a range of variables including age of crack initiation, frequency of recent use, and lifetime cocaine dependence. Cocaine dependence was common with 62.8% of the sample having experienced it. There were no statistically significant differences between dependent and non-dependent users for age of crack initiation or frequency of crack use. In terms of sociodemographics, only race/ethnicity was significant, with proportionally fewer African-Americans than whites meeting the criteria for cocaine dependence. Controlling for sociodemographics, partial correlation analysis showed positive, statistically significant relationships between lifetime cocaine dependence and anti-social personality disorder, attention deficit/hyperactivity disorder, and lifetime dependence on alcohol, cannabis, amphetamine, sedative-hypnotics, and opioids. These results highlight the importance addressing race/ethnicity and comorbid disorders when developing, implementing, and evaluating interventions targeting people who use crack cocaine. Additional research is needed to better understand the role of race/ethnicity in the development of cocaine dependence resulting from crack use.

Fatigue-Crack-Growth Structural Analysis

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.

1986-01-01

Elastic and plastic deformations calculated under variety of loading conditions. Prediction of fatigue-crack-growth lives made with FatigueCrack-Growth Structural Analysis (FASTRAN) computer program. As cyclic loads are applied to initial crack configuration, FASTRAN predicts crack length and other parameters until complete break occurs. Loads are tensile or compressive and of variable or constant amplitude. FASTRAN incorporates linear-elastic fracture mechanics with modifications of load-interaction effects caused by crack closure. FASTRAN considered research tool, because of lengthy calculation times. FASTRAN written in FORTRAN IV for batch execution.

On size and geometry effects on the brittle fracture of ferritic and tempered martensitic steels

NASA Astrophysics Data System (ADS)

Odette, G. R.; Chao, B. L.; Lucas, G. E.

1992-09-01

A finite element computation of nonsingular crack tip fields was combined with a weakest link statistics model of cleavage fracture. Model predictions for three point bend specimens with various widths and crack depth to width ratios are qualitatively consistent with a number of trends observed in a 12 Cr martensitic stainless steel. The toughness “benefits” of small sizes and shallow cracks are primarily reflected in strain limits rather than net section stress capacities, which is significant to fusion structures subject to large secondary stresses.

The Analysis of Crack Growth Initiation, Propagation, and Arrest in Flawed Ship Structures Subjected to Dynamic Loading

DTIC Science & Technology

1984-08-10

most current efforts in EPFM are focused on the application of the J-resistance curve to predict crack initiation and fracture instability. However...element code FRACDYN, which has since been used to solve a variety of problems related to the Navy, NRC, and several industrial applications . Of...that this parameter remains constant during elastic-plastic stable crack growth--see Reference (9). This fact, together with its ease of application

Crack Detection Using Combinations of Acoustic Emission and Guided Wave Signals from Bonded Piezoelectric Transducers

DTIC Science & Technology

2011-09-01

and bond integrity. Lastly, the PZT transducers are also utilized to track the lower frequency mechanical strains created during fatigue loading...face of the coupon and on either side of the gage section. Each coupon undergoes cyclic tensile loading to initiate and grow fatigue cracks. At...various intervals, the fatigue cycling is paused and the coupon is visually inspected for crack initiation and growth. While the cycling is paused

Mixed-mode stress intensity factors for kink cracks with finite kink length loaded in tension and bending: application to dentin and enamel.

PubMed

Bechtle, Sabine; Fett, Theo; Rizzi, Gabriele; Habelitz, Stefan; Schneider, Gerold A

2010-05-01

Fracture toughness resistance curves describe a material's resistance against crack propagation. These curves are often used to characterize biomaterials like bone, nacre or dentin as these materials commonly exhibit a pronounced increase in fracture toughness with crack extension due to co-acting mechanisms such as crack bridging, crack deflection and microcracking. The knowledge of appropriate stress intensity factors which depend on the sample and crack geometry is essential for determining these curves. For the dental biomaterials enamel and dentin it was observed that, under bending and tensile loading, crack propagation occurs under certain constant angles to the initial notch direction during testing procedures used for fracture resistance curve determination. For this special crack geometry (a kink crack of finite length in a finite body) appropriate geometric function solutions are missing. Hence, we present in this study new mixed-mode stress intensity factors for kink cracks with finite kink length within samples of finite dimensions for two loading cases (tension and bending) which were derived from a combination of mixed-mode stress intensity factors of kink cracks with infinitely small kinks and of slant cracks. These results were further applied to determine the fracture resistance curves of enamel and dentin by testing single edge notched bending (SENB) specimens. It was found that kink cracks with finite kink length exhibit identical stress fields to slant cracks as soon as the kink length exceeds 0.15 times the initial straight crack or notch length. The use of stress intensity factor solutions for infinitely small kink cracks for the determination of dentin fracture resistance curves (as was done by other researchers) leads to an overestimation of dentin's fracture resistance of up to 30%. Copyright 2010 Elsevier Ltd. All rights reserved.

The effect of heat treatment and test parameters on the aqueous stress corrosion cracking of D6AC steel

NASA Technical Reports Server (NTRS)

Gilbreath, W. P.; Adamson, M. J.

1974-01-01

The crack growth behavior of D6AC steel as a function of stress intensity, stress and corrosion history and test technique, under sustained load in natural seawater, 3.3 percent NaCl solution, distilled water, and high humidity air was investigated. Reported investigations of D6AC were considered with emphasis on thermal treatment, specimen configuration, fracture toughness, crack-growth rates, initiation period, threshold, and the extension of corrosion fatigue data to sustained load conditions. Stress history effects were found to be most important in that they controlled incubation period, initial crack growth rates, and apparent threshold.

Double torsion fracture mechanics testing of shales under chemically reactive conditions

NASA Astrophysics Data System (ADS)

Chen, X.; Callahan, O. A.; Holder, J. T.; Olson, J. E.; Eichhubl, P.

2015-12-01

Fracture properties of shales is vital for applications such as shale and tight gas development, and seal performance of carbon storage reservoirs. We analyze the fracture behavior from samples of Marcellus, Woodford, and Mancos shales using double-torsion (DT) load relaxation fracture tests. The DT test allows the determination of mode-I fracture toughness (KIC), subcritical crack growth index (SCI), and the stress-intensity factor vs crack velocity (K-V) curves. Samples are tested at ambient air and aqueous conditions with variable ionic concentrations of NaCl and CaCl2, and temperatures up to 70 to determine the effects of chemical/environmental conditions on fracture. Under ambient air condition, KIC determined from DT tests is 1.51±0.32, 0.85±0.25, 1.08±0.17 MPam1/2 for Marcellus, Woodford, and Mancos shales, respectively. Tests under water showed considerable change of KIC compared to ambient condition, with 10.6% increase for Marcellus, 36.5% decrease for Woodford, and 6.7% decrease for Mancos shales. SCI under ambient air condition is between 56 and 80 for the shales tested. The presence of water results in a significant reduction of the SCI from 70% to 85% compared to air condition. Tests under chemically reactive solutions are currently being performed with temperature control. K-V curves under ambient air conditions are linear with stable SCI throughout the load-relaxation period. However, tests conducted under water result in an initial cracking period with SCI values comparable to ambient air tests, which then gradually transition into stable but significantly lower SCI values of 10-20. The non-linear K-V curves reveal that crack propagation in shales is initially limited by the transport of chemical agents due to their low permeability. Only after the initial cracking do interactions at the crack tip lead to cracking controlled by faster stress corrosion reactions. The decrease of SCI in water indicates higher crack propagation velocity due to faster stress corrosion rate in water than in ambient air. The experimental results are applicable for the prediction of fracture initiation based on KIC, modeling fracture pattern based on SCI, and the estimation of dynamic fracture propagation such as crack growth velocity and crack re-initiation.

Phase-contrast x-ray imaging of microstructure and fatigue-crack propagation in single-crystal nickel-base superalloys

NASA Astrophysics Data System (ADS)

Husseini, Naji Sami

Single-crystal nickel-base superalloys are ubiquitous in demanding turbine-blade applications, and they owe their remarkable resilience to their dendritic, hierarchical microstructure and complex composition. During normal operations, they endure rapid low-stress vibrations that may initiate fatigue cracks. This failure mode in the very high-cycle regime is poorly understood, in part due to inadequate testing and diagnostic equipment. Phase-contrast imaging with coherent synchrotron x rays, however, is an emergent technique ideally suited for dynamic processes such as crack initiation and propagation. A specially designed portable ultrasonic-fatigue apparatus, coupled with x-ray radiography, allows real-time, in situ imaging while simulating service conditions. Three contrast mechanisms - absorption, diffraction, and phase contrast - span the immense breadth of microstructural features in superalloys. Absorption contrast is sensitive to composition and crack displacements, and diffraction contrast illuminates dislocation aggregates and crystallographic misorientations. Phase contrast enhances electron-density gradients and is particularly useful for fatigue-crack studies, sensitive to internal crack tips and openings less than one micrometer. Superalloy samples were imaged without external stresses to study microstructure and mosaicity. Maps of rhenium and tungsten concentrations revealed strong segregation to the center of dendrites, as manifested by absorption contrast. Though nominally single crystals, dendrites were misoriented from the bulk by a few degrees, as revealed by diffraction contrast. For dynamic studies of cyclic fatigue, superalloys were mounted in the portable ultrasonic-fatigue apparatus, subjected to a mean tensile stress of ˜50-150 MPa, and cycled in tension to initiate and propagate fatigue cracks. Radiographs were recorded every thousand cycles over the multimillion-cycle lifetime to measure micron-scale crack growth. Crack openings were very small, as determined by absorption and phase contrast, and suggested multiple fracture modes for propagation along {111} planes at room temperature, which was verified by finite element analysis. With increasing temperature, cracks became Mode I (perpendicular to the loading axis) in character and more sensitive to the microstructure. Advancing plastic zones ahead of crack tips altered the crystallographic quality, from which diffraction contrast anticipated initiation and propagation. These studies demonstrate the extreme sensitivity of x-ray radiography for detailed studies of superalloys and crack growth processes.

Fatigue crack identification method based on strain amplitude changing

NASA Astrophysics Data System (ADS)

Guo, Tiancai; Gao, Jun; Wang, Yonghong; Xu, Youliang

2017-09-01

Aiming at the difficulties in identifying the location and time of crack initiation in the castings of helicopter transmission system during fatigue tests, by introducing the classification diagnostic criteria of similar failure mode to find out the similarity of fatigue crack initiation among castings, an engineering method and quantitative criterion for detecting fatigue cracks based on strain amplitude changing is proposed. This method is applied on the fatigue test of a gearbox housing, whose results indicates: during the fatigue test, the system alarms when SC strain meter reaches the quantitative criterion. The afterwards check shows that a fatigue crack less than 5mm is found at the corresponding location of SC strain meter. The test result proves that the method can provide accurate test data for strength life analysis.

Origins of Negative Strain Rate Dependence of Stress Corrosion Cracking Initiation in Alloy 690, and Intergranular Crack Formation in Thermally Treated Alloy 690

NASA Astrophysics Data System (ADS)

Kim, Young Suk; Kim, Sung Soo

2016-09-01

We show that enhanced stress corrosion cracking (SCC) initiation in cold-rolled Alloy 690 with decreasing strain rate is related to the rate of short-range ordering (SRO) but not to the time-dependent corrosion process. Evidence for SRO is provided by aging tests on cold-rolled Alloy 690 at 623 K and 693 K (350 °C and 420 °C), respectively, which demonstrate its enhanced lattice contraction and hardness increase with aging temperature and time, respectively. Secondary intergranular cracks formed only in thermally treated and cold-rolled Alloy 690 during SCC tests, which are not SCC cracks, are caused by its lattice contraction by SRO before SCC tests but not by the orientation effect.

Laser Engineered Net Shape (LENS) Technology for the Repair of Ni-Base Superalloy Turbine Components

NASA Astrophysics Data System (ADS)

Liu, Dejian; Lippold, John C.; Li, Jia; Rohklin, Stan R.; Vollbrecht, Justin; Grylls, Richard

2014-09-01

The capability of the laser engineered net shape (LENS) process was evaluated for the repair of casting defects and improperly machined holes in gas turbine engine components. Various repair geometries, including indentations, grooves, and through-holes, were used to simulate the actual repair of casting defects and holes in two materials: Alloy 718 and Waspaloy. The influence of LENS parameters, including laser energy density, laser scanning speed, and deposition pattern, on the repair of these defects and holes was studied. Laser surface remelting of the substrate prior to repair was used to remove machining defects and prevent heat-affected zone (HAZ) liquation cracking. Ultrasonic nondestructive evaluation techniques were used as a possible approach for detecting lack-of-fusion in repairs. Overall, Alloy 718 exhibited excellent repair weldability, with essentially no defects except for some minor porosity in repairs representative of deep through-holes and simulated large area casting defects. In contrast, cracking was initially observed during simulated repair of Waspaloy. Both solidification cracking and HAZ liquation cracking were observed in the repairs, especially under conditions of high heat input (high laser power and/or low scanning speed). For Waspaloy, the degree of cracking was significantly reduced and, in most cases, completely eliminated by the combination of low laser energy density and relatively high laser scanning speeds. It was found that through-hole repairs of Waspaloy made using a fine powder size exhibited excellent repair weldability and were crack-free relative to repairs using coarser powder. Simulated deep (7.4 mm) blind-hole repairs, representative of an actual Waspaloy combustor case, were successfully produced by the combination use of fine powder and relatively high laser scanning speeds.

Creep deformation at crack tips in elastic-viscoplastic solids

NASA Astrophysics Data System (ADS)

Riedel, H.

1981-02-01

THE EVALUATION of crack growth tests under creep conditions must be based on the stress analysis of a cracked body taking into account elastic, plastic and creep deformation. In addition to the well-known analysis of a cracked body creeping in secondary (steady-state) creep, the stress field at the tip of a stationary crack is calculated for primary (strain-hardening) or tertiary (strain-softening) creep of the whole specimen. For the special hardening creep-law considered, a path-independent integral C∗h, can be defined which correlates the near-tip field to the applied load. It is also shown how, after sudden load application, creep strains develop in the initially elastic or, for a higher load level, plastic body. Characteristic times are derived to distinguish between short times when the creep-zones, in which creep strains are concentrated, are still small, and long times when the whole specimen creeps extensively in primary and finally in secondary and tertiary creep. Comparing the creep-zone sizes with the specimen dimensions or comparing the characteristic times with the test duration, one can decide which deformation mechanism prevails in the bulk of the specimen and which load parameter enters into the near-tip stress field and determines crack growth behavior. The governing load parameter is the stress intensity factor K 1 if the bulk of the specimen is predominantly elastic and it is the J-integral in a fully-plastic situation when large creep strains are still confined to a small zone. The C∗h-integral applies if the bulk of the specimen deforms in primary or tertiary creep, and C∗ is the relevant load parameter for predominantly secondary creep of the whole specimen.

Cryoseism Vibrational Movement and Sorting of Detritus of Mars' Regolith Bedforms (E.G., ~ Streaks, Gullies): a New, Dry, Midsummer Antarctic Analogue Mechanism

NASA Astrophysics Data System (ADS)

Ford, A. B.

2015-12-01

"SNAP!, CRACK!, POP!" The sounds reverberated across newly shaded permafrost of unusual talus aprons (Ford & Andersen, 1967; J. Geol., 75, 722-732) of interior Antarctica (lats. >84°S; Thiel, Pensacola mtns.), coming from ice cracking under tensile failure (cryoseisms). Apron regoliths show conspicuously reversed downslope particle-size sorting and downslope-oriented lineations (debris-cleared tracts; stone stripes) formed by vibrational movement of detritus by midsummer, diurnal cracking of ice. Moving laterally by vibrations away from cracks, with downslope component by gravity, finer detritus becomes concentrated downslope from coarser debris of initial cliff fall — winnowed, as if on a gigantic vibrating shaking table. Slopes outside shade zones remain free of cracking. Diurnal midday shading of solar-warmed, debris-mantled permafrost- and glacier-surface ice at low ambient midsummer temperatures produces high strain-loading rates that exceed tensile toughness of inhomogeneous, polycrystalline ice containing zones of older but sealed cracks. This dry, mechanical, cryoseism mechanism is here proposed also for now waterless Mars and other icy Solar System bodies. Regolith features of Mars' cryosphere may appear different from anrarctic analogues owing to likely operation over tens if not hundreds of millions of years longer than on Earth. The strain distributions in tensile failure of ice better explain a common spacing uniformity of many martian linear features than others' proposed origins, and for some "active" streaks and gully channels, TARS, RSL and dune-slipface channels, as well as for dune orthogonality, diurnal moonquakes and asteroid-regolith detrital sorting (e.g., "rubble-pile" 25143-Itokawa). Because periodic shade from topography (canyons, craters, etc.) is needed, the mechanism is not expected on flattish terrains where more normal annual cooling rates produce the common polygonal tensile fracturing of ice

Influence of Initial Inclined Surface Crack on Estimated Residual Fatigue Lifetime of Railway Axle

NASA Astrophysics Data System (ADS)

Náhlík, Luboš; Pokorný, Pavel; Ševčík, Martin; Hutař, Pavel

2016-11-01

Railway axles are subjected to cyclic loading which can lead to fatigue failure. For safe operation of railway axles a damage tolerance approach taking into account a possible defect on railway axle surface is often required. The contribution deals with an estimation of residual fatigue lifetime of railway axle with initial inclined surface crack. 3D numerical model of inclined semi-elliptical surface crack in railway axle was developed and its curved propagation through the axle was simulated by finite element method. Presence of press-fitted wheel in the vicinity of initial crack was taken into account. A typical loading spectrum of railway axle was considered and residual fatigue lifetime was estimated by NASGRO approach. Material properties of typical axle steel EA4T were considered in numerical calculations and lifetime estimation.

Fatigue life improvements of the AISI 304 stainless steel ground surfaces by wire brushing

NASA Astrophysics Data System (ADS)

Ben Fredj, Nabil; Ben Nasr, Mohamed; Ben Rhouma, Amir; Sidhom, Habib; Braham, Chedly

2004-10-01

The surface and subsurface integrity of metallic ground components is usually characterized by an induced tensile residual stress, which has a detrimental effect on the fatigue life of these components. In particular, it tends to accelerate the initiation and growth of the fatigue cracks. In this investigation, to deliberately generate compressive residual stresses into the ground surfaces of the AISI 304 stainless steel (SS), wire brushing was applied. It was found that under the experimental conditions selected in this investigation, while the surface roughness was slightly improved by the brushing process, the surface residual stress shifted from a tensile stress (σ‖=+450 MPa) to a compressive stress (σ‖=-435 MPa). On the other hand, the work-hardened deformation layer was almost two times deeper after wire brushing. Concerning the fatigue life, an improvement of 26% in terms of endurance limit at 2×106 cycles was realized. Scanning electron microscope (SEM) observations of the fatigue fracture location and size were carried out to explain the fatigue life improvement. It was found that the enhancement of the fatigue strength could be correlated with the distribution and location of the fatigue fracture nucleation sites. Concerning the ground surfaces, it was seen that the fatigue cracks initiated at the bottom of the grinding grooves and were particularly long (150-200 µm). However, the fatigue cracks at the brushed surfaces were shorter (20-40 µm) and appeared to initiate sideways to the plowed material caused by the wire brushing. The results of the wire-brushed surface characterization have shown that significant advantages can be realized regarding surface integrity by the application of this low-cost process compared to shot peening.

Health Monitoring and Diagnosis of Solid Rocket Motors with Bore Cracks

DTIC Science & Technology

2015-11-01

Bore Cracks 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Anhduong Q. Le, L. Z. Sun, and Timothy C. Miller 5d...element-based computational model is used to investigate the effects of bore cracking on the changes in stress distributions along the bondline of solid...between the crack depth and the sensor data to inversely estimate the size of bore cracks in the motor. It is shown that the proposed type of sensing

Numerical investigation on the prefabricated crack propagation of FV520B stainless steel

NASA Astrophysics Data System (ADS)

Pan, Juyi; Qin, Ming; Chen, Songying

FV520B is a common stainless steel for manufacturing centrifugal compressor impeller and shaft. The internal metal flaw destroys the continuity of the material matrix, resulting in the crack propagation fracture of the component, which seriously reduces the service life of the equipment. In this paper, Abaqus software was used to simulate the prefabricated crack propagation of FV520B specimen with unilateral gap. The results of static crack propagation simulation results show that the maximum value of stress-strain located at the tip of the crack and symmetrical distributed like a butterfly along the prefabricated crack direction, the maximum stress is 1990 MPa and the maximum strain is 9.489 × 10-3. The Mises stress and stress intensity factor KI increases with the increase of the expansion step, the critical value of crack initiation is reached at the 6th extension step. The dynamic crack propagation simulation shows that the crack propagation path is perpendicular to the load loading direction. Similarly, the maximum Mises stress located at the crack tip and is symmetrically distributed along the crack propagation direction. The critical stress range of the crack propagation is 23.3-43.4 MPa. The maximum value of stress-strain curve located at the 8th extension step, that is, the crack initiation point, the maximum stress is 55.22 MPa, and the maximum strain is 2.26 × 10-4. On the crack tip, the stress changed as 32.24-40.16 MPa, the strain is at 1.292 × 10-4-1.897 × 10-4.

Micromechanical models of delamination in aluminum-lithium alloys

NASA Astrophysics Data System (ADS)

Messner, Mark Christian

Aluminum lithium (Al-Li) alloys are lighter, stiffer, and tougher than conventional aerospace aluminum alloys. Replacing conventional aluminums with Al-Li could substantially decrease the weight and cost of aerospace structures. However, Al-Li alloys often fracture intergranularly via a mechanism called delamination cracking. While secondary delamination cracks can improve the effective toughness of a component, no current model accurately predicts the initiation and growth of intergranular cracks. Since simulations cannot incorporate delamination into a structural model, designers cannot quantify the effect of delamination cracking on a particular component. This uncertainty limits the application of Al-Li alloys. Previous experiments identify microstructural features linked to delamination. Fractography of failed surfaces indicates plastic void growth triggers intergranular failure. Furthermore, certain types of soft/stiff grain boundaries tend to localize void growth and nucleate delamination cracks. This dissertation develops a mechanism for the initiation of delamination on the microscale that accounts for these experimental observations. Microscale simulations of grain boundaries near a long primary crack explore the delamination mechanism on the mesoscale. In these simulations, a physically-based crystal plasticity (CP) model represents the constitutive response of individual grains. This CP model incorporates plastic voriticity correction terms into a standard objective stress rate integration, to accurately account for the kinematics of lattice deformation. The CP model implements slip system hardening with a modular approach to facilitate quick testing and calibration of different theories of hardening. The microscale models reveal soft/stiff grain boundaries develop elevated mean stress and plastic strain as a consequence of the mechanics of the interface. These elevated stresses and strain drive plastic void growth. The results indicate plastic void growth localizes to the grain boundaries even without the presence of material defects, such as precipitate free zones. Microscale simulations also explain the strong T-stress effect often observed in experimental fracture tests on Al-Li alloys. Finally, this dissertation develops a multiscale model of intergranular damage that incorporates the results of the microscale CP simulations. The multiscale model represents the mechanics of microscale deformation near grain boundaries with a simplified compatibility/equilibrium method. The intergranular stresses and strains from the simplified interface model drive a microscale damage index based on the physics of plastic void growth. Finally, a mesh-size independent scheme homogenizes damage on many grain boundaries into a macroscale damage index and projects the damage index to fail a plane of a macroscale structural model. The multiscale damage model, applied to 2195 Al-Li, successfully predicts delamination crack growth in a variety of standard experimental test configurations. The model correctly represents the microscale physics of delamination initiation and growth; after calibration to experimental data it can reliably predict the growth of delamination cracks in a component with any material configuration and loading. Therefore, the multiscale damage model forms the basis of a simulation method that allows designers to predict the development and net effect of delamination cracking in a structural model -- facilitating the application of lightweight Al-Li alloys in high-performance aerospace structures.

Crack-shape effects for indentation fracture toughness measurements

DOE Office of Scientific and Technical Information (OSTI.GOV)

Smith, S.M.; Scattergood, R.O.

1992-02-01

Various methods to measure fracture toughness using indentation precracks were compared using soda-lime glass as a test material. In situ measurements of crack size as a function of applied stress allow both the toughness K[sub c] and the residual-stress factor [chi] to be independently determined. Analysis of the data showed that stress intensity factors based on classical half-penny crack shapes overestimate toughness values and produce an apparent R-curve effect. This is due to a constraint on crack shape imposed by primary lateral cracks in soda-lime glass. Models based on elliptical cracks were developed to account for the crack-shape effects.

Laser-driven mechanical fracture in fused silica

NASA Astrophysics Data System (ADS)

Dahmani, Faiz

1999-10-01

Fused silica, widely used as optical-window material in high-fluence requirements on glass and KrF lasers, experiences optical damage. Under fatigue conditions, the damage is initiated by slow crack growth and culminates, if not arrested, with catastrophic crack growth and implosive failure when the stress intensity approaches the critical value. Since laser-induced cracks cannot be eliminated entirely, the behavior of cracked structures under service conditions must be quantified to be predicted. Systematic scientific rules must be devised to characterize laser-induced cracks and their effects, and to predict if and when it may become necessary to replace the damaged components. This thesis makes a contribution toward this end. Measurements of fatigue failure strength of laser-cracked fused silica in air at room temperature for different number of laser pulses and laser fluences are presented. The failure-strength variability is found to be due mainly to the spectrum of crack depths. Agreement with theory suggests the incorporation of a residual term into the failure-strength equation. Experiments on residual stresses induced in fused silica by the presence of a laser-induced crack are carried out using two different techniques. Theoretical modelings show that this residual stress field is of shear nature and mouth-opening. A correlation between the reduction in fracture strength of fused silica and the increase of the residual-stress field is established, providing laser systems designers and operators with guidance on the rate of crack growth as well as on the stress-related ramifications such as laser-driven cracks entail. Specifically, a hoop-stress in the immediate vicinity of a crack growing along the beam propagation direction is identified as strongly coupling to both the laser fluence and the crack growth. This coupling prompted the question of whether or not breaking the hoop stress symmetry by some external perturbation will accelerate or stymie crack growth. Experimental results on stress-inhibited laser-driven crack growth and stress-delayed-laser-damage initiation thresholds in fused silica and borosilicate glass (BK7) are presented. The results obtained show that, for very low compressive stresses (<10 psi), the damage initiation threshold is raised by as much as 78%, while the crack growth is arrested by 70%. Different loading- geometries are tested, giving different crack growth rates and raising the distinction between uniaxial and biaxial states of stresses.

Seeding Cracks Using a Fatigue Tester for Accelerated Gear Tooth Breaking

NASA Technical Reports Server (NTRS)

Nenadic, Nenad G.; Wodenscheck, Joseph A.; Thurston, Michael G.; Lewicki, David G.

2011-01-01

This report describes fatigue-induced seeded cracks in spur gears and compares them to cracks created using a more traditional seeding method, notching. Finite element analysis (FEA) compares the effective compliance of a cracked tooth to the effective compliance of a notched tooth where the crack and the notch are of the same depth. In this analysis, cracks are propagated to the desired depth using FRANC2D and effective compliances are computed in ANSYS. A compliance-based feature for detecting cracks on the fatigue tester is described. The initiated cracks are examined using both nondestructive and destructive methods. The destructive examination reveals variability in the shape of crack surfaces.

Mesoscale simulation of concrete spall failure

NASA Astrophysics Data System (ADS)

Knell, S.; Sauer, M.; Millon, O.; Riedel, W.

2012-05-01

Although intensively studied, it is still being debated which physical mechanisms are responsible for the increase of dynamic strength and fracture energy of concrete observed at high loading rates, and to what extent structural inertia forces on different scales contribute to the observation. We present a new approach for the three dimensional mesoscale modelling of dynamic damage and cracking in concrete. Concrete is approximated as a composite of spherical elastic aggregates of mm to cm size embedded in an elastic cement stone matrix. Cracking within the matrix and at aggregate interfaces in the μm range are modelled with adaptively inserted—initially rigid—cohesive interface elements. The model is applied to analyse the dynamic tensile failure observed in Hopkinson-Bar spallation experiments with strain rates up to 100/s. The influence of the key mesoscale failure parameters of strength, fracture energy and relative weakening of the ITZ on macromechanic strength, momentum and energy conservation is numerically investigated.

A Size Effect on the Fatigue Crack Growth Rate Threshold of Alloy 718

NASA Technical Reports Server (NTRS)

Garr, K. R.; Hresko, G. C., III

1998-01-01

Fatigue crack growth rate (FCGR) tests were conducted on Alloy 718 in the solution annealed and aged condition at room temperature. In each test, the FCGR threshold was measured using the decreasing (Delta)K method. Initial testing was at two facilities, one of which used C(T) specimens with W = 127 mm. Previous data at the other facility had been obtained with specimens with W = 50.8 mm. A comparison of test results at R = 0.1 showed that the threshold for the 127 mm specimen was considerably higher than that of the 50.8 mm specimen. A check showed that this difference was not due to a heat-to-heat or lab-to-lab variation. Additional tests were conducted on specimens with W = 25.4 mm and at other R values. Data for the various specimens is presented along with parameters usually used to describe threshold behavior.

Fracture mechanics data for 2024-T861 and 2124-T851 aluminum

NASA Technical Reports Server (NTRS)

Pionke, L. J.; Linback, R. K.

1974-01-01

The fracture toughness and fatigue flaw growth characteristics of 2024-T861 and 2124-T851 aluminum were evaluated under plane stress conditions. Center cracked tension specimens were employed to evaluate these properties under a number of different test conditions which included variations in specimen thickness, specimen orientation, test environment, and initial flaw size. The effect of buckling was also investigated for all tests of thin gage specimens, and the effect of frequency and stress ratio was evaluated for the cyclic tests. Fracture toughness test results were analyzed and presented in terms of fracture resistance curves; fatigue flaw growth data was analyzed using empirical rate models. The results of the study indicate that both fracture toughness and resistance to fatigue crack growth improve with increasing temperature and decreasing thickness. The presence of buckling during testing of thin gage panels was found to degrade the resistance to fatigue flaw growth only at elevated temperatures.

Axial crack propagation and arrest in pressurized fuselage

NASA Technical Reports Server (NTRS)

Kosai, M.; Shimamoto, A.; Yu, C.-T.; Walker, S. I.; Kobayashi, A. S.; Tan, P.

1994-01-01

The crack arrest capability of a tear strap in a pressurized precracked fuselage was studied through instrumented axial rupture tests of small scale models of an idealized fuselage. Upon pressurization, rapid crack propagation initiated at an axial through crack along the stringer and immediately kinked due to the mixed modes 1 and 2 state caused by the one-sided opening of the crack flap. The diagonally running crack further turned at the tear straps. Dynamic finite element analysis of the rupturing cylinder showed that the crack kinked and also ran straight in the presence of a mixed mode state according to a modified two-parameter crack kinking criterion.

Fatigue Crack Closure Analysis Using Digital Image Correlation

NASA Technical Reports Server (NTRS)

Leser, William P.; Newman, John A.; Johnston, William M.

2010-01-01

Fatigue crack closure during crack growth testing is analyzed in order to evaluate the critieria of ASTM Standard E647 for measurement of fatigue crack growth rates. Of specific concern is remote closure, which occurs away from the crack tip and is a product of the load history during crack-driving-force-reduction fatigue crack growth testing. Crack closure behavior is characterized using relative displacements determined from a series of high-magnification digital images acquired as the crack is loaded. Changes in the relative displacements of features on opposite sides of the crack are used to generate crack closure data as a function of crack wake position. For the results presented in this paper, remote closure did not affect fatigue crack growth rate measurements when ASTM Standard E647 was strictly followed and only became a problem when testing parameters (e.g., load shed rate, initial crack driving force, etc.) greatly exceeded the guidelines of the accepted standard.

Detection and Location of Transverse Matrix Cracks in Cross-Ply Gr/Ep Composites Using Acoustic Emission

NASA Technical Reports Server (NTRS)

Prosser, W. H.; Jackson, K. E.; Kellas, S.; Smith, B. T.; McKeon, J.; Friedman, A.

1995-01-01

Transverse matrix cracking in cross-ply gr/ep laminates was studied with advanced acoustic emission (AE) techniques. The primary goal of this research was to measure the load required to initiate the first transverse matrix crack in cross-ply laminates of different thicknesses. Other methods had been previously used for these measurements including penetrant enhanced radiography, optical microscopy, and audible acoustic microphone measurements. The former methods required that the mechanical test be paused for measurements at load intervals. This slowed the test procedure and did not provide the required resolution in load. With acoustic microphones, acoustic signals from cracks could not be clearly differentiated from other noise sources such as grip damage, specimen slippage, or test machine noise. A second goal for this work was to use the high resolution source location accuracy of the advanced acoustic emission techniques to determine whether the crack initiation site was at the specimen edge or in the interior of the specimen.In this research, advanced AE techniques using broad band sensors, high capture rate digital waveform acquisition, and plate wave propagation based analysis were applied to cross-ply composite coupons with different numbers of 0 and 90 degree plies. Noise signals, believed to be caused by grip damage or specimen slipping, were eliminated based on their plate wave characteristics. Such signals were always located outside the sensor gage length in the gripped region of the specimen. Cracks were confirmed post-test by microscopic analysis of a polished specimen edge, backscatter ultrasonic scans, and in limited cases, by penetrant enhanced radiography. For specimens with three or more 90 degree plies together, there was an exact 1-1 correlation between AE crack signals and observed cracks. The ultrasonic scans and some destructive sectioning analysis showed that the cracks extended across the full width of the specimen. Furthermore, the locations of the cracks from the AE data were in excellent agreement with the locations measured with the microscope. The high resolution source location capability of this technique, combined with an array of sensors, was able to determine that the cracks initiated at the specimen edges, rather than in the interior. For specimens with only one or two 90 degree plies, the crack-like signals were significantly smaller in amplitude and there was not a 1-1 correlation to observed cracks. This was similar to previous results. In this case, however, ultrasonic and destructive sectioning analysis revealed that the cracks did not extend across the specimen. They initiated at the edge, but did not propagate any appreciable distance into the specimen. This explains the much smaller AE signal amplitudes and the difficulty in correlating these signals to actual cracks in this, as well as in the previous study.

Interaction of Cracks Between Two Adjacent Indents in Glass

NASA Technical Reports Server (NTRS)

Choi, S. R.; Salem, J. A.

1993-01-01

Experimental observations of the interaction behavior of cracks between two adjacent indents were made using an indentation technique in soda-lime glass. It was specifically demonstrated how one indent crack initiates and propagates in the vicinity of another indent crack. Several types of crack interactions were examined by changing the orientation and distance of one indent relative to the other. It was found that the residual stress field produced by elastic/plastic indentation has a significant influence on controlling the mode of crack interaction. The interaction of an indent crack with a free surface was also investigated for glass and ceramic specimens.

A probabilistic method for determining the volume fraction of pre-embedded capsules in self-healing materials

NASA Astrophysics Data System (ADS)

Lv, Zhong; Chen, Huisu

2014-10-01

Autonomous healing of cracks using pre-embedded capsules containing healing agent is becoming a promising approach to restore the strength of damaged structures. In addition to the material properties, the size and volume fraction of capsules influence crack healing in the matrix. Understanding the crack and capsule interaction is critical in the development and design of structures made of self-healing materials. Assuming that the pre-embedded capsules are randomly dispersed we theoretically model flat ellipsoidal crack interaction with capsules and determine the probability of a crack intersecting the pre-embedded capsules i.e. the self-healing probability. We also develop a probabilistic model of a crack simultaneously meeting with capsules and catalyst carriers in two-component self-healing system matrix. Using a risk-based healing approach, we determine the volume fraction and size of the pre-embedded capsules that are required to achieve a certain self-healing probability. To understand the effect of the shape of the capsules on self-healing we theoretically modeled crack interaction with spherical and cylindrical capsules. We compared the results of our theoretical model with Monte-Carlo simulations of crack interaction with capsules. The formulae presented in this paper will provide guidelines for engineers working with self-healing structures in material selection and sustenance.

Oxidation products of INCONEL alloys 600 and 690 in pressurized water reactor environments and their role in intergranular stress corrosion cracking

NASA Astrophysics Data System (ADS)

Ferguson, J. B.; Lopez, Hugo F.

2006-08-01

In this work, thermodynamic arguments for the stability of Ni and Cr compounds developed under pressurized water reactor environments ( P_{H_2 O} and P_{H_2 } ) were experimentally tested. A mechanism is proposed to explain crack initiation and propagation alloy 600 along the grain boundaries, where Cr2O3 has formed from the leaching of Cr from the matrix, leaving behind a porous Ni-rich region. The mechanism is based on the thermodynamic potential for the transformation of a protective NiO surface layer into an amorphous nonprotective Ni(OH)2 gel. This gel would also form along the grain boundaries and when hydrogenated steam reaches the porous Ni-rich regions. Crack initiation is then favored by tensile stressing of the grain boundary regions, which can easily rupture the gelatinous film. The leaching of matrix Cr to form nonprotective CrOOH gel at the crack tip followed by the exposure of fresh porous Ni to the environment could explain crack propagation in INCONEL alloy 600. The proposed crack initiation mechanism is not expected to occur in alloy 690 where a protective Cr2O3 film covers the entire metal surface. However, crack propagation along the grain boundaries in alloy 600 and precracked alloy 690 is expected to be active as hydroxide-forming reactions weaken the boundaries.

Impact initiation of explosives and propellants via statistical crack mechanics

NASA Astrophysics Data System (ADS)

Dienes, J. K.; Zuo, Q. H.; Kershner, J. D.

2006-06-01

A statistical approach has been developed for modeling the dynamic response of brittle materials by superimposing the effects of a myriad of microcracks, including opening, shear, growth and coalescence, taking as a starting point the well-established theory of penny-shaped cracks. This paper discusses the general approach, but in particular an application to the sensitivity of explosives and propellants, which often contain brittle constituents. We examine the hypothesis that the intense heating by frictional sliding between the faces of a closed crack during unstable growth can form a hot spot, causing localized melting, ignition, and fast burn of the reactive material adjacent to the crack. Opening and growth of a closed crack due to the pressure of burned gases inside the crack and interactions of adjacent cracks can lead to violent reaction, with detonation as a possible consequence. This approach was used to model a multiple-shock experiment by Mulford et al. [1993. Initiation of preshocked high explosives PBX-9404, PBX-9502, PBX-9501, monitored with in-material magnetic gauging. In: Proceedings of the 10th International Detonation Symposium, pp. 459-467] involving initiation and subsequent quenching of chemical reactions in a slab of PBX 9501 impacted by a two-material flyer plate. We examine the effects of crack orientation and temperature dependence of viscosity of the melt on the response. Numerical results confirm our theoretical finding [Zuo, Q.H., Dienes, J.K., 2005. On the stability of penny-shaped cracks with friction: the five types of brittle behavior. Int. J. Solids Struct. 42, 1309-1326] that crack orientation has a significant effect on brittle behavior, especially under compressive loading where interfacial friction plays an important role. With a reasonable choice of crack orientation and a temperature-dependent viscosity obtained from molecular dynamics calculations, the calculated particle velocities compare well with those measured using embedded velocity gauges.

Oxidation products of Inconel alloys 600 and 690 in hydrogenated steam environments and their role in stress corrosion cracking

NASA Astrophysics Data System (ADS)

Ferguson, J. Bryce

Inconel Alloys 600 and 690 are used extensively in components of Nuclear Pressurized Water Reactors (PWR) in the primary water loop which consists of H2 supersaturated steam. Alloy 600 has been found to crack intergranularly when exposed to primary water conditions. Alloy 690 was designed as a replacement and is generally regarded as immune to cracking. There is no consensus as to the mechanism which is responsible for cracking or the lack thereof in these alloys. In this work thermodynamic arguments for the stability of Ni and Cr compounds developed under pressurized water reactor environments ( PH2O and PH2 ) were experimentally tested. A mechanism is proposed to explain crack initiation and propagation alloy 600 along the grain boundaries where Cr2O3 has formed from the leaching of Cr from the matrix leaving behind a porous Ni-rich region. The mechanism is based on the thermodynamic potential for the transformation of a protective NiO surface layer into an amorphous non-protective Ni(OH)2 gel. This gel would also form along the grain boundaries and when hydrogenated steam reaches the porous Ni-rich regions. Crack initiation is then favored by tensile stressing of the grain boundary regions which can easily rupture the gelatinous film. The leaching of matrix Cr to form non-protective CrOOH gel at the crack tip followed by the exposure of fresh porous Ni to the environment also explains crack propagation in inconel alloy 600. The proposed crack initiation mechanism is not expected to occur in alloy 690 where a protective Cr2O 3 film covers the entire metal surface. However, crack propagation along the grain boundaries in alloy 600 and pre-cracked alloy 690 is expected to be active as hydroxide-forming reactions weaken the material at the grain boundaries.

Application of Self Nulling Eddy Current Probe Technique to the Detection of Fatigue Crack Initiation and Control of Test Procedures

NASA Technical Reports Server (NTRS)

Namkung, M.; Nath, S.; Wincheski, B.; Fulton, J. P.

1994-01-01

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles and the knowledge of the precise location of the crack tip at any given time. One technique currently available for measuring fatigue crack length is the Potential Drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another popular approach is to optically view the crack using a high magnification microscope, but this entails a person constantly monitoring it. The present proposed technique uses an automated scheme, in order to eliminate the need for a person to constantly monitor the experiment. Another technique under development elsewhere is to digitize an optical image of the test specimen surface and then apply a pattern recognition algorithm to locate the crack tip. A previous publication showed that the self nulling eddy current probe successfully tracked a simulated crack in an aluminum sample. This was the impetus to develop an online real time crack monitoring system. An automated system has been developed which includes a two axis scanner mounted on the tensile testing machine, the probe and its instrumentation and a personal computer (PC) to communicate and control all the parameters. The system software controls the testing parameters as well as monitoring the fatigue crack as it propagates. This paper will discuss the experimental setup in detail and demonstrate its capabilities. A three dimensional finite element model is utilized to model the magnetic field distribution due to the probe and how the probe voltage changes as it scans the crack. Experimental data of the probe for different samples under zero load, static load and high cycle fatigue load will be discussed. The final section summarizes the major accomplishments of the present work, the elements of the future R&D needs and the advantages and disadvantages of using this system in the laboratory and field.

An Application of a New Electromagnetic Sensor to Real-Time Monitoring of Fatigue Crack Growth in Thin Metal Plates

NASA Technical Reports Server (NTRS)

Namkung, M.; Fulton, J. P.; Wincheski, B.; Clendenin, C. G.

1993-01-01

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles which necessitates automation of the whole process. If the rate of crack growth can be determined the experimenter can vary externally controlled parameters such as load level, load cycle frequency and so on. Hence, knowledge of the precise location of the crack tip at any given time is very valuable. One technique currently available for measuring fatigue crack length is the DC potential drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another approach is to digitize an optical image of the test specimen surface and then apply a pattern recognition technique to locate the crack tip, but this method is still under development. The present work is an initial study on applying eddy current-type probes to monitoring fatigue crack growth. The performance of two types of electromagnetic probes, a conventional eddy current probe and a newly developed self-nulling probe, was evaluated for the detection characteristics at and near the tips of fatigue cracks. The scan results show that the latter probe provides a very well defined local maximum in its output in the crack tip region suggesting the definite possibility of precisely locating the tip, while the former provides a somewhat ambiguous distribution of the sensor output in the same region. The paper is organized as follows: We start by reviewing the design and performance characteristics of the self-nulling probe and then describe the scan results which demonstrate the basic properties of the self-nulling probe. Next, we provide a brief description of the software developed for tracing a simulated crack and give a brief discussion of the main results of the test. The final section summarizes the major accomplishments of the present work and the elements of the future R&D needs.

Fracture Analysis of Semi-Elliptical Surface Cracks in Ductile Materials

NASA Technical Reports Server (NTRS)

Daniewicz, S. R.; Newman, J. C., Jr.; Leach, A. M.

2004-01-01

Accurate life assessment of structural components may require advanced life prediction criteria and methodologies. Structural components often exhibit several different types of defects, among the most prevalent being surface cracks. A semi-elliptical surface crack subjected to monotonic loading will exhibit stable crack growth until the crack has reached a critical size, at which the crack loses stability and fracture ensues (Newman, 2000). The shape and geometry of the flaw are among the most influential factors. When considering simpler crack configurations, such as a through-the-thickness crack, a three-dimensional (3D) geometry may be modeled under the approximation of two-dimensional (2D) plane stress or plane strain. The more complex surface crack is typically modeled numerically with the Finite Element Method (FEM). A semi-elliptical surface crack is illustrated in Figure 1-1.

A Review of the Proposed KIsi Offset-Secant Method for Size-Insensitive Linear-Elastic Fracture Toughness Evaluation

NASA Technical Reports Server (NTRS)

James, Mark; Wells, Doug; Allen, Phillip; Wallin, Kim

2017-01-01

Recently proposed modifications to ASTM E399 would provide a new size-insensitive approach to analyzing the force-displacement test record. The proposed size-insensitive linear-elastic fracture toughness, KIsi, targets a consistent 0.5mm crack extension for all specimen sizes by using an offset secant that is a function of the specimen ligament length. The KIsi evaluation also removes the Pmax/PQ criterion and increases the allowable specimen deformation. These latter two changes allow more plasticity at the crack tip, prompting the review undertaken in this work to ensure the validity of this new interpretation of the force-displacement curve. This paper provides a brief review of the proposed KIsi methodology and summarizes a finite element study into the effects of increased crack tip plasticity on the method given the allowance for additional specimen deformation. The study has two primary points of investigation: the effect of crack tip plasticity on compliance change in the force-displacement record and the continued validity of linear-elastic fracture mechanics to describe the crack front conditions. The analytical study illustrates that linear-elastic fracture mechanics assumptions remain valid at the increased deformation limit; however, the influence of plasticity on the compliance change in the test record is problematic. A proposed revision to the validity criteria for the KIsi test method is briefly discussed.

Imaging inert fluorinated gases in cracks: perhaps in David's ankles.

PubMed

Kuethe, Dean O; Scholz, Markus D; Fantazzini, Paola

2007-05-01

Inspired by the challenge of determining the nature of cracks on the ankles of Michelangelo's statue David, we discovered that one can image SF(6) gas in cracks in marble samples with alacrity. The imaging method produces images of gas with a signal-to-noise ratio (SNR) of 100-250, which is very high for magnetic resonance imaging (MRI) in general, let alone for an image of a gas at thermal equilibrium polarization. To put this unusual SNR in better perspective, we imaged SF(6) in a crack in a marble sample and imaged the lung tissue of a live rat (a more familiar variety of sample to many MRI scientists) using the same pulse sequence, the same size coils and the same MRI system. In both cases, we try to image subvoxel thin sheets of material that should appear bright against a darker background. By choosing imaging parameters appropriate for the different relaxation properties of SF(6) gas versus lung tissue and by choosing voxel sizes appropriate for the different goals of detecting subvoxel cracks on marble versus resolving subvoxel thin sheets of tissue, the SNR for voxels full of material was 220 and 14 for marble and lung, respectively. A major factor is that we chose large voxels to optimize SNR for detecting small cracks and we chose small voxels for resolving lung features at the expense of SNR. Imaging physics will cooperate to provide detection of small cracks on marble, but David's size poses a challenge for magnet designers. For the modest goal of imaging cracks in the left ankle, we desire a magnet with an approximately 32-cm gap and a flux density of approximately 0.36 T that weighs <500 kg.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

PubMed Central

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-01-01

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations. PMID:28772809

Of cuts and cracks: data analytics on constrained graphs for early prediction of failure in cementitious materials

NASA Astrophysics Data System (ADS)

Kahagalage, Sanath; Tordesillas, Antoinette; Nitka, Michał; Tejchman, Jacek

2017-06-01

Using data from discrete element simulations, we develop a data analytics approach using network flow theory to study force transmission and failure in a `dog-bone' concrete specimen submitted to uniaxial tension. With this approach, we establish the extent to which the bottlenecks, i.e., a subset of contacts that impedes flow and are prone to becoming overloaded, can predict the location of the ultimate macro-crack. At the heart of this analysis is a capacity function that quantifies, in relative terms, the maximum force that can be transmitted through the different contacts or edges in the network. Here we set this function to be solely governed by the size of the contact area between the deformable spherical grains. During all the initial stages of the loading history, when no bonds are broken, we find the bottlenecks coincide consistently with, and therefore predict, the location of the crack that later forms in the failure regime after peak force. When bonds do start to break, they are spread throughout the specimen: in, near, and far from, the bottlenecks. In one stage leading up to peak force, bonds collectively break in the lower portion of the specimen, momentarily shifting the bottlenecks to this location. Just before and around peak force, however, the bottlenecks return to their original location and remain there until the macro-crack emerges right along the bottlenecks.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy.

PubMed

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-04-25

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique-ultrasonic spot welding (USW)-at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with "river-flow" patterns and characteristic fatigue striations.

Generation Mechanism of Nonlinear Rayleigh Surface Waves for Randomly Distributed Surface Micro-Cracks.

PubMed

Ding, Xiangyan; Li, Feilong; Zhao, Youxuan; Xu, Yongmei; Hu, Ning; Cao, Peng; Deng, Mingxi

2018-04-23

This paper investigates the propagation of Rayleigh surface waves in structures with randomly distributed surface micro-cracks using numerical simulations. The results revealed a significant ultrasonic nonlinear effect caused by the surface micro-cracks, which is mainly represented by a second harmonic with even more distinct third/quadruple harmonics. Based on statistical analysis from the numerous results of random micro-crack models, it is clearly found that the acoustic nonlinear parameter increases linearly with micro-crack density, the proportion of surface cracks, the size of micro-crack zone, and the excitation frequency. This study theoretically reveals that nonlinear Rayleigh surface waves are feasible for use in quantitatively identifying the physical characteristics of surface micro-cracks in structures.

Generation Mechanism of Nonlinear Rayleigh Surface Waves for Randomly Distributed Surface Micro-Cracks

PubMed Central

Ding, Xiangyan; Li, Feilong; Xu, Yongmei; Cao, Peng; Deng, Mingxi

2018-01-01

This paper investigates the propagation of Rayleigh surface waves in structures with randomly distributed surface micro-cracks using numerical simulations. The results revealed a significant ultrasonic nonlinear effect caused by the surface micro-cracks, which is mainly represented by a second harmonic with even more distinct third/quadruple harmonics. Based on statistical analysis from the numerous results of random micro-crack models, it is clearly found that the acoustic nonlinear parameter increases linearly with micro-crack density, the proportion of surface cracks, the size of micro-crack zone, and the excitation frequency. This study theoretically reveals that nonlinear Rayleigh surface waves are feasible for use in quantitatively identifying the physical characteristics of surface micro-cracks in structures. PMID:29690580

Micro-fracture Behavior of Organic Matters in Kerogen-Rich Shale (KRS) Composites from Micro- to Milli-meter Scales

NASA Astrophysics Data System (ADS)

Haque, M. H.; Han, Y.; Hull, K. L.; Abousleiman, Y. N.

2017-12-01

Understanding the failure behavior of kerogen-rich shale (KRS) at multiscale is critical to efficient hydraulic fracture stimulations in unconventional source shale reservoirs. As a composite material consisting of compacted clay particles, silt-sized grains, and organic matter (OM), KRS is highly complex both structurally and mechanically. The OM, which is intertwined within the shale matrix, presents a particular challenge as it can be much more compliant than its surrounding minerals while at the same time have a significantly higher tensile strength. The mode-I fracture toughness and tensile failure behavior of KRS has been studied at the core scale by traditional rock mechanics methods i.e., Brazilian tests and more recently with non-traditional approaches at the micro-scale using nanoindentation techniques. However, core scale testing fails in precisely capturing the effects of OM due to its coarse resolution, while nanoindention may capture the behavior of isolated component but in some cases miss the collective properties of the composite system. To bridge this gap, while still complying with ASTM/ISRM standards in principle, we investigate fracture initiation and propagation in KRS using the single-edge notched beam (SENB) miniature samples with span length in the millimeter scale. The size scale attempts to isolate the contributions from individual components, especially the OM, to the emergent and systematic fracturing behavior of KRS. Crack propagation along and across the bedding planes have left noticeable signatures on fractured OM while travelling through and around an OM body depending upon its size and spatial position along the crack path illustrating what looks like crack arrest and/or crack bridging in a composite porous matrix. The fractured surface of OM, even being polymeric in nature, exhibits smooth and even surface profile when ripped apart but not in all observed surfaces. Unique microscale features such as- ridges, twists, and inclusions have also been observed for the OM indicating a mix of complex modes of failures. This study helps further the understanding of fracture morphologies in source rock reservoirs.

Microstructure-sensitive small fatigue crack growth assessment. Effect of strain ratio multiaxial strain state and geometric discontinuities

DOE Office of Scientific and Technical Information (OSTI.GOV)

Castelluccio, Gustavo M.; McDowell, David L.

Fatigue crack initiation in the high cycle fatigue regime is strongly influenced by microstructural features. Research efforts have usually focused on predicting fatigue resistance against crack incubation without considering the early fatigue crack growth after encountering the first grain boundary. However, a significant fraction of the variability of the total fatigue life can be attributed to growth of small cracks as they encounter the first few grain boundaries, rather than crack formation within the first grain. Our paper builds on the framework previously developed by the authors to assess microstructure-sensitive small fatigue crack formation and early growth under complex loadingmore » conditions. Moreover, the scheme employs finite element simulations that explicitly render grains and crystallographic directions along with simulation of microstructurally small fatigue crack growth from grain to grain. The methodology employs a crystal plasticity algorithm in ABAQUS that was previously calibrated to study fatigue crack initiation in RR1000 Ni-base superalloy. Our work present simulations with non-zero applied mean strains and geometric discontinuities that were not previously considered for calibration. Results exhibit trends similar to those found in experiments for multiple metallic materials, conveying a consistent physical description of fatigue damage phenomena.« less

Dynamic fracture and hot-spot modeling in energetic composites

NASA Astrophysics Data System (ADS)

Grilli, Nicolò; Duarte, Camilo A.; Koslowski, Marisol

2018-02-01

Defects such as cracks, pores, and particle-matrix interface debonding affect the sensitivity of energetic materials by reducing the time-to-ignition and the threshold pressure to initiate an explosion. Frictional sliding of preexisting cracks is considered to be one of the most important causes of localized heating. Therefore, understanding the dynamic fracture of crystalline energetic materials is of extreme importance to assess the reliability and safety of polymer-bonded explosives. Phase field damage model simulations, based on the regularization of the crack surface as a diffuse delta function, are used to describe crack propagation in cyclotetramethylene-tetranitramine crystals embedded in a Sylgard matrix. A thermal transport model that includes heat generation by friction at crack interfaces is coupled to the solution of crack propagation. 2D and 3D dynamic compression simulations are performed with different boundary velocities and initial distributions of cracks and interface defects to understand their effect on crack propagation and heat generation. It is found that, at an impact velocity of 400 m/s, localized damage at the particle-binder interface is of key importance and that the sample reaches temperatures high enough to create a hot-spot that will lead to ignition. At an impact velocity of 10 m/s, preexisting cracks advanced inside the particle, but the increase of temperature will not cause ignition.

Microstructure-sensitive small fatigue crack growth assessment. Effect of strain ratio multiaxial strain state and geometric discontinuities

DOE PAGES

Castelluccio, Gustavo M.; McDowell, David L.

2015-09-16

Fatigue crack initiation in the high cycle fatigue regime is strongly influenced by microstructural features. Research efforts have usually focused on predicting fatigue resistance against crack incubation without considering the early fatigue crack growth after encountering the first grain boundary. However, a significant fraction of the variability of the total fatigue life can be attributed to growth of small cracks as they encounter the first few grain boundaries, rather than crack formation within the first grain. Our paper builds on the framework previously developed by the authors to assess microstructure-sensitive small fatigue crack formation and early growth under complex loadingmore » conditions. Moreover, the scheme employs finite element simulations that explicitly render grains and crystallographic directions along with simulation of microstructurally small fatigue crack growth from grain to grain. The methodology employs a crystal plasticity algorithm in ABAQUS that was previously calibrated to study fatigue crack initiation in RR1000 Ni-base superalloy. Our work present simulations with non-zero applied mean strains and geometric discontinuities that were not previously considered for calibration. Results exhibit trends similar to those found in experiments for multiple metallic materials, conveying a consistent physical description of fatigue damage phenomena.« less

Experimental and numerical investigation of crack initiation and propagation in silicon nitride ceramic under rolling and cyclic contact

NASA Astrophysics Data System (ADS)

Raga, Rahul; Khader, Iyas; Zdeněk, Chlup; Kailer, Andreas

2017-05-01

The focus of the work was to investigate crack initiation and propagation mechanisms in silicon nitride undergoing non-conforming hybrid contact under various tribological conditions. In order to understand the prevailing modes of damage in silicon nitride, two distinct model experiments were proposed, namely, rolling contact and cyclic contact experiments. The rolling contact experiment was designed in order to mimic the contact conditions appearing in hybrid bearings at contact pressures ranging from 3 to 6 GPa. On the other hand, cyclic contact experiments with stresses ranging from 4 to 15 GPa under different media were carried out to study damage under localised stresses. In addition, the experimentally observed cracks were implemented in a finite element model to study the stress redistribution and correlate the generated stresses with the corresponding mechanisms. Crack propagation under rolling contact was attributed to two different mechanisms, namely, fatigue induced fracture and lubricant driven crack propagation. The numerical simulations shed light on the tensile stress driven surface and subsurface crack propagation mechanisms. On the other hand, the cyclic contact experiments showed delayed crack formation for lubricated cyclic contact. Ceramographic cross-sectional analysis showed crack patterns similar to Hertzian crack propagation under cyclic contact load.

Study on Corrosion-induced Crack Initiation and Propagation of Sustaining Loaded RCbeams

NASA Astrophysics Data System (ADS)

Zhong, X. P.; Li, Y.; Yuan, C. B.; Yang, Z.; Chen, Y.

2018-05-01

For 13 pieces of reinforced concrete beams with HRB500 steel bars under long-term sustained loads, at time of corrosion-induced initial crack of concrete, and corrosion-induced crack widths of 0.3mm and 1mm, corrosion of steel bars and time-varying behavior of corrosion-induced crack width were studied by the ECWD (Electro-osmosis - constant Current – Wet and Dry cycles) accelerated corrosion method. The results show that when cover thickness was between 30 and 50mm,corrosion rates of steel bars were between 0.8% and 1.7% at time of corrosion-induced crack, and decreased with increasing concrete cover thickness; when corrosion-induced crack width was 0.3mm, the corrosion rate decreased with increasing steel bar diameter, and increased with increasing cover thickness; its corrosion rate varied between 0.98% and 4.54%; when corrosion-induced crack width reached 1mm, corrosion rate of steel bars was between 4% and 4.5%; when corrosion rate of steel bars was within 5%, the maximum and average corrosion-induced crack and corrosion rate of steel bars had a good linear relationship. The calculation model predicting the maximum and average width of corrosion-induced crack is given in this paper.

Critical flaw size in silicon nitride ball bearings

NASA Astrophysics Data System (ADS)

Levesque, George Arthur

Aircraft engine and bearing manufacturers have been aggressively pursuing advanced materials technology systems solutions to meet main shaft-bearing needs of advanced military aircraft engines. Ceramic silicon nitride hybrid bearings are being developed for such high performance applications. Though silicon nitride exhibits many favorable properties such as high compressive strength, high hardness, a third of the density of steel, low coefficient of thermal expansion, and high corrosion and temperature resistance, they also have low fracture toughness and are susceptible to failure from fatigue spalls emanating from pre-existing surface flaws that can grow under rolling contact fatigue (RCF). Rolling elements and raceways are among the most demanding components in aircraft engines due to a combination of high cyclic contact stresses, long expected component lifetimes, corrosive environment, and the high consequence of fatigue failure. The cost of these rolling elements increases exponentially with the decrease in allowable flaw size for service applications. Hence the range of 3D non-planar surface flaw geometries subject to RCF is simulated to determine the critical flaw size (CFS) or the largest allowable flaw that does not grow under service conditions. This dissertation is a numerical and experimental investigation of surface flaws in ceramic balls subjected to RCF and has resulted in the following analyses: Crack Shape Determination: the nucleation of surface flaws from ball impact that occurs during the manufacturing process is simulated. By examining the subsurface Hertzian stresses between contacting spheres, their applicability to predicting and characterizing crack size and shape is established. It is demonstrated that a wide range of cone and partial cone cracks, observed in practice, can be generated using the proposed approaches. RCF Simulation: the procedure and concerns in modeling nonplanar 3D cracks subject to RCF using FEA for stress intensity factor (SIF) trends observed from parametrically varying different physical effects are plotted and discussed. Included are developments in contact algorithms for 3D nonplanar cracks, meshing of nonplanar cracks for SIFs, parametric studies via MATLAB and other subroutines in python and FORTRAN. Establishing Fracture Parameters: the fracture toughness, K c, is determined by using numerical techniques on experimental tests namely the Brazilian disc test and a novel compression test on an indented ball. The fatigue threshold for mixed-mode loading, Keff, is determined by using a combination of numerical modeling and results from the V-ring single ball RCF test. CFS Determination: the range of 3D non-planar surface flaw geometries subject to RCF are simulated to calculate mixed mode SIFs to determine the critical flaw size, or the largest allowable flaw that does not grow under service conditions. The CFS results are presented as a function of Hertzian contact stress, traction magnitude, and crack size. Empirical Equations: accurate empirical equations (response functions) for the KI, KII, and K III SIFs for semi-elliptical surface cracks subjected to RCF as a function of the contact patch diameter, angle of crack to the surface, max pressure, position along the crack front, and aspect ratio of the crack are developed via parametric 3D FEA. Statistical Probability of Failure: since the variability in mechanical properties for brittle materials is high a probabilistic investigation of variations in flaw size, flaw orientation, fracture toughness, and Hertzian load on failure probability is conducted to statistically determine the probability of ball failure for an existing flaw subjected to the service conditions. (Full text of this dissertation may be available via the University of Florida Libraries web site. Please check http://www.uflib.ufl.edu/etd.html)

A Crack Growth Evaluation Method for Interacting Multiple Cracks

NASA Astrophysics Data System (ADS)

Kamaya, Masayuki

When stress corrosion cracking or corrosion fatigue occurs, multiple cracks are frequently initiated in the same area. According to section XI of the ASME Boiler and Pressure Vessel Code, multiple cracks are considered as a single combined crack in crack growth analysis, if the specified conditions are satisfied. In crack growth processes, however, no prescription for the interference between multiple cracks is given in this code. The JSME Post-Construction Code, issued in May 2000, prescribes the conditions of crack coalescence in the crack growth process. This study aimed to extend this prescription to more general cases. A simulation model was applied, to simulate the crack growth process, taking into account the interference between two cracks. This model made it possible to analyze multiple crack growth behaviors for many cases (e. g. different relative position and length) that could not be studied by experiment only. Based on these analyses, a new crack growth analysis method was suggested for taking into account the interference between multiple cracks.

Intragranular cracking as a critical barrier for high-voltage usage of layer-structured cathode for lithium-ion batteries

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yan, Pengfei; Zheng, Jianming; Gu, Meng

LiNi 1/3Mn 1/3Co 1/3O 2 (NMC333) layered cathode is often fabricated as secondary particles of consisting of densely packed primary particles, which offers advantage of high energy density and alleviation of cathode side reactions/corrosions, but introduces other drawbacks, such as intergranular cracking. Here, we report unexpected observations on the nucleation and growth of intragranular cracks in the commercial NMC333 layered cathode by using advanced S/TEM. We found that the formation of the intragranular cracks is directly associated with high voltage cycling, which is an electrochemically driven and diffusion controlled process. The intragranular cracks were noticed to be characteristically initiated frommore » grain interior, a consequence of dislocation based crack incubation mechanism. This observation is in sharp contrast with the general theoretical models, predicting the initiation of intragranular cracks from grain boundaries or particle surface. As a result, our study indicates that maintain a structural stability is the key step toward high voltage operation of layered cathode materials.« less

Analysis of damaging process and crack propagation

NASA Astrophysics Data System (ADS)

Semenski, D.; Wolf, H.; Božić, Ž.

2010-06-01

Supervising and health monitoring of structures can assess the actual state of existing structures after initial loading or in the state of operation. Structural life management requires the integration of design and analysis, materials behavior and structural testing, as given for several examples. Procedure of survey of structural elements and criteria for their selection must be strongly defined as it is for the offshore gas platforms. Numerical analysis of dynamic loading is shown for the Aeolian vibrations of overhead transmission line conductors. Since the damper’s efficiency strongly depends on its position, the procedure of determining the optimum position of the damper is described. The optical method of caustics is established in isotropic materials for determination of the stress intensity factors (SIFs) of the cracks in deformed structures and is advantageously improved for the application to fiberreinforced composites. A procedure for simulation of crack propagation for multiple cracks was introduced and SIFs have been calculated by using finite element method. Crack growth of a single crack or a periodical array of cracks initiated at the stiffeners in a stiffened panel has been investigated.

Intragranular cracking as a critical barrier for high-voltage usage of layer-structured cathode for lithium-ion batteries

DOE PAGES

Yan, Pengfei; Zheng, Jianming; Gu, Meng; ...

2017-01-16

LiNi 1/3Mn 1/3Co 1/3O 2 (NMC333) layered cathode is often fabricated as secondary particles of consisting of densely packed primary particles, which offers advantage of high energy density and alleviation of cathode side reactions/corrosions, but introduces other drawbacks, such as intergranular cracking. Here, we report unexpected observations on the nucleation and growth of intragranular cracks in the commercial NMC333 layered cathode by using advanced S/TEM. We found that the formation of the intragranular cracks is directly associated with high voltage cycling, which is an electrochemically driven and diffusion controlled process. The intragranular cracks were noticed to be characteristically initiated frommore » grain interior, a consequence of dislocation based crack incubation mechanism. This observation is in sharp contrast with the general theoretical models, predicting the initiation of intragranular cracks from grain boundaries or particle surface. As a result, our study indicates that maintain a structural stability is the key step toward high voltage operation of layered cathode materials.« less

Analysis of surface cracks in finite plates under tension or bending loads

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.; Raju, I. S.

1979-01-01

Stress-intensity factors calculated with a three-dimensional, finite-element analysis for shallow and deep semielliptical surface cracks in finite elastic isotropic plates subjected to tension or bending loads are presented. A wide range of configuration parameters was investigated. The ratio of crack depth to plate thickness ranged from 0.2 to 0.8 and the ratio of crack depth to crack length ranged from 0.2 to 2.0. The effects of plate width on stress-intensity variations along the crack front was also investigated. A wide-range equation for stress-intensity factors along the crack front as a function of crack depth, crack length, plate thickness, and plate width was developed for tension and bending loads. The equation was used to predict patterns of surface-crack growth under tension or bending fatigue loads. A modified form of the equation was also used to correlate surface-crack fracture data for a brittle epoxy material within + or - 10 percent for a wide range of crack shapes and crack sizes.

40 CFR Table 12 to Subpart Uuu of... - Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units

Code of Federal Regulations, 2013 CFR

2013-07-01

... 40 Protection of Environment 13 2013-07-01 2012-07-01 true Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units 12 Table 12 to Subpart UUU of Part 63 Protection of... Sulfur Recovery Units Pt. 63, Subpt. UUU, Table 12 Table 12 to Subpart UUU of Part 63—Initial Compliance...

40 CFR Table 12 to Subpart Uuu of... - Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units

Code of Federal Regulations, 2011 CFR

2011-07-01

... 40 Protection of Environment 12 2011-07-01 2009-07-01 true Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units 12 Table 12 to Subpart UUU of Part 63 Protection of... Units Pt. 63, Subpt. UUU, Table 12 Table 12 to Subpart UUU of Part 63—Initial Compliance With Organic...

40 CFR Table 12 to Subpart Uuu of... - Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units

Code of Federal Regulations, 2010 CFR

2010-07-01

... 40 Protection of Environment 12 2010-07-01 2010-07-01 true Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units 12 Table 12 to Subpart UUU of Part 63 Protection of... Units Pt. 63, Subpt. UUU, Table 12 Table 12 to Subpart UUU of Part 63—Initial Compliance With Organic...

40 CFR Table 12 to Subpart Uuu of... - Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units

Code of Federal Regulations, 2014 CFR

2014-07-01

... 40 Protection of Environment 13 2014-07-01 2014-07-01 false Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units 12 Table 12 to Subpart UUU of Part 63 Protection of... Sulfur Recovery Units Pt. 63, Subpt. UUU, Table 12 Table 12 to Subpart UUU of Part 63—Initial Compliance...

40 CFR Table 12 to Subpart Uuu of... - Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units

Code of Federal Regulations, 2012 CFR

2012-07-01

... 40 Protection of Environment 13 2012-07-01 2012-07-01 false Initial Compliance With Organic HAP Emission Limits for Catalytic Cracking Units 12 Table 12 to Subpart UUU of Part 63 Protection of... Sulfur Recovery Units Pt. 63, Subpt. UUU, Table 12 Table 12 to Subpart UUU of Part 63—Initial Compliance...

High temperature low cycle fatigue mechanisms for nickel base and a copper base alloy. M.S. Thesis Final Report

NASA Technical Reports Server (NTRS)

Shih, C. I.

1982-01-01

Damage mechanisms were studied in Rene' 95 and NARloy Z, using optical, scanning and transmission in microscopy. In necklace Rene' 95, crack initiation was mainly associated with cracking of surface MC carbides, except for hold time tests at higher strain ranges where initiation was associated more with a grain boundary mechanism. A mixed mode of propagation with a faceted fracture morphology was typical for all cycle characters. The dependence of life on maximum tensile stress can be demonstrated by the data falling onto three lines corresponding to the three tensile hold times, in the life against maximum tensile stress plot. In NARloy Z, crack initiation was always at the grain boundaries. The mode of crack propagation depended on the cycle character. The life decreased with decreasing strain rate and with tensile holds. In terms of damage mode, different life prediction laws may be applicable to different cycle characters.

Review of the Effects of Microstructure on Fatigue in Aluminum Alloys. Ph.D. Thesis - Cincinnati Univ.

NASA Technical Reports Server (NTRS)

Telesman, J.

1984-01-01

Literature survey was conducted to determine the effects of different microstructural features and different load histories on fatigue crack initiation and propagation of aluminum alloys. Comparison of microstructure and monotonic and cyclic properties between powder metallurgy (P/M) and ingot metallurgy (I/M) alloys is presented. The two alloys that are representative of each process on which the comparison is focused are X7091 and 7050. Included is a detailed description of the microstructure produced through the P/M and I/M proesses. The effect of each pertinent microstructural feature on monotonic and cyclic properties, such as yield strength, toughness, crack initiation and propagation is discussed. Also discussed are the proposed mechanisms for crack initiation and propagation, as well as the effects of aggressive environments on these cyclic properties. The effects of variable amplitude loadin on fatigue crack propagation and the various models proposed to predict load interaction effects are discussed.

An evaluation of fatigue limit of notched specimen of a C/C composite

NASA Astrophysics Data System (ADS)

Makabe, C.; Fujikawa, M.; Ferdous, M. S.

2018-06-01

The fatigue strengths in notched specimens of carbon fiber reinforced carbon composites (C/C composites) were investigated. The fatigue limit was measured by S-N curves and load increase tests. The value of fatigue limit obtained by those methods was almost the same. Slits of several sizes were cut on both sides of a test section, and different sizes of slit length were chosen. Also, specimens with blunt-notches were used to compare the fatigue strength. The weakest fatigue limit was obtained in the case of specimens with blunt-notches. However, the stress concentration factor of those is smaller than that of slit specimens. The relationships between fatigue strengths and specimen shapes were analyzed by stress distribution. The effect of slit configuration on fatigue strength was then discussed regarding the experimental consequences. Consequently, it was discussed that the fatigue strength of the present specimens was determined depending on the damage conditions in the vicinity of the notch and on the crack initiation behavior. It is expected that the tendency of the S-N curve and fatigue limit was related to the shear damage and shear mode of the crack growth.

Fiber Laser Welded AZ31 Magnesium Alloy: The Effect of Welding Speed on Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

Chowdhury, S. H.; Chen, D. L.; Bhole, S. D.; Powidajko, E.; Weckman, D. C.; Zhou, Y.

2012-06-01

This study was aimed at characterizing microstructural change and evaluating tensile and fatigue properties of fiber laser welded AZ31B-H24 Mg alloy with special attention to the effect of welding speed. Laser welding led to the formation of equiaxed dendrites in the fusion zone and columnar dendrites near the fusion zone boundary along with divorced eutectic Mg17Al12 particles and recrystallized grains in the heat-affected zone. The lowest hardness across the weld appeared in the fusion zone. Although the yield strength, ductility, and fatigue life decreased, the hardening capacity increased after laser welding, with a joint efficiency reaching about 90 pct. A higher welding speed resulted in a narrower fusion zone, smaller grain size, higher yield strength, and longer fatigue life, as well as a slightly lower strain-hardening capacity mainly because of the smaller grain sizes. Tensile fracture occurred in the fusion zone, whereas fatigue failure appeared essentially in between the heat-affected zone and the fusion zone. Fatigue cracks initiated from the near-surface welding defects and propagated by the formation of fatigue striations together with secondary cracks.

An analysis of premature cracking associated with microstructural alterations in an AISI 52100 failed wind turbine bearing using X-ray tomography

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gould, Benjamin; Greco, Aaron; Stadler, Kenred

2017-03-01

Crack surrounded by local areas of microstructural alteration deemed "White etching cracks" (WECs) lead to unpredictable and premature failures within a multitude of applications including wind turbine gearbox bearings. While the exact cause of these failures remains unknown, a large number of hypotheses exist as to how and why these cracks form. The aim of the current work is to elucidate some of these hypotheses by mapping WEC networks within failed wind turbine bearings using high energy X-ray tomography, in an attempt to determine the location of WEC initiation, and the role of defects within the steel, such as inclusionsmore » or carbide clusters. Four completely subsurface WECs were found throughout the presented analysis, thereby confirming subsurface initiation as method of WEC formation. Additionally, a multitude of small butterfly like cracks were found around inclusions in the steel, however further analysis is needed to verify if these inclusions are initiation sites for WECs. (C) 2017 Elsevier Ltd. All rights reserved.« less

Reliability analysis of structures under periodic proof tests in service

NASA Technical Reports Server (NTRS)

Yang, J.-N.

1976-01-01

A reliability analysis of structures subjected to random service loads and periodic proof tests treats gust loads and maneuver loads as random processes. Crack initiation, crack propagation, and strength degradation are treated as the fatigue process. The time to fatigue crack initiation and ultimate strength are random variables. Residual strength decreases during crack propagation, so that failure rate increases with time. When a structure fails under periodic proof testing, a new structure is built and proof-tested. The probability of structural failure in service is derived from treatment of all the random variables, strength degradations, service loads, proof tests, and the renewal of failed structures. Some numerical examples are worked out.

Crack Closure and Fatigue Crack Growth in 2219-T851 Aluminum Alloy

DTIC Science & Technology

1976-08-01

assumes the length of the crack perimeter to remain es - ’I sentially constant. At the maximum load, the crack is ap- proximately parabolic (or ellipical...for center cracked j specimens) in shape. With unloading, the parabola (or el- lipse) is collapsed. The resulting change in shape produces an apparent...reloading process, the electrical potential remained es - j sentially constant initially and was less than that at the corresponding load during unloading

How Do Cracks Initiate and Grow in a Thin Glass Plate? A Peridynamic Analysis

DTIC Science & Technology

2014-06-17

evolution of these cracks, and confirm these results with fractography experiments of post-mortem samples. The results provide evidence of the predictive...face Questions to be answered  Can we understand how and why each type of crack system forms?  Crack surface fractography can give indication of...Symmetrical cracks form on the lower-right quarter of the plate. Jared Wright (ARL) fractography results Conclusions • The simplest peridynamic model

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

NASA Technical Reports Server (NTRS)

McClung, R. C.; Chell, G. G.; Millwater, H. R.; Russell, D. A.; Millwater, H. R.

1999-01-01

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semielliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT versus SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

NASA Technical Reports Server (NTRS)

McClung, R. C.; Chell, G. G.; Millwater, H. R.; Russell, D. A.; Orient, G. E.

1996-01-01

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

Treatment of singularities in a middle-crack tension specimen

NASA Technical Reports Server (NTRS)

Shivakumar, K. N.; Raju, I. S.

1990-01-01

A three-dimensional finite-element analysis of a middle-crack tension specimen subjected to mode I loading was performed to study the stress singularity along the crack front. The specimen was modeled using 20-node isoparametric elements with collapsed nonsingular elements at the crack front. The displacements and stresses from the analysis were used to estimate the power of singularities, by a log-log regression analysis, along the crack front. Analyses showed that finite-sized cracked bodies have two singular stress fields. Because of two singular stress fields near the free surface and the classical square root singularity elsewhere, the strain energy release rate appears to be an appropriate parameter all along the crack front.

Healing of damaged metal by a pulsed high-energy electromagnetic field

NASA Astrophysics Data System (ADS)

Kukudzhanov, K. V.; Levitin, A. L.

2018-04-01

The processes of defect (intergranular micro-cracks) transformation are investigated for metal samples in a high-energy short-pulsed electromagnetic field. This investigation is based on a numerical coupled model of the impact of high-energy electromagnetic field on the pre-damaged thermal elastic-plastic material with defects. The model takes into account the melting and evaporation of the metal and the dependence of its physical and mechanical properties on the temperature. The system of equations is solved numerically by finite element method with an adaptive mesh using the arbitrary Euler–Lagrange method. The calculations show that the welding of the crack and the healing of micro-defects under treatment by short pulses of the current takes place. For the macroscopic description of the healing process, the healing and damage parameters of the material are introduced. The healing of micro-cracks improves the material healing parameter and reduces its damage. The micro-crack shapes practically do not affect the time-dependence of the healing and damage under the treatment by the current pulses. These changes are affected only by the value of the initial damage of the material and the initial length of the micro-crack. The time-dependence of the healing and the damage is practically the same for all different shapes of micro-defects, provided that the initial lengths of micro-cracks and the initial damages are the same for these different shapes of defects.

Detection of submicron scale cracks and other surface anomalies using positron emission tomography

DOEpatents

Cowan, Thomas E.; Howell, Richard H.; Colmenares, Carlos A.

2004-02-17

Detection of submicron scale cracks and other mechanical and chemical surface anomalies using PET. This surface technique has sufficient sensitivity to detect single voids or pits of sub-millimeter size and single cracks or fissures of millimeter size; and single cracks or fissures of millimeter-scale length, micrometer-scale depth, and nanometer-scale length, micrometer-scale depth, and nanometer-scale width. This technique can also be applied to detect surface regions of differing chemical reactivity. It may be utilized in a scanning or survey mode to simultaneously detect such mechanical or chemical features over large interior or exterior surface areas of parts as large as about 50 cm in diameter. The technique involves exposing a surface to short-lived radioactive gas for a time period, removing the excess gas to leave a partial monolayer, determining the location and shape of the cracks, voids, porous regions, etc., and calculating the width, depth, and length thereof. Detection of 0.01 mm deep cracks using a 3 mm detector resolution has been accomplished using this technique.

The detection of fatigue cracks by nondestructive testing methods

NASA Technical Reports Server (NTRS)

Rummel, W. D.; Todd, P. H., Jr.; Frecska, S. A.; Rathke, R. A.

1974-01-01

X-radiographic penetrant, ultrasonic, eddy current, holographic, and acoustic emission techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens. One hundred eighteen specimens containing a total of 328 fatigue cracks were evaluated. The cracks ranged in length from 0.500 inch (1.27 cm) to 0.007 inch (0.018 cm) and in depth from 0.178 inch (0.451 cm) and 0.001 inch (0.003 cm). Specimen thicknesses were nominally 0.060 inch (0.152 cm) and 0.210 inch (0.532 cm) and surface finishes were nominally 32 and 125 rms and 64 and 200 rms respectively. Specimens were evaluated in the as-milled surface condition, in the chemically milled surface condition and, after proof loading, in a randomized inspection sequence. Results of the nondestructive test (NDT) evaluations were compared with actual crack size obtained by measurement of the fractured specimens. Inspection data was then analyzed to provide a statistical basis for determinating the threshold crack detection sensitivity (the largest crack size that would be missed) for each of the inspection techniques at a 95% probability and 95% confidence level.

Optimizing Probability of Detection Point Estimate Demonstration

NASA Technical Reports Server (NTRS)

Koshti, Ajay M.

2017-01-01

Probability of detection (POD) analysis is used in assessing reliably detectable flaw size in nondestructive evaluation (NDE). MIL-HDBK-18231and associated mh18232POD software gives most common methods of POD analysis. Real flaws such as cracks and crack-like flaws are desired to be detected using these NDE methods. A reliably detectable crack size is required for safe life analysis of fracture critical parts. The paper provides discussion on optimizing probability of detection (POD) demonstration experiments using Point Estimate Method. POD Point estimate method is used by NASA for qualifying special NDE procedures. The point estimate method uses binomial distribution for probability density. Normally, a set of 29 flaws of same size within some tolerance are used in the demonstration. The optimization is performed to provide acceptable value for probability of passing demonstration (PPD) and achieving acceptable value for probability of false (POF) calls while keeping the flaw sizes in the set as small as possible.

Surface-crack growth: Models, experiments, and structures; Proceedings of the Symposium, Sparks, NV, Apr. 25, 1988

NASA Technical Reports Server (NTRS)

Reuter, Walter G. (Editor); Underwood, John H. (Editor); Newman, James C., Jr. (Editor)

1990-01-01

The present volume on surface-crack growth modeling, experimental methods, and structures, discusses elastoplastic behavior, the fracture analysis of three-dimensional bodies with surface cracks, optical measurements of free-surface effects on natural surfaces and through cracks, an optical and finite-element investigation of a plastically deformed surface flaw under tension, fracture behavior prediction for rapidly loaded surface-cracked specimens, and surface cracks in thick laminated fiber composite plates. Also discussed are a novel study procedure for crack initiation and growth in thermal fatigue testing, the growth of surface cracks under fatigue and monotonically increasing load, the subcritical growth of a surface flaw, surface crack propagation in notched and unnotched rods, and theoretical and experimental analyses of surface cracks in weldments.

Failure mechanism of monolayer graphene under hypervelocity impact of spherical projectile

PubMed Central

Xia, Kang; Zhan, Haifei; Hu, De’an; Gu, Yuantong

2016-01-01

The excellent mechanical properties of graphene have enabled it as appealing candidate in the field of impact protection or protective shield. By considering a monolayer graphene membrane, in this work, we assessed its deformation mechanisms under hypervelocity impact (from 2 to 6 km/s), based on a serial of in silico studies. It is found that the cracks are formed preferentially in the zigzag directions which are consistent with that observed from tensile deformation. Specifically, the boundary condition is found to exert an obvious influence on the stress distribution and transmission during the impact process, which eventually influences the penetration energy and crack growth. For similar sample size, the circular shape graphene possesses the best impact resistance, followed by hexagonal graphene membrane. Moreover, it is found the failure shape of graphene membrane has a strong relationship with the initial kinetic energy of the projectile. The higher kinetic energy, the more number the cracks. This study provides a fundamental understanding of the deformation mechanisms of monolayer graphene under impact, which is crucial in order to facilitate their emerging future applications for impact protection, such as protective shield from orbital debris for spacecraft. PMID:27618989

Failure mechanism of monolayer graphene under hypervelocity impact of spherical projectile

NASA Astrophysics Data System (ADS)

Xia, Kang; Zhan, Haifei; Hu, De'An; Gu, Yuantong

2016-09-01

The excellent mechanical properties of graphene have enabled it as appealing candidate in the field of impact protection or protective shield. By considering a monolayer graphene membrane, in this work, we assessed its deformation mechanisms under hypervelocity impact (from 2 to 6 km/s), based on a serial of in silico studies. It is found that the cracks are formed preferentially in the zigzag directions which are consistent with that observed from tensile deformation. Specifically, the boundary condition is found to exert an obvious influence on the stress distribution and transmission during the impact process, which eventually influences the penetration energy and crack growth. For similar sample size, the circular shape graphene possesses the best impact resistance, followed by hexagonal graphene membrane. Moreover, it is found the failure shape of graphene membrane has a strong relationship with the initial kinetic energy of the projectile. The higher kinetic energy, the more number the cracks. This study provides a fundamental understanding of the deformation mechanisms of monolayer graphene under impact, which is crucial in order to facilitate their emerging future applications for impact protection, such as protective shield from orbital debris for spacecraft.

A Progressive Damage Methodology for Residual Strength Predictions of Center-Crack Tension Composite Panels

NASA Technical Reports Server (NTRS)

Coats, Timothy William

1996-01-01

An investigation of translaminate fracture and a progressive damage methodology was conducted to evaluate and develop a residual strength prediction capability for laminated composites with through penetration notches. This is relevant to the damage tolerance of an aircraft fuselage that might suffer an in-flight accident such as an uncontained engine failure. An experimental characterization of several composite materials systems revealed an R-curve type of behavior. Fractographic examinations led to the postulate that this crack growth resistance could be due to fiber bridging, defined here as fractured fibers of one ply bridged by intact fibers of an adjacent ply. The progressive damage methodology is currently capable of predicting the initiation and growth of matrix cracks and fiber fracture. Using two difference fiber failure criteria, residual strength was predicted for different size panel widths and notch lengths. A ply discount fiber failure criterion yielded extremely conservative results while an elastic-perfectly plastic fiber failure criterion showed that the fiber bridging concept is valid for predicting residual strength for tensile dominated failure loads. Furthermore, the R-curves predicted by the model using the elastic-perfectly plastic fiber criterion compared very well with the experimental R-curves.

USAF Damage Tolerant Design Handbook: Guidelines for the Analysis and Design of Damage Tolerant Aircraft Structures. Revision B

DTIC Science & Technology

1984-05-01

Effect of Block Programming and Block Size on Crack Growth Life (All Histories Have Same Cycle Content) Alloy : 2024 -T3 Aluminum (Reference 27...1 I 6 o T 1 >0 100 Crack Growth Life for l-in. Crack Growth 1000 Figure 5.1.10, Effect of Humidity on Fatigue Crack Propagation...Growth Life (All Histories Have Same Cycle Content) Alloy : 2024 -T3 Aluminum (Reference 27). 5.2.6 Yield Zone Due to Overload (r T), Current Crack

Analysis of microstructure of steel 20 in the range of healing of internal crack

NASA Astrophysics Data System (ADS)

Zhang, Yongjun; Han, Jingtao

2012-03-01

The microstructure and hardness of steel 20 are studied in the range of healing of an artificially created internal crack. In the range of healing of the crack the microstructure is represented primarily by ferrite. The ferrite grains grow through the boundary of the internal crack and contain polyhedral subgrains several hundred nanometers in size. The hardness of the ferrite in the range of healing of the internal crack is higher than in the matrix. A possible cause of this is substructural hardening.

Williams Element with Generalized Degrees of Freedom for Fracture Analysis of Multiple-Cracked Beam

NASA Astrophysics Data System (ADS)

Xu, Hua; Wei, Quyang; Yang, Lufeng

2017-10-01

In this paper, the method of finite element with generalized degrees of freedom (FEDOFs) is used to calculate the stress intensity factor (SIF) of multiple cracked beam and analysed the effect of minor cracks on the main crack SIF in different cases. Williams element is insensitive to the size of singular region. So that calculation efficiency is highly improved. Examples analysis validates that the SIF near the crack tip can be obtained directly though FEDOFs. And the result is well consistent with ANSYS solution and has a satisfied accuracy.

Transition Fracture Toughness Characterization of Eurofer 97 Steel using Pre-Cracked Miniature Multi-notch Bend Bar Specimens

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Xiang; Sokolov, Mikhail A.; Linton, Kory D.

In this report, we present the feasibility study of using pre-cracked miniature multi-notch bend bar specimens (M4CVN) with a dimension of 45mm (length) x 3.3mm (width) x 1.65mm (thickness) to characterize the transition fracture toughness of Eurofer97 based on the ASTM E1921 Master Curve method. From literature survey results, we did not find any obvious specimen size effects on the measured fracture toughness of unirradiated Eurofer97. Nonetheless, in order to exclude the specimen size effect on the measured fracture toughness of neutron irradiated Eurofer97, comparison of results obtained from larger size specimens with those from smaller size specimens after neutronmore » irradiation is necessary, which is not practical and can be formidably expensive. However, limited literature results indicate that the transition fracture toughness of Eurofer97 obtained from different specimen sizes and geometries followed the similar irradiation embrittlement trend. We then described the newly designed experimental setup to be used for testing neutron irradiated Eurofer97 pre-cracked M4CVN bend bars in the hot cell. We recently used the same setup for testing neutron irradiated F82H pre-cracked miniature multi-notch bend bars with great success. Considering the similarity in materials, specimen types, and the nature of tests between Eurofer97 and F82H, we believe the newly designed experimental setup can be used successfully in fracture toughness testing of Eurofer97 pre-cracked M4CVN specimens.« less

Very High Cycle Fatigue Failure Analysis and Life Prediction of Cr-Ni-W Gear Steel Based on Crack Initiation and Growth Behaviors.

PubMed

Deng, Hailong; Li, Wei; Sakai, Tatsuo; Sun, Zhenduo

2015-12-02

The unexpected failures of structural materials in very high cycle fatigue (VHCF) regime have been a critical issue in modern engineering design. In this study, the VHCF property of a Cr-Ni-W gear steel was experimentally investigated under axial loading with the stress ratio of R = -1, and a life prediction model associated with crack initiation and growth behaviors was proposed. Results show that the Cr-Ni-W gear steel exhibits the constantly decreasing S-N property without traditional fatigue limit, and the fatigue strength corresponding to 10⁸ cycles is around 485 MPa. The inclusion-fine granular area (FGA)-fisheye induced failure becomes the main failure mechanism in the VHCF regime, and the local stress around the inclusion play a key role. By using the finite element analysis of representative volume element, the local stress tends to increase with the increase of elastic modulus difference between inclusion and matrix. The predicted crack initiation life occupies the majority of total fatigue life, while the predicted crack growth life is only accounts for a tiny fraction. In view of the good agreement between the predicted and experimental results, the proposed VHCF life prediction model involving crack initiation and growth can be acceptable for inclusion-FGA-fisheye induced failure.

Fracture behavior of 20% Nb particulate reinforced alumina composite

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lane, S.; Biner, S.B.; Buck, O.

1993-11-01

The composites consist of alumina matrix with 0.05 wt % MgO and 20 Vol % Nb with an average particle size of 30 to 100 microns produced by dry mixing and sintering to near their theoretical densities. Fracture toughness tests were carried out in three point bending on chevron notched samples. Results indicate that R-curve of the composites exhibited more than 300% increase in crack growth resistance compared to crack growth resistance of alumina produced with the identical procedures. Crack growth resistance curve of the composites increased with increasing Nb particle size. Metallorgraph indicated that failure of Nb particles inmore » crack path ranges from full interface separation without any significant deformation of Nb particles to cleavage failure without any evidence of interface separation.« less

Numerical investigation of shape domain effect to its elasticity and surface energy using adaptive finite element method

NASA Astrophysics Data System (ADS)

Alfat, Sayahdin; Kimura, Masato; Firihu, Muhammad Zamrun; Rahmat

2018-05-01

In engineering area, investigation of shape effect in elastic materials was very important. It can lead changing elasticity and surface energy, and also increase of crack propagation in the material. A two-dimensional mathematical model was developed to investigation of elasticity and surface energy in elastic material by Adaptive Finite Element Method. Besides that, behavior of crack propagation has observed for every those materials. The government equations were based on a phase field approach in crack propagation model that developed by Takaishi-Kimura. This research has varied four shape domains where physical properties of materials were same (Young's modulus E = 70 GPa and Poisson's ratio ν = 0.334). Investigation assumptions were; (1) homogeneous and isotropic material, (2) there was not initial cracking at t = 0, (3) initial displacement was zero [u1, u2] = 0) at initial condition (t = 0), and (4) length of time simulation t = 5 with interval Δt = 0.005. Mode I/II or mixed mode crack propagation has been used for the numerical investigation. Results of this studies were very good and accurate to show changing energy and behavior of crack propagation. In the future time, this research can be developed to complex phenomena and domain. Furthermore, shape optimization can be investigation by the model.

Simulating the x-ray image contrast to setup techniques with desired flaw detectability

NASA Astrophysics Data System (ADS)

Koshti, Ajay M.

2015-04-01

The paper provides simulation data of previous work by the author in developing a model for estimating detectability of crack-like flaws in radiography. The methodology is developed to help in implementation of NASA Special x-ray radiography qualification, but is generically applicable to radiography. The paper describes a method for characterizing the detector resolution. Applicability of ASTM E 2737 resolution requirements to the model are also discussed. The paper describes a model for simulating the detector resolution. A computer calculator application, discussed here, also performs predicted contrast and signal-to-noise ratio calculations. Results of various simulation runs in calculating x-ray flaw size parameter and image contrast for varying input parameters such as crack depth, crack width, part thickness, x-ray angle, part-to-detector distance, part-to-source distance, source sizes, and detector sensitivity and resolution are given as 3D surfaces. These results demonstrate effect of the input parameters on the flaw size parameter and the simulated image contrast of the crack. These simulations demonstrate utility of the flaw size parameter model in setting up x-ray techniques that provide desired flaw detectability in radiography. The method is applicable to film radiography, computed radiography, and digital radiography.

Turbine engine rotor health monitoring evaluation by means of finite element analyses and spin tests data

NASA Astrophysics Data System (ADS)

Abdul-Aziz, Ali; Woike, Mark R.; Clem, Michelle; Baaklini, George Y.

2014-04-01

Generally, rotating engine components undergo high centrifugal loading environment which subject them to various types of failure initiation mechanisms. Health monitoring of these components is a necessity and is often challenging to implement. This is primarily due to numerous factors including the presence of scattered loading conditions, flaw sizes, component geometry and materials properties, all which hinder the simplicity of applying health monitoring applications. This paper represents a summary work of combined experimental and analytical modeling that included data collection from a spin test experiment of a rotor disk addressing the aforementioned durability issues. It further covers presentation of results obtained from a finite element modeling study to characterize the structural durability of a cracked rotor as it relates to the experimental findings. The experimental data include blade tip clearance, blade tip timing and shaft displacement measurements. The tests were conducted at the NASA Glenn Research Center's Rotordynamics Laboratory, a high precision spin rig. The results are evaluated and examined to determine their significance on the development of a health monitoring system to pre-predict cracks and other anomalies and to assist in initiating a supplemental physics based fault prediction analytical model.

Mechanics of evolving thin film structures

NASA Astrophysics Data System (ADS)

Liang, Jim

In the Stranski-Krastanov system, the lattice mismatch between the film and the substrate causes the film to break into islands. During annealing, both the surface energy and the elastic energy drive the islands to coarsen. Motivated by several related studies, we suggest that stable islands should form when a stiff ceiling is placed at a small gap above the film. We show that the role of elasticity is reversed: with the ceiling, the total elastic energy stored in the system increases as the islands coarsen laterally. Consequently, the islands select an equilibrium size to minimize the combined elastic energy and surface energy. In lithographically-induced self-assembly, when a two-phase fluid confined between parallel substrates is subjected to an electric field, one phase can self-assemble into a triangular lattice of islands in another phase. We describe a theory of the stability of the island lattice. The islands select the equilibrium diameter to minimize the combined interface energy and electrostatic energy. Furthermore, we study compressed SiGe thin film islands fabricated on a glass layer, which itself lies on a silicon wafer. Upon annealing, the glass flows, and the islands relax. A small island relaxes by in-plane expansion. A large island, however, wrinkles at the center before the in-plane relaxation arrives. The wrinkles may cause significant tensile stress in the island, leading to fracture. We model the island by the von Karman plate theory and the glass layer by the Reynolds lubrication theory. Numerical simulations evolve the in-plane expansion and the wrinkles simultaneously. We determine the critical island size, below which in-plane expansion prevails over wrinkling. Finally, in devices that integrate dissimilar materials in small dimensions, crack extension in one material often accompanies inelastic deformation in another. We analyze a channel crack advancing in an elastic film under tension, while an underlayer creeps. We use a two-dimensional shear lag model to approximate the three-dimensional fracture process. Based on the computational results, we propose new experiments to measure fracture toughness and creep laws in small structures. Similarly, we study delayed crack initiation, steady crack growth, and transient crack growth when the underlayer is viscoelastic.

Snow fracture: From micro-cracking to global failure

NASA Astrophysics Data System (ADS)

Capelli, Achille; Reiweger, Ingrid; Schweizer, Jürg

2017-04-01

Slab avalanches are caused by a crack forming and propagating in a weak layer within the snow cover, which eventually causes the detachment of the overlying cohesive slab. The gradual damage process leading to the nucleation of the initial failure is still not entirely understood. Therefore, we studied the damage process preceding snow failure by analyzing the acoustic emissions (AE) generated by bond failure or micro-cracking. The AE allow studying the ongoing progressive failure in a non-destructive way. We performed fully load-controlled failure experiments on snow samples presenting a weak layer and recorded the generated AE. The size and frequency of the generated AE increased before failure revealing an acceleration of the damage process with increased size and frequency of damage and/or microscopic cracks. The AE energy was power-law distributed and the exponent (b-value) decreased approaching failure. The waiting time followed an exponential distribution with increasing exponential coefficient λ before failure. The decrease of the b-value and the increase of λ correspond to a change in the event distribution statistics indicating a transition from homogeneously distributed uncorrelated damage producing mostly small AE to localized damage, which cause larger correlated events which leads to brittle failure. We observed brittle failure for the fast experiment and a more ductile behavior for the slow experiments. This rate dependence was reflected also in the AE signature. In the slow experiments the b value and λ were almost constant, and the energy rate increase was moderate indicating that the damage process was in a stable state - suggesting the damage and healing processes to be balanced. On a shorter time scale, however, the AE parameters varied indicating that the damage process was not steady but consisted of a sum of small bursts. We assume that the bursts may have been generated by cascades of correlated micro-cracks caused by localization of stresses at a small scale. The healing process may then have prevented the self-organization of this small scale damage and, therefore, the total failure of the sample.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brickstad, B.; Bergman, M.

A computerized procedure has been developed that predicts the growth of an initial circumferential surface crack through a pipe and further on to failure. The crack growth mechanism can either be fatigue or stress corrosion. Consideration is taken to complex crack shapes and for the through-wall cracks, crack opening areas and leak rates are also calculated. The procedure is based on a large number of three-dimensional finite element calculations of cracked pipes. The results from these calculations are stored in a database from which the PC-program, denoted LBBPIPE, reads all necessary information. In this paper, a sensitivity analysis is presentedmore » for cracked pipes subjected to both stress corrosion and vibration fatigue.« less

Evaluation of a Small-Crack Monitoring System

NASA Technical Reports Server (NTRS)

Newman, John A.; Johnston, William M.

2010-01-01

A new system has been developed to obtain fatigue crack growth rate data from a series of images acquired during fatigue testing of specimens containing small surface cracks that initiate at highly-polished notches. The primary benefit associated with replica-based crack growth rate data methods is preserving a record of the crack configuration during the life of the specimen. Additionally, this system has the benefits of both reducing time and labor, and not requiring introduction of surface replica media into the crack. Fatigue crack growth rate data obtained using this new system are found to be in good agreement with similar results obtained from surface replicas.

Matrix fatigue crack development in a notched continuous fiber SCS-6/Ti-15-3 composite

NASA Technical Reports Server (NTRS)

Hillberry, B. M.; Johnson, W. S.

1990-01-01

In this study the extensive matrix fatigue cracking that has been observed in notched SCS-6/Ti-15-3 composites is investigated. Away from the notch uniform spacing of the fatigue cracks develops. Closer to the notch, fiber-matrix debonding which occurs increases the crack spacing. Crack spacing and debond length determined from shear-lag cylinder models compare favorably with experimental observations. Scanning electron microscope (SEM) fractography showed that the principal fatigue crack initiation occurred around the zero degree fibers. Interface failure in the 90 degree plies does not lead to the development of the primary fatigue cracking.

Matrix fatigue crack development in a notched continuous fiber SCS-6/Ti-15-3 composite

NASA Technical Reports Server (NTRS)

Hillberry, B. M.; Johnson, W. S.

1990-01-01

In this study the extensive matrix fatigue cracking that has been observed in notched SCS-6/Ti-15-3 composites is investigated. Away from the notch a uniform spacing of the fatigue cracks develops. Closer to the notch, fiber-matrix debonding which occurs increases the crack spacing. Crack spacing and debond length determined from shear-lag cylinder models compare favorably with experimental observations. Scanning electron microscope (SEM) fractography showed that the principal fatigue crack initiation occurred around the zero degree fibers. Interface failure in the 90 degree plies does not lead to the development of the primary fatigue cracking.

An investigation of pore cracking in titanium welds

NASA Astrophysics Data System (ADS)

Khaled, Z.

1994-06-01

Two welded Ti-6A1- 4V pressure vessels leaked prematurely in service. The leaks were caused by cracks emanating from weld porosity. The cracks originated during fabrication, with subsequent growth in serv-ice leading to the formation of the leak paths. Pore cracking is thought to be caused by a mechanism that involves both sustained- load and cyclic contributions, with the former being the more prominent. It is shown that the tendency for cracking is influenced by pore position and that pore size is not a deciding factor in that regard. The factors that govern pore cracking are discussed, and the possible role of inter-stitial embrittlement is assessed.

An investigation of pore cracking in titanium welds

NASA Astrophysics Data System (ADS)

Khaled, T.

1994-02-01

Two welded Ti-6A1-4V pressure vessels leaked prematurely in service. The leaks were caused by cracks emanating from weld porosity. The cracks originated during fabrication, with subsequent growth in service leading to the formation of the leak paths. Pore cracking is thought to be caused by a mechanism that involves both sustained-load and cyclic contributions, with the former being the more prominent. It is shown that the tendency for cracking is influenced by pore position and that pore size is not a deciding factor in that regard. The factors that govern pore cracking are discussed, and the possible role of interstitial embrittlement is assessed.

New specimen design for studying the growth of small fatigue cracks with surface acoustic waves

NASA Astrophysics Data System (ADS)

London, Blair

1985-08-01

The study of small surface fatigue cracks in AISI 4140 quenched and tempered steel by a nondestructive surface acoustic wave technique is summarized. A novel cantilevered bending, plate-type fatigue specimen is described that is compatible with the acoustic method. Small cracks are initiated from a 25-μm deep surface pit produced by an electrospark machine. The importance of studying these cracks which closely approximate naturally occurring fatigue cracks is briefly discussed.

Duplex precipitates and their effects on the room-temperature fracture behaviour of a NiAl-strengthened ferritic alloy

DOE PAGES

Sun, Zhiqian; Song, Gian; Ilavsky, Jan; ...

2015-03-23

Duplex precipitates are presented in a NiAl-strengthened ferritic alloy. They were characterized by the ultra-small angle X-ray scattering and transmission electron microscope. Fine cooling precipitates with the size of several to tens of nanometres harden the matrix considerably at room temperature. The cracks will likely to initiate from precipitates, and coalesce and propagate quickly through the matrix due to the excessive hardening effect of cooling precipitates, which lead to the premature fracture of NiAl-strengthened ferritic alloys.

Single-Cycle Versus Multicycle Proof Testing

NASA Technical Reports Server (NTRS)

Hudak, S. J., Jr.; Mcclung, R. C.; Bartlett, M. L.; Fitzgerald, J. H.; Russell, D. A.

1992-01-01

Report compares single-cycle with multiple-cycle mechanical-stress tests of parts under mechanical stresses. Objective of proof testing: to screen out gross manufacturing or material deficiencies and provide additional assurance of quality. Report concludes that changes in distribution of crack sizes during multicycle proof testing depend on initial distribution, number of cycles, relationship between resistance of material and elastic/plastic fracture-mechanics parameter, relationship between load control and displacement control, and magnitude of applied load or displacement. Whether single-cycle or multicycle testing used depends on shape, material, and technique of fabrication of components tested.

Progress on ultrasonic flaw sizing in turbine-engine rotor components: bore and web geometries

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rose, J.H.; Gray, T.A.; Thompson, R.B.

1983-01-01

The application of generic flaw-sizing techniques to specific components generally involves difficulties associated with geometrical complexity and simplifications arising from a knowledge of the expected flaw distribution. This paper is concerned with the case of ultrasonic flaw sizing in turbine-engine rotor components. The sizing of flat penny-shaped cracks in the web geometry discussed and new crack-sizing algorithms based on the Born and Kirchhoff approximations are introduced. Additionally, we propose a simple method for finding the size of a flat, penny-shaped crack given only the magnitude of the scattering amplitude. The bore geometry is discussed with primary emphasis on the cylindricalmore » focusing of the incident beam. Important questions which are addressed include the effects of diffraction and the position of the flaw with respect to the focal line. The appropriate deconvolution procedures to account for these effects are introduced. Generic features of the theory are compared with experiment. Finally, the effects of focused transducers on the Born inversion algorithm are discussed.« less

Transmit-receive eddy current probes for defect detection and sizing in steam generator tubes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Obrutsky, L.S.; Cecco, V.S.; Sullivan, S.P.

1997-02-01

Inspection of steam generator tubes in aging Nuclear Generating Stations is increasingly important. Defect detection and sizing, especially in defect prone areas such as the tubesheet, support plates and U-bend regions, are required to assess the fitness-for-service of the steam generators. Information about defect morphology is required to address operational integrity issues, i.e., risk of tube rupture, number of tubes at risk, consequential leakage. A major challenge continues to be the detection and sizing of circumferential cracks. Utilities around the world have experienced this type of tube failure. Conventional in-service inspection, performed with eddy current bobbin probes, is ineffectual inmore » detecting circumferential cracks in tubing. It has been demonstrated in CANDU steam generators, with deformation, magnetite and copper deposits that multi-channel probes with transmit-receive eddy current coils are superior to those using surface impedance coils. Transmit-receive probes have strong directional properties, permitting probe optimization according to crack orientation. They are less sensitive to lift-off noise and magnetite deposits and possess good discrimination to internal defects. A single pass C3 array transmit-receive probe developed by AECL can detect and size circumferential stress corrosion cracks as shallow as 40% through-wall. Since its first trial in 1992, it has been used routinely for steam generator in-service inspection of four CANDU plants, preventing unscheduled shutdowns due to leaking steam generator tubes. More recently, a need has surfaced for simultaneous detection of both circumferential and axial cracks. The C5 probe was designed to address this concern. It combines transmit-receive array probe technology for equal sensitivity to axial and circumferential cracks with a bobbin probe for historical reference. This paper will discuss the operating principles of transmit-receive probes, along with inspection results.« less

Characterization of Fatigue Crack-Inititation Facets in Relation to Lifetime Variablility in Ti-6Al-4V (Preprint)

DTIC Science & Technology

2011-07-01

in evaluation and design of materials for fracture critical applications. The material of interest in the present study was Ti-6Al-4V (Ti- 6 - 4 ...distribution unlimited. pertinent to fatigue crack-initiation in + titanium alloys and titanium alloys in general. The + titanium alloys, in particular Ti- 6 ...et al. [16] observed that subsurface crack initiation inTi- 6 -2- 4 - 6 occurred within a microtextured region in which the  phase was suitably oriented

Life prediction and constitutive behavior

NASA Technical Reports Server (NTRS)

Halford, G. R.

1983-01-01

One of the primary drivers that prompted the initiation of the hot section technology (HOST) program was the recognized need for improved cyclic durability of costly hot section components. All too frequently, fatigue in one form or another was directly responsible for the less than desired durability, and prospects for the future weren't going to improve unless a significant effort was mounted to increase our knowledge and understanding of the elements governing cyclic crack initiation and propagation lifetime. Certainly one of the important factors is the ability to perform accurate structural stress-strain analyses on a routine basis to determine the magnitudes of the localized stresses and strains since it is these localized conditions that govern the initiation and crack growth processes. Developing the ability to more accurately predict crack initiation lifetimes and cyclic crack growth rates for the complex loading conditions found in turbine engine hot sections is of course the ultimate goal of the life prediction research efforts. It has been found convenient to divide the research efforts into those dealing with nominally isotropic and anisotropic alloys; the latter for application to directionally solidified and single crystal turbine blades.

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

NASA Technical Reports Server (NTRS)

Forman, Royce G.; Zanganehgheshlaghi, Mohannad

2014-01-01

The research results described in this paper presents a new understanding of the behavior of fatigue crack growth in the threshold region. It is believed by some crack growth experts that the ASTM load shedding test method does not produce true or valid threshold properties. The concern involves the observed fanning of threshold region da/dN data plots for some materials in which the low R-ratio data fans out or away from the high R-ratio data. This data fanning or elevation of threshold values is obviously caused by an increase in crack closure in the low R-ratio tested specimens. This increase in crack closure is assumed by some investigators to be caused by a plastic wake on the crack surfaces that was created during the load shedding test phase. This study shows that the increase in crack closure is the result of an extensive occurrence of crack bifurcation behavior in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the particular fanning behavior in aluminum alloys is a function of intrinsic dislocation property of the materials and that the fanned data represents valid material properties. However, for corrosion sensitive steel alloys used in this study the fanning was caused by a build-up of iron oxide at the crack tip from fretting corrosion.

The use of COD and plastic instability in crack propagation and arrest in shells

NASA Technical Reports Server (NTRS)

Erdogan, F.; Ratwani, M.

1974-01-01

The initiation, growth, and possible arrest of fracture in cylindrical shells containing initial defects are dealt with. For those defects which may be approximated by a part-through semi-elliptic surface crack which is sufficiently shallow so that part of the net ligament in the plane of the crack is still elastic, the existing flat plate solution is modified to take into account the shell curvature effect as well as the effect of the thickness and the small scale plastic deformations. The problem of large defects is then considered under the assumptions that the defect may be approximated by a relatively deep meridional part-through surface crack and the net ligament through the shell wall is fully yielded. The results given are based on an 8th order bending theory of shallow shells using a conventional plastic strip model to account for the plastic deformations around the crack border.

Influence of microstructure on the fretting resistance of Al-Cu-Li alloys

NASA Astrophysics Data System (ADS)

Delacroix, Jessica; Cazottes, Sophie; Daniélou, Armelle; Fouvry, Siegfried; Buffiere, Jean-Yves

The resistance of two Al-Cu-Li alloys (2050 and 2196) to fretting has been investigated. For each material two heat treatments have been studied (T8 and low temperature ageing). Fretting tests with a cylinder-plane configuration have been performed in the partial slip regime. The results obtained show that the low temperature temper gives a better resistance to fretting crack initiation and propagation than the T8 temper for both alloys. The 3D shape of the fretting cracks has been observed by high resolution synchrotron X-ray tomography. Multiple initiation sites were observed below the contact. In their early stages of development, the fretting cracks grow approximately radially within the material leading to thumb nail cracks which eventually merge laterally. The difference in fretting resistance is analysed with respect to the 3D fracture surface of the fretting cracks in relation with the alloys precipitation state.

Fine characterization rock thermal damage by acoustic emission technique

NASA Astrophysics Data System (ADS)

Kong, Biao; Li, Zenghua; Wang, Enyuan

2018-02-01

This paper examines the differences in the thermal mechanical properties and acoustic emission (AE) characteristics during the deformation and fracture of rock under the action of continuous heating and after high-temperature treatment. Using AE 3D positioning technology, the development and evolution of the internal thermal cracks and the time domain of AE signals in rock were analyzed. High-temperature treatment causes thermal damage to rock. Under the action of continuous heating, the phase characteristics of AE time series correspond to the five stages of rock thermal deformation and fracture, respectively: the micro-defect development stage, the threshold interval of rock micro-cracks, the crack initiation stage, the crack propagation stage, and the crack multistage propagation evolution. When the initial crack propagates, the crack initiation of the rock causes the AE signal to produce a sudden mutation change. Mechanical fraction characteristics during rock uniaxial compression after temperature treatment indicated that the decrease rate of the rock compressive strength, wave velocity, and elastic modulus are relatively large during uniaxial compression tests after high-temperature treatment. During the deformation and fracture of rock under loading, there is faster growth of AE counts and AE events, indicating an increase in the speed of rock deformation and fracture under loading. AE counts show obvious changes during the latter loading stages, whereas AE events show obvious changes during the loading process. The results obtained are valuable for rock thermal stability detection and evaluation in actual underground engineering.

Failure mechanisms and lifetime prediction methodology for polybutylene pipe in water distribution system

NASA Astrophysics Data System (ADS)

Niu, Xiqun

Polybutylene (PB) is a semicrystalline thermoplastics. It has been widely used in potable water distribution piping system. However, field practice shows that failure occurs much earlier than the expected service lifetime. What are the causes and how to appropriately evaluate its lifetime motivate this study. In this thesis, three parts of work have been done. First is the understanding of PB, which includes material thermo and mechanical characterization, aging phenomena and notch sensitivity. The second part analyzes the applicability of the existing lifetime testing method for PB. It is shown that PB is an anomaly in terms of the temperature-lifetime relation because of the fracture mechanism transition across the testing temperature range. The third part is the development of the methodology of lifetime prediction for PB pipe. The fracture process of PB pipe consists of three stages, i.e., crack initiation, slow crack growth (SCG) and crack instability. The practical lifetime of PB pipe is primarily determined by the duration of the first two stages. The mechanism of crack initiation and the quantitative estimation of the time to crack initiation are studied by employing environment stress cracking technique. A fatigue slow crack growth testing method has been developed and applied in the study of SCG. By using Paris-Erdogan equation, a model is constructed to evaluate the time for SCG. As a result, the total lifetime is determined. Through this work, the failure mechanisms of PB pipe has been analyzed and the lifetime prediction methodology has been developed.

Nanoindentation cannot accurately predict the tensile strength of graphene or other 2D materials

NASA Astrophysics Data System (ADS)

Han, Jihoon; Pugno, Nicola M.; Ryu, Seunghwa

2015-09-01

Due to the difficulty of performing uniaxial tensile testing, the strengths of graphene and its grain boundaries have been measured in experiments by nanoindentation testing. From a series of molecular dynamics simulations, we find that the strength measured in uniaxial simulation and the strength estimated from the nanoindentation fracture force can differ significantly. Fracture in tensile loading occurs simultaneously with the onset of crack nucleation near 5-7 defects, while the graphene sheets often sustain the indentation loads after the crack initiation because the sharply concentrated stress near the tip does not give rise to enough driving force for further crack propagation. Due to the concentrated stress, strength estimation is sensitive to the indenter tip position along the grain boundaries. Also, it approaches the strength of pristine graphene if the tip is located slightly away from the grain boundary line. Our findings reveal the limitations of nanoindentation testing in quantifying the strength of graphene, and show that the loading-mode-specific failure mechanism must be taken into account in designing reliable devices from graphene and other technologically important 2D materials.Due to the difficulty of performing uniaxial tensile testing, the strengths of graphene and its grain boundaries have been measured in experiments by nanoindentation testing. From a series of molecular dynamics simulations, we find that the strength measured in uniaxial simulation and the strength estimated from the nanoindentation fracture force can differ significantly. Fracture in tensile loading occurs simultaneously with the onset of crack nucleation near 5-7 defects, while the graphene sheets often sustain the indentation loads after the crack initiation because the sharply concentrated stress near the tip does not give rise to enough driving force for further crack propagation. Due to the concentrated stress, strength estimation is sensitive to the indenter tip position along the grain boundaries. Also, it approaches the strength of pristine graphene if the tip is located slightly away from the grain boundary line. Our findings reveal the limitations of nanoindentation testing in quantifying the strength of graphene, and show that the loading-mode-specific failure mechanism must be taken into account in designing reliable devices from graphene and other technologically important 2D materials. Electronic ESI (ESI) available: Modelling of polycrystalline graphene, verification of loading speed, biaxial tensile simulations, comparison of stress distribution, size effects of indenter radius, force-deflection curves, and stability analysis of crack propagation. See DOI: 10.1039/c5nr04134a

Investigation of the ElectroPuls E3000 Test Machine for Fatigue Testing of Structural Materials

DTIC Science & Technology

2016-12-01

sharpening of the crack tip and deformation of a portion of the newly formed surface (the surface created during loading portion of the cycle) during...cracking process is that the size of the final plastic zone formed by pre-cracking can affect the crack growth rate in subsequent testing. To...similar. In other structural materials, such as aluminium , striations are often well-defined. Typically, fatigue striations on an aluminium fracture

Crack growth and fracture toughness of amorphous Li-Si anodes: Mechanisms and role of charging/discharging studied by atomistic simulations

NASA Astrophysics Data System (ADS)

Khosrownejad, S. M.; Curtin, W. A.

2017-10-01

Fracture is the main cause of degradation and capacity fading in lithiated silicon during cycling. Experiments on the fracture of lithiated silicon show conflicting results, and so mechanistic models can help interpret experiments and guide component design. Here, large-scale K-controlled atomistic simulations of crack propagation (R-curve KI vs. Δa) are performed at LixSi compositions x = 0.5 , 1.0 , 1.5 for as-quenched/relaxed samples and at x = 0.5 , 1.0 for samples created by discharging from higher Li compositions. In all cases, the fracture mechanism is void nucleation, growth, and coalescence. In as-quenched materials, with increasing Li content the plastic flow stress and elastic moduli decrease but void nucleation and growth happen at smaller stress, so that the initial fracture toughness KIc ≈ 1.0 MPa√{ m} decreases slightly but the initial fracture energy JIc ≈ 10.5J/m2 is similar. After 10 nm of crack growth, the fracture toughnesses increase and become similar at KIc ≈ 1.9 MPa√{ m} across all compositions. Plane-strain equi-biaxial expansion simulations of uncracked samples provide complementary information on void nucleation and growth. The simulations are interpreted within the framework of Gurson model for ductile fracture, which predicts JIc = ασy D where α ≃ 1 and D is the void spacing, and good agreement is found. In spite of flowing plastically, the fracture toughness of LixSi is low because voids nucleate within nano-sized distances ahead of the crack (D ≈ 1nm). Scaling simulation results to experimental conditions, reasonable agreement with experimentally-estimated fracture toughnesses is obtained. The discharging process facilitates void nucleation but decreases the flow stress (as shown previously), leading to enhanced fracture toughness at all levels of crack growth. Therefore, the fracture behavior of lithiated silicon at a given composition is not a material property but instead depends on the history of charging/discharging. These findings indicate that the mechanical behavior (flow and fracture) of lithiated Si must be interpreted within a fully rate- and history-dependent framework.

Crack healing in silicon nitride due to oxidation

NASA Technical Reports Server (NTRS)

Choi, Sung R.; Tikare, Veena; Pawlik, Ralph

1991-01-01

The crack healing behavior of a commercial, MgO-containing, hot pressed Si3N4 was studied as a function of temperature in oxidizing and inert annealing environments. Crack healing occurred at a temperature 800 C or higher due to oxidation regardless of crack size, which ranged from 100 microns (indentation crack) to 1.7 mm (SEPB precrack). The resulting strength and apparent fracture toughness increased at crack healing temperature by 100 percent and 300 percent, respectively. The oxide layer present in the crack plane was found to be highly fatigue resistant, indicating that the oxide is not solely silicate glass, but a mixture of glass, enstatite, and/or cristobalite that was insensitive to fatigue in a room temperature water environment.

Application of the bridged crack model for evaluation of materials repairing and self-healing

NASA Astrophysics Data System (ADS)

Perelmuter, M.

2017-12-01

The bridged crack model is used for analysis of repairing and self-healing of cracked structures. Material repairing is treated as insertions of external ligaments into cracks or placement of the reinforcing patches over cracks. Bonds destruction and regeneration at the crack bridged zone is evaluated by the thermo-fluctuation kinetic theory. The healing time is dependent on the chemical reaction rate of the healing agent, the crack size and the external loads. The decreasing of the stress intensity factors is used as the measure of the repairing and healing effects. The mathematical background of the problem solution is based on the methods of the singular integral-differential equations. The model can be used for the evaluation of composite materials durability.

40 CFR 60.103 - Standard for carbon monoxide.

Code of Federal Regulations, 2011 CFR

2011-07-01

... Refineries § 60.103 Standard for carbon monoxide. Each owner or operator of any fluid catalytic cracking unit... the fluid catalytic cracking unit catalyst regenerator will be operated, or 180 days after initial... discharge or cause the discharge into the atmosphere from any fluid catalytic cracking unit catalyst...

40 CFR 60.103 - Standard for carbon monoxide.

Code of Federal Regulations, 2010 CFR

2010-07-01

... Refineries § 60.103 Standard for carbon monoxide. Each owner or operator of any fluid catalytic cracking unit... the fluid catalytic cracking unit catalyst regenerator will be operated, or 180 days after initial... discharge or cause the discharge into the atmosphere from any fluid catalytic cracking unit catalyst...

Drying step optimization to obtain large-size transparent magnesium-aluminate spinel samples

NASA Astrophysics Data System (ADS)

Petit, Johan; Lallemant, Lucile

2017-05-01

In the transparent ceramics processing, the green body elaboration step is probably the most critical one. Among the known techniques, wet shaping processes are particularly interesting because they enable the particles to find an optimum position on their own. Nevertheless, the presence of water molecules leads to drying issues. During the water removal, its concentration gradient induces cracks limiting the sample size: laboratory samples are generally less damaged because of their small size but upscaling the samples for industrial applications lead to an increasing cracking probability. Thanks to the drying step optimization, large size spinel samples were obtained.

The effect of cathodic polarization on the corrosion fatigue behavior of a precipitation hardened aluminum alloy

NASA Astrophysics Data System (ADS)

Smith, E. F.; Duquette, D. J.

1986-02-01

Fatigue experiments were conducted on polycrystalline and monocrystalline samples of a high purity Al, 5.5 wt pct Zn, 2.5 wt pct Mg, 1.5 wt pct Cu alloy in the peak-hardened heat treatment condition. These experiments were conducted in dry laboratory air and in 0.5 N NaCl solutions at the corrosion potential and at applied potentials cathodic to the corrosion potential. It has been shown that saline solutions severely reduce the fatigue resistance of the alloy, resulting in considerable amounts of intergranular crack initiation and propagation under freely corroding conditions for polycrystalline samples. Applied cathodic potentials resulted in still larger decreases in fatigue resistance and, for poly crystals, increases in the degree of transgranular crack initiation and propagation. Increasing amounts of intergranular cracking were observed when applied cyclic stresses were reduced (longer test times). The characteristics of cracking, combined with results obtained on tensile tests of deformed and hydrogen charged samples, suggest that environmental cracking of these alloys is associated with a form of hydrogen embrittlement of the process zones of growing cracks. Further, it is suggested that stress corrosion cracking and corrosion fatigue of these alloys occurs by essentially the same mechanism, but that the often observed transgranular cracking under cyclic loading conditions occurs due to enhanced hydrogen transport and/or concentrations associated with mobile dislocations at growing crack tips.

Characterization of Environmentally Assisted Cracking for Design: State of the Art.

DTIC Science & Technology

1982-01-01

Barsom, J.M., Effect of cyclic stress form on corrosion fatigue crack propagation below Kiscc in a high yield strength steel , in Corrosion Fatigue... Effect of Prestressing on the Stress Corrosion Resistance of Two High Strength Steels , Boeing Document D6-25275, Boeing Company, Seattle, Washington...sT’e Residual stress Crack growth High strength steel Seawater Crack initiation Hydrogen embrittlement Stress corrosion Design Linear elastic fracture

Use of Slow Strain Rate Tensile Testing to Assess the Ability of Several Superalloys to Resist Environmentally-Assisted Intergranular Cracking

NASA Technical Reports Server (NTRS)

Gabb, Timothy P.; Telesman, Jack; Banik, Anthony; McDevitt, Erin

2014-01-01

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720(TradeMark) ATI 718Plus(Registered TradeMark) alloy, Haynes 282(Trademark), and Inconel 740(TradeMark) Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Characterization of Pore Defects and Fatigue Cracks in Die Cast AM60 Using 3D X-ray Computed Tomography

NASA Astrophysics Data System (ADS)

Yang, Zhuofei; Kang, Jidong; Wilkinson, David S.

2015-08-01

AM60 high pressure die castings have been used in automobile applications to reduce the weight of vehicles. However, the pore defects that are inherent in die casting may negatively affect mechanical properties, especially the fatigue properties. Here we have studied damage ( e.g., pore defects, fatigue cracks) during strained-controlled fatigue using 3-dimensional X-ray computed tomography (XCT). The fatigue test was interrupted every 2000 cycles and the specimen was removed to be scanned using a desktop micro-CT system. XCT reveals pore defects, cracks, and fracture surfaces. The results show that pores can be accurately measured and modeled in 3D. Defect bands are found to be made of pores under 50 µm (based on volume-equivalent sphere diameter). Larger pores are randomly distributed in the region between the defect bands. Observation of fatigue cracks by XCT is performed in three ways such that the 3D model gives the best illustration of crack-porosity interaction while the other two methods, with the cracks being viewed on transverse or longitudinal cross sections, have better detectability on crack initiation and crack tip observation. XCT is also of value in failure analysis on fracture surfaces. By assessing XCT data during fatigue testing and observing fracture surfaces on a 3D model, a better understanding on the crack initiation, crack-porosity interaction, and the morphology of fracture surface is achieved.