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At least 217 records · Page 12

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NASA NTRS2018

Implementation of J-A Methodology Elastic-Plastic Crack Instability Analysis Capability into the WARP-3D Code

Characterization of the near crack-tip stress/strain fields is the foundation of fracture mechanics. The description of the near tip stress field and the prediction of when fracture occurs is well established for brittle materials that exhibit linear elastic behavior. However, in ductile materials or conditions that violate linear elastic assumptions (Aluminum alloys, Al 2024-T3, Al 2024- T351 etc.), the elastic-plastic crack-tip stress fields are characterized by the Hutchison-Rice-Rosengren (HRR) field. The J-integral is commonly used to characterize amplitude of the HRR field under elastic-plastic conditions. The J-integral has been demonstrated for crack-tip fields that are under high constraint conditions (i.e., small-scale plasticity where the J-dominance is maintained). However, as the external load increases, yielding changes from small- to largescale plasticity and usually a loss of constraint (i.e., reduction in the triaxial stress field along the crack front). The loss of constraint leads to the deviation of the crack-tip stress fields from that given by the HRR field. Hence, the J-dominance will be gradually lost and additional parameter(s) are required to quantify the crack-tip stress fields and predict fracture behavior. The assessment objectives were to: 1) implement a two-parameter (i.e., J-A) fracture criterion into an elastic-plastic three-dimensional (3D) finite element analysis (FEA), 2) validate the implementation by comparison with the A parameter from literature data, 3) conduct material characterization tests to quantify the material behavior and provide fracture data for validation of the J-A fracture criteria, and (4) perform evaluations to establish if the J-A criteria can be used to predict fracture in a ductile metallic material (e.g., aluminum alloys). The A parameter in these criteria is the second parameter in a three-term elastic-plastic asymptotic expansion of the neartip stress behavior. A series of extensive FEAs were performed using WARP3D software package to obtain solutions for the A parameter for different specimen configurations. The methodology needed for the estimation of the A parameter in the asymptotic expansion was developed and implemented using Matlab®. A user material (UMAT) routine was used to model the material stress-strain response using a Ramberg-Osgood power law with a hardening exponent (n) and a material coefficient (alpha). This UMAT routine was successfully implemented in WARP3D software and validated through comparison with the experimental data. Three configurations were extracted from published results: 1) center cracked plate (CCP), 2) single edge-cracked plate (SECP), and 3) double edge-cracked plate (DECP). These configurations and four other configurations (three-hole tension (THT)), three-point bend (3PTB), three-hole compact tension (3PCT), and compact tension (CT)) were analyzed to verify the methodology that was developed and implemented into WARP3D. Solutions of the A parameter were obtained for remote tension loading conditions that started with small-scale yielding and continued into the large-scale plasticity regime. The results indicate that the methodology developed can be used to calculate the elastic-plastic J-A parameters for test specimens with a range of crack geometries, material strain hardening behaviors, and loading conditions. The J-A parameters were implemented as fracture criteria and used to predict the test results. For comparison, other fracture criteria were used to predict the same test results. Major findings include: The A constraint parameter A varies with specimen type and applied load thus accurate determination is crucial in predicting the failure load, and the A parameter is asymptotic as the failure load is approached, making an accurate determination difficult (i.e., small differences in the A parameter can cause large variations in failure load) for materials exhibiting elastic-plastic behavior. The failure predictions from J-A methodology were more accurate than the traditionally used KC and J methods, and have comparable scatter to that observed when using the crack-tip opening angle (CTOA) method. However, the J-A methodology requires considerable effort (expertise level and labor) to implement and to evaluate the A parameter for different specimen types and materials, or to apply this methodology to part-through crack (e.g., 3D problems) structural applications.

Hamm, Kenneth R., Jr.↗

DOE OSTI2021

Seawater sea-sand engineered/strain-hardening cementitious composites (ECC/SHCC): Assessment and modeling of crack characteristics

Highlights: • A probabilistic model was proposed to model the crack width evolution of SS-ECC at different strain levels. • The Weibull distribution fit the crack width distribution better than the log-normal distribution. • A 5-D representation was proposed to assess the SS-ECC by considering both cracking and mechanical performance. • Larger sea-sand size and lower fiber dosage led to larger crack widths in SS-ECC under the same tensile strain. • 18-mm PE fiber led to larger crack widths in SS-ECC at strain >2%, due to a large fraction of fiber rupture. Seawater sea-sand Engineered Cementitious Composites (SS-ECC) is a new version of ECC for marine constructions facing the scarcity of freshwater and river/manufactured sand. This study aims to assess and model the crack characteristics of SS-ECC, which are critical for its applications with non-corrosive reinforcements. The influence of sea-sand size, fiber length and fiber dosage on the crack characteristics of SS-ECC was explored. A five-dimensional representation was proposed to assess the overall performance of SS-ECC, by comprehensively considering both the crack characteristics (i.e., crack width and its variation) and the mechanical properties (i.e., compressive and tensile properties). A probabilistic model was also proposed to describe the stochastic nature and evolution of crack width, and it can be used to estimate the critical tensile strain on SS-ECC for a given crack-width limit and cumulative probability. The findings and proposed methods can facilitate the design of SS-ECC in marine and coastal structures.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Nonlinear modeling and performance analysis of cracked beam microgyroscopes

Cracks constitute a common structural defect in microelectromechanical systems that may arise during manufacturing, mechanical fatigue, or shock loading. Areas weakened by cracks increase the flexibility of the microstructure. Furthermore, depending on the crack severity, the increased flexibility can cause dramatic changes in the static and dynamic behaviors of electrically actuated MEMS. In this study, a numerical investigation of the depth and location of multiple edge cracks on the performance of beam microgyroscopes is conducted. Applying the Griffith strain energy release theorem for an edge crack, the vibrational characteristics of microgyroscopes with multiple cracks including the static deflection, natural frequencies, and mode shapes are studied analytically. Then, the differential quadrature method is employed to model the nonlinear dynamic behaviors of the cracked gyroscope system. Cracks initiated along the driving or sensing directions of the microgyroscope are found to have differing effects on its nonlinear dynamic response. This numerical study reveals that the onset of severe single cracks or a series of multiple cracks can significantly affect the sensitivity of the microgyroscope to base rotations and therefore leads to a degradation in the performance of the damaged MEMS sensor. This study also shows that a potential design approach for broadband microgyroscope systems manufactured with cracks can be proposed.

42 ENGINEERING↗

DOE OSTI2021

Crack nucleation at forging flaws studied by non-local peridynamics simulations

We present a computational study and framework that allows us to study and understand the crack nucleation process from forging flaws. Forging flaws may be present in large steel rotor components commonly used for rotating power generation equipment including gas turbines, electrical generators, and steam turbines. The service life of these components is often limited by crack nucleation and subsequent growth from such forging flaws, which frequently exhibit themselves as non-metallic oxide inclusions. The fatigue crack growth process can be described by established engineering fracture mechanics methods. However, the initial crack nucleation process from a forging flaw is challenging for traditional engineering methods to quantify as it depends on the details of the flaw, including flaw morphology. We adopt the peridynamics method to describe and study this crack nucleation process. For a specific industrial gas turbine rotor steel, we present how we integrate and fit commonly known base material property data such as elastic properties, yield strength, and S-N curves, as well as fatigue crack growth data into a peridynamic model. The obtained model is then utilized in a series of high-performance two-dimensional peridynamic simulations to study the crack nucleation process from forging flaws for ambient and elevated temperatures in a rectangular simulation cell specimen. The simulations reveal an initial local nucleation at multiple small oxide inclusions followed by micro-crack propagation, arrest, coalescence, and eventual emergence of a dominant micro-crack that governs the crack nucleation process. The dependence on temperature and density of oxide inclusions of both the details of the microscopic processes and cycles to crack nucleation is also observed. The results are compared with fatigue experiments performed with specimens containing forging flaws of the same rotor steel.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Separate-Effects Tests for Studying Temperature-Gradient-Driven Cracking in UO 2 Pellets

We report a variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, higher centerline temperatures, and localized stress in cladding, all of which impact fuel performance. It is important to experimentally characterize the thermal and mechanical behavior in the pellet before and after cracking to improve cracking models in fuel performance codes. However, in-reactor observation and measurement of cracking is very challenging due to the harsh environment and logistics. Recently, an experimental pellet cracking test stand was developed for separate effects testing of normal operations and accident temperature conditions, using thermal imaging to capture the pellet surface temperature for evaluation of thermal stresses and optical imaging to capture the evolution of cracking in real time. Experiments were performed using depleted uranium dioxide (UO 2 ) pellets, which are useful for collecting data valuable for development and validation of cracking models. A combination of induction and resistance heating was used to create an average temperature gradient of 236°C/cm and 193°C/cm before and after cracking respectively. Characterization of the pellets were done before as well as after cracking. The cracking patterns are somewhat different than those expected in a typical reactor because of the differences in thermal conditions and pellet microstructure. However, if the actual conditions of these experiments are reproduced in computational models, these out-of-pile tests on UO 2 pellets provide relevant data for modeling purposes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Quantitative analysis of three-dimensional fatigue crack path selection in Mg alloy WE43 using high-energy X-ray diffraction microscopy

Fatigue short-cracks in Mg alloys display complex growth behavior due to high plastic anisotropy and crack path dependence on local microstructural features. In this study, the three-dimensional crystallography of short-crack paths in Mg alloy WE43 was characterized by mapping near-field high-energy X-ray diffraction microscopy (HEDM) reconstructed grain maps to high-resolution X-ray CT reconstructions of the fracture surfaces in the crack initiation and short-crack growth regions of six ultrasonic fatigue specimens. Crack–grain–boundary intersections were analyzed at 81 locations across the six crack paths. The basal intragranular, non-basal intragranular, or intergranular character of short-crack growth following each boundary intersection was correlated to crystallographic and geometric parameters of the trailing and leading grains, three-dimensional grain boundary plane, and advancing crack front. The results indicate that crack paths are dependent on the combined crystallographic and geometric character of the local microstructure, and crack path prediction can be improved by use of dimensionality reduction on subsets of high-linear-correlation microstructural parameters.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Review of modelling small-crack behavior and fatigue-life predictions for aluminum alloys

The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic-zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic-zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.

CRACK CLOSURE MODELLING↗

DOE OSTI2020

Residually Stressed Bimaterial Beam Specimen for Measuring Environmentally Assisted Crack Growth

Background: Subcritical crack growth can occur in a brittle material when the stress intensity factor is smaller than the fracture toughness if an oxidizing agent (such as water) is present at the crack tip. Objective: Here we present a novel bi-material beam specimen which can measure environmentally assisted crack growth rates. The specimen is “self-loaded” by residual stress and requires no external loading. Methods: Two materials with different coefficient of thermal expansion are diffusion bonded at high temperature. After cooling to room temperature a subcritical crack is driven by thermal residual stresses. A finite element model is used to design the specimen geometry in terms of material properties in order to achieve the desired crack tip driving force. Results: The specimen is designed so that the crack driving force decreases as the crack extends, thus enabling the measurement of the crack velocity versus driving force relationship with a single test. The method is demonstrated by measuring slow crack growth data in soda lime silicate glass and validated by comparison to previously published data. Conclusions: The self-loaded nature of the specimen makes it ideal for measuring the very low crack velocities needed to predict brittle failure at long lifetimes.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Fatigue-Crack Detection and Monitoring through the Scattered-Wave Two-Dimensional Cross-Correlation Imaging Method Using Piezoelectric Transducers

Piezoelectric transducers are convenient enablers for generating and receiving Lamb waves for damage detection. Fatigue cracks are one of the most common causes for the failure of metallic structures. Increasing emphasis on the integrity of critical structures creates an urgent need to monitor structures and to detect cracks at an early stage to prevent catastrophic failures. This paper presents a two-dimensional (2D) cross-correlation imaging technique that can not only detect a fatigue crack but can also precisely image the fatigue cracks in metallic structures. The imaging method was based on the cross-correlation algorithm that uses incident waves and the crack-scattered waves of all directions to generate the crack image. Fatigue testing for crack generation was then conducted in both an aluminum plate and a stainless-steel plate. Piezoelectric wafer transducer was used to actuate the interrogating Lamb wave. To obtain the scattered waves as well as the incident waves, a scanning laser Doppler vibrometer was adopted for acquiring time-space multidimensional wavefield, followed with frequency-wavenumber processing. The proof-of-concept study was conducted in an aluminum plate with a hairline fatigue crack. A frequency-wavenumber filtering method was used to obtain the incident wave and the scattered wave wavefields for the cross-correlation imaging. After this, the imaging method was applied to evaluate cracks on a stainless-steel plate generated during fatigue loading tests. The presented imaging method showed successful inspection and quantification results of the crack and its growth.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Numerical and Analytical Modeling of the Effect of Cracks on the Self-Inductance of a COTS YJ-41003-TC Toroid

COTS inductors and transformers often contain partial cracks whose effect on inductance, a key performance parameter, have not been carefully studied. In this report, the effects of both partial and complete cracks on the self-inductance of a 100 turn square cross section COTS YJ-41003-TC toroid comprised of J Material was comprehensively investigated using both analytically derived closed form expressions and 3D computational techniques employing commercial codes. Both partial (half-penny) and complete (air gap) cracks of 10 and 25 μm were investigated. The crack is defined as the physical distance between two faces of the toroid's magnetic core, such that the surface normal of either face is along the Φ-direction, in alignment with the B-field. For the purposes of validation, two different approaches were incorporated for both the analytical and numerical models. The two analytical methods are comprised of a first principles approach based on the physics of electromagnetics, as well as linear circuit theory. The former directly utilizes the integral form of Maxwell's equations while the latter exploits the interchangeable relationship between electric and magnetic circuits. Validation within the computational scheme is realized through a code-to-code comparison between commercial solvers, COMSOL Multiphysics and CST, with the former employing the Finite Element Method (FEM) and the latter the Finite Difference Time Domain (FDTD) technique. Sound agreement between all four methods (ie., two analytical and two numerical) is observed, with results indicating that only a perturbation in self-inductance occurs for the half-penny cracks, while a substantial reduction takes place for the case of complete cracks. It is important to note that even though a static μ r is applied, representing the linear region of the BH curve (based on manufacturer specifications), the complete crack results still place a lower conservative bound on the inductance. This follows from the fact that even in the case of a half-penny crack, if the magnetic core portion of the crack approaches saturation, the crack begins to behave like an air gap, or complete crack. When an air gap is introduced into a magnetic core, a substantial reduction in inductance can occur due to the significant difference in permeabilities between the two mediums (ie., μ core >> μ air ). The once intact bulk magnetic core of the toroid essentially begins to behave like an air core.

36 MATERIALS SCIENCE↗

NASA NTRS1974

A finite element analysis of fatigue crack closure

Experiments have shown that fatigue cracks close at positive loads during constant-amplitude load cycling. The crack-closure phenomenon is caused by residual plastic deformations remaining in the wake of an advancing crack tip. The present paper is concerned with the application of a two-dimensional, nonlinear, finite-element analysis for predicting crack-closure and crack-opening stresses during cyclic loading. A two-dimensional finite-element computer program, which accounts for both elastic-plastic material behavior and changing boundary conditions associated with crack extension and intermittent contact of the crack surfaces under cyclic loading, has been developed. An efficient technique to account for changing boundary conditions was also incorporated into the nonlinear analysis program. This program was subsequently used to study crack extension and crack closure under constant-amplitude and two-level block loading. The calculated crack-closure and crack-opening stresses were qualitatively consistent with experimental observations.

Newman, J. C., Jr.↗

NASA NTRS1981

Application of the line-spring model to a cylindrical shell containing a circumferential or axial part-through crack

An approximate solution was obtained for a cylindrical shell containing a part-through surface crack. It was assumed that the shell contains a circumferential or axial semi-elliptic internal or external surface crack and was subjected to a uniform membrane loading or a uniform bending moment away from the crack region. A Reissner type theory was used to account for the effects of the transverse shear deformations. The stress intensity factor at the deepest penetration point of the crack was tabulated for bending and membrane loading by varying three dimensionless length parameters of the problem formed from the shell radius, the shell thickness, the crack length, and the crack depth. The upper bounds of the stress intensity factors are provided by the results of the elasticity solution obtained from the axisymmetric crack problem for the circumferential crack, and that found from the plane strain problem for a circular ring having a radial crack for the axial crack. The line-spring model gives the expected results in comparison with the elasticity solutions. Results also compare well with the existing finite element solution of the pressurized cylinder containing an internal semi-elliptic surface crack.

Delale, F.↗

NASA NTRS1984

On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant-amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant-amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In each case the marker loading was selected so as to have minimal influence on the growth rate under the primary loading. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information.

Swain, M. H.↗

NASA NTRS1988

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

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.

Newman, J. C., Jr.↗

NASA NTRS1991

The surface and through crack problems in layered orthotropic plates

An analytical method is developed for a relatively accurate calculation of Stress Intensity Factors in a laminated orthotropic plate containing a through or part-through crack. The laminated plate is assumed to be under bending or membrane loading and the mode 1 problem is considered. First three transverse shear deformation plate theories (Mindlin's displacement based first-order theory, Reissner's stress-based first-order theory, and a simple-higher order theory due to Reddy) are reviewed and examined for homogeneous, laminated and heterogeneous orthotropic plates. Based on a general linear laminated plate theory, a method by which the stress intensity factors can be obtained in orthotropic laminated and heterogeneous plates with a through crack is developed. Examples are given for both symmetrically and unsymmetrically laminated plates and the effects of various material properties on the stress intensity factors are studied. In order to implement the line-spring model which is used later to study the surface crack problem, the corresponding plane elasticity problem of a two-bonded orthotropic plated containing a crack perpendicular to the interface is also considered. Three different crack profiles: an internal crack, an edge crack, and a crack terminating at the interface are considered. The effect of the different material combinations, geometries, and material orthotropy on the stress intensity factors and on the power of stress singularity for a crack terminating at the interface is fully examined. The Line Spring model of Rice and Levy is used for the part-through crack problem. The surface crack is assumed to lie in one of the two-layered laminated orthotropic plates due to the limitation of the available plane strain results. All problems considered are of the mixed boundary value type and are reduced to Cauchy type of singular integral equations which are then solved numerically.

Erdogan, Fazil↗

NASA NTRS1994

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

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.

Dawicke, D. S.↗

NASA NTRS1994

Near tip stress and strain fields for short elastic cracks

Recent experimental fatigue crack growth studies have concluded an apparent anomalous behavior of short cracks. To investigate the reasons for this unexpected behavior, the present paper focuses on identifying the crack length circumstances under which the requirements for a single parameter (K(sub I) or delta K(sub I) if cyclic loading is considered) characterization are violated. Furthermore, an additional quantity, the T stress, as introduced by Rice, and the related biaxiality ratio, B, are calculated for several crack lengths and two configurations, the single-edge-cracked and the centrally-cracked specimen. It is postulated that a two-parameter characterization by K and T (or B) is needed for the adequate description of the stress and strain field around a short crack. To further verify the validity of this postulate, the influence of the third term of the Williams series on the stress, strain and displacement fields around the crack tip and in particular on the B parameter is also examined. It is found that the biaxiality ratio would be more negative if the third term effects are included in both geometries. The study is conducted using the finite element method with linearly elastic material and isoparametric elements and axial (mode I) loading. Moreover, it is clearly shown that it is not proper to postulate the crack size limits for 'short crack' behavior as a normalized ratio with the specimen width, a/w; it should instead be stated as an absolute, or normalized with respect to a small characteristic dimension such as the grain size. Finally, implications regarding the prediction of cyclic (fatigue) growth of short cracks are discussed.

Soediono, A. H.↗

NASA NTRS1994

A Review Of Modelling Small-Crack Behavior And Fatigue-Life Predictions For Aluminum Alloys

The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.

Newman, J. C., Jr.↗