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NASA NTRS1987

Stochastic and fractal analysis of fracture trajectories

Analyses of fracture trajectories are used to investigate structures that fall between 'micro' and 'macro' scales. It was shown that fracture trajectories belong to the class of nonstationary processes. It was also found that correlation distance, which may be related to a characteristic size of a fracture process, increases with crack length. An assemblage of crack trajectory processes may be considered as a diffusive process. Chudnovsky (1981-1985) introduced a 'crack diffusion coefficient' d which reflects the ability of the material to deviate the crack trajectory from the most energetically efficient path and thus links the material toughness to its structure. For the set of fracture trajectories in AISI 304 steel, d was found to be equal to 1.04 microns. The fractal dimension D for the same set of trajectories was found to be 1.133.

Bessendorf, Michael H.↗

NASA NTRS1986

Fracture mechanics

The application of fracture mechanics to the design of ceramic structures will require the precise measurement of crack growth and fracture resistance of these materials over their entire range of anticipated service temperatures and standardized test methods for making such measurements. The development of a standard test for measuring the plane strain fracture toughness is sought. Stress intensity factor coefficients were determined for three varieties of chevron-notch specimens, and fracture toughness measurements were made on silicon nitrides, silicon carbides, and aluminum oxides to assess the performance of each specimen variety. It was determined that silicon nitride and silicon carbides have flat crack growth resistance curves, but aluminum oxide does not. Additionally, batch-to-batch differences were noticed for the aluminum oxide. Experiments are continuing to explain the rising crack growth resistance and batch-to-batch variations for the aluminum oxide.

Shannon, John L., Jr.↗

NASA NTRS1989

Fracture toughness of SiC/Al metal matrix composite

An experimental study was conducted to evaluate fracture toughness of SiC/Al metal matrix composite (MMC). The material was a 12.7 mm thick extrusion of 6061-T6 aluminum alloy with 40 v/o SiC particulates. Specimen configuration and test procedure conformed to ASTM E399 Standard for compact specimens. It was found that special procedures were necessary to obtain fatigue cracks of controlled lengths in the preparation of precracked specimens for the MMC material. Fatigue loading with both minimum and maximum loads in compression was used to start the precrack. The initial precracking would stop by self-arrest. Afterwards, the precrack could be safely extended to the desired length by additional cyclic tensile loading. Test results met practically all the E399 criteria for the calculation of plane strain fracture toughness of the material. A valid K sub IC value of the SiC/Al composite was established as K sub IC = 8.9 MPa square root of m. The threshold stress intensity under which crack would cease to grow in the material was estimated as delta K sub th = 2MPa square root of m for R = 0.09 using the fatigue precracking data. Fractographic examinations show that failure occurred by the micromechanism involved with plastic deformation although the specimens broke by brittle fracture. The effect of precracking by cyclic loading in compression on fracture toughness is included in the discussion.

Flom, Yury↗

NASA NTRS1988

Concepts for interrelating ultrasonic attenuation, microstructure, and fracture toughness in polycrystalline solids

Conceptual models are advanced for explaining and predicting empirical correlations found between ultrasonic measurements and fracture toughness of polycrystalline solids. The models lead to insights concerning microstructural factors governing fracture processes and associated stress wave interactions. Analysis of the empirical correlations suggested by the models indicate that, in addition to grain size and shape, grain boundary reflections, elastic anisotropy, and dislocation damping are factors that underlie both fracture toughness and ultrasonic attenuation. One outcome is that ultrasonic attenuation can predict the size of crack blunting or process zones that develop in the vicinity of active cracks in metals. This forms a basis for ultrasonic ranking according to variations in fracture toughness.

Vary, A.↗

NASA NTRS1989

A nonlinear high temperature fracture mechanics basis for strainrange partitioning

A direct link was established between Strainrange Partitioning (SRP) and high temperature fracture mechanics by deriving the general SRP inelastic strain range versus cyclic life relationships from high temperature, nonlinear, fracture mechanics considerations. The derived SRP life relationships are in reasonable agreement based on the experience of the SRP behavior of many high temperature alloys. In addition, fracture mechanics has served as a basis for derivation of the Ductility-Normalized SRP life equations, as well as for examination of SRP relations that are applicable to thermal fatigue life prediction. Areas of additional links between nonlinear fracture mechanics and SRP were identified for future exploration. These include effects of multiaxiality as well as low strain, nominally elastic, long life creep fatigue interaction.

Kitamura, Takayuki↗

NASA NTRS1990

The effect of hydrogen and microstructure on the deformation and fracture behavior of a single crystal nickel-base superalloy

A study was conducted on the effects of internal hydrogen and microstructure on the deformation and fracture of a single crystal nickel-base superalloy. In particular, room temperature plane strain fracture toughness and tensile tests were performed on hydrogen-free and hydrogen charged samples of PWA 1480. The role of microstructure was incorporated by varying the levels of porosity and eutectic gamma/gamma prime through hot isostatic pressing and heat treatment. The room temperature behavior of PWA 1480 was unusual because precipitate shearing was not the primary deformation mechanism at all strains. At strains over 1 percent, dislocations were trapped in the gamma matrix and an attempt was made to relate this behavior to compositional differences between PWA 1480 and other superalloys. Another unique feature of the tensile behavior was cleavage of the eutectic gamma/gamma prime, which is believed to initiate the failure process. Fracture occurred on (111) planes and is likely a result of shear localization along these planes. Elimination of the eutectic gamma/gamma prime greatly improved the tensile ductility, but pososity had no effect on tensile properties. Large quantities of hydrogen (1.74 at. percent) were gas-phase charged into the material, but surprisingly this was not a function of the amount of porosity or eutectic gamma/gamma prime present. Desorption experiments suggest that the vast majority of hydrogen is at reversible lattice trapping sites. This large, uniform concentration of hydrogen dramatically reduced the tensile strain to failure, but only slightly affected the reduction in area. Available hydrogen embrittlement models were examined in light of these results and it was found that the hydrogen enhanced localized plasticity model can explain much of the tensile behavior. K(IC) fracture toughness tests were conducted, but it was necessary to also perform J(IC) tests to provide valid data.

Walston, William S.↗

NASA NTRS1990

Hydrogen induced fracture characteristics of single crystal nickel-based superalloys

A stereoscopic method for use with x ray energy dispersive spectroscopy of rough surfaces was adapted and applied to the fracture surfaces single crystals of PWA 1480E to permit rapid orientation determinations of small cleavage planes. The method uses a mathematical treatment of stereo pair photomicrographs to measure the angle between the electron beam and the surface normal. One reference crystal orientation corresponding to the electron beam direction (crystal growth direction) is required to perform this trace analysis. The microstructure of PWA 1480E was characterized before fracture analysis was performed. The fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was studied. The hydrogen-induced fracture behavior of single crystals of the PWA 1480E nickel-based superalloy was also studied. In order to understand the temperature dependence of hydrogen-induced embrittlement, notched single crystals with three different crystal growth orientations near zone axes (100), (110), and (111) were tensile tested at 871 C (1600 F) in both helium and hydrogen atmospheres at 34 MPa. Results and conclusions are given.

Chen, Po-Shou↗

NASA NTRS1990

Thermal stresses, differential subsidence, and flexure at oceanic fracture zones

Geosat geoid undulations over four Pacific fracture zones have been analyzed. After correcting for the isostatic thermal edge effect, the amplitudes of the residuals are shown to be proportional to the age offset. The shape of the residuals seems to broaden with increasing age. Both geoid anomalies and available ship bathymetry data suggest that slip must sometimes occur on the main fracture zone or secondary faults. Existing models for flexure at fracture zones cannot explain the observed anomalies. A combination model accounting for slip and including flexure from thermal stresses and differential subsidence is presented. This model accounts for lateral variations in flexural rigidity from brittle and ductile yielding due to both thermal and flexural stresses and explains both the amplitudes and the shape of the anomalies along each fracture zone. The best fitting models have mechanical plate thicknesses that are described by the depth to the 600-700 C isotherms.

Wessel, Pal↗

NASA NTRS1989

Fracture toughness in SiC/Al composite material

Crack initiation fracture toughness does not depend on SiC particle size. Crack growth fracture toughness increases as the size of the SiC particle increases. The fracture process is confined to a very narrow band and takes place within the matrix. In the case of composite reinforced with SiC particles of 20 microns and above, fracture of SiC begins to dominate. The matrix is influenced by a triaxial tension in the matrix and a high density of dislocations generated at SiC/Al interfaces due to the difference in coefficient of thermal expansion between SiC and the Al matrix.

Flom, Y.↗

NASA NTRS1989

Fracture toughness of SiC/Al metal matrix composite

Flom, Yury↗

NASA NTRS1990

Load biaxiality and fracture - Synthesis and summary

The question of load biaxiality strongly affecting almost all of the characteristics of brittle fracture behavior of a cracked body is investigated. Results of research published piecemeal over the years by the authors have shown that the stress and displacement fields, the elastic strain energy density, and the maximum shear stress near the crack tip are all altered by loads applied parallel to the crack, as are the angle of initial crack extension, the strain energy of the entire body, the fracture load, and the rate of fatigue crack growth. A synthesis and summary of this research is presented showing the shortcomings inherent in both Griffith's global energy rate theory for crack instability and Irwin's local crack-tip stress intensity theory for fracture toughness. In both theories only the tensile load perpendicular to the crack influences fracture behavior of the body.

Eftis, J.↗

NASA NTRS1991

The effect of temperature on the fracture toughness of Weldalite(TM) 049

The uncertain effect of temperature is characterized on the deformation and fracture behavior of Weldalite(TM) 049 from cryogenic to elevated temperatures. Fracture resistance is measured and the determination of fracture mechanisms emphasized, including slip plane cracking, high angle boundary delamination, subgrain boundary cracking, and microvoid coalescence. Microstructure is controlled to produce either predominantly T(sub 1) or T(sub 1) + delta (after Blankenship and Starke) and to examine the effect of dislocation-precipitate interaction on fracture toughness.

Lach, Cynthia L.↗

NASA NTRS1990

Composite structure global fracture toughness via computational simulation

A computational method for the simulation of damage and fracture propagation in laminated composites is presented. A quantitative evaluation of the global fracture toughness of composites is shown as a tool for monitoring the fracture stability of composites under sustained loading. Changes in overall structural properties such as natural frequencies and the fundamental buckling load are also computed with increasing load-induced damage. Structural degradation, delamination, fracture, and damage propagation are included in the simulation. An angle-plied composite plate structure subjected to inplane tensile loading is used as an example to demonstrate some of the feature of the computational method.

Minnetyan, L.↗

NASA NTRS1991

On representation of fracture profiles by fractional integrals of a Wiener process

An enhancement of the crack diffusion model of brittle fracture is proposed. In the model, certain probabilities are evaluated as averages over the set of all virtual crack paths, and the latter are modeled as realization of a Wiener process. However, commonly observed fracture profiles are smoother. In fact, one can show that their fractal dimension is smaller than the value 3/2 for a Wiener process. Accordingly, it is proposed to represent fracture profiles by graphs of fractional integrals of a Wiener process. This allows one to employ additional fractographic information obtained from fracture profiles, e.g. their fractal dimension, in a predictive formalism, evaluating probabilities of failure.

Kunin, B.↗

NASA NTRS1992

Fracture resistance and fatigue crack growth characteristics of two Al-Cu-Mg-Zr alloys

The dependence of strength, fracture resistance, and fatigue crack growth rate on the aging conditions of two alloy compositions based on Al-3.7Cu-1.85Mg-0.2Mn is investigated. Mechanical properties were evaluated in two heat treatment conditions and in two orientations (longitudinal and transverse). Compact tension specimens were used to determine fatigue crack growth characteristics and fracture resistance. The aging response was monitored on coupons using hardness measurements determined with a standard Rockwell hardness tester. Fracture resistance is found to increase with increasing yield strength during artificial aging of age-hardenable 2124-Zr alloys processed by powder metallurgy techniques. Fatigue crack growth rate increases with increasing strength. It is argued that these changes are related to deformation modes of the alloys; a homogeneous deformation mode tends to increase fracture resistance and to decrease the resistance to the fatigue crack propagation rate.

Sarkar, Bhaskar↗

NASA NTRS1992

Determination of cleavage planes and fracture characterization of Ni-based single crystal superalloys

The room temperature fracture behavior of the Ge Rene N-4, CMSX-2, and CMSX-4C single crystal Ni-based superalloys was studied. All crystals were grown along the (001) direction and tensile tested in both helium and hydrogen atmospheres. A stereoscopic technique developed for use with a scanning electron microscope was applied to determine cleavage planes. Planar gamma(') morphologies also were examined to help determine cleavage planes. Helium charged specimens failed on a number of planes including the (111), (110), and (320). In most cases planes of the (111)-type initiated at the notch region and became smaller and smaller as they moved in radially. Tensile strengths in helium averaged 1000 MPa higher than that of the hydrogen charged specimens. Specimens tested in hydrogen generally failed on (100)-type planes originating from the notch region. This (100) region comprised 60 to 80 percent of the total fracture surface on most samples and appeared as large flat planes perpendicular to the growth direction of the crystal. The interior regions contained (100)-type planes as well as (321), (320), (210), and (111)-types. Hydrogen charged specimens also showed a high percentage of large cracks oriented at 90 deg to one another, indicative of the (100)-type fracture. The Ge Rene N4 and the CMSX-4C samples contained 3-5 percent gamma/gamma(') eutectic, while the CMSX-2 samples had little or no gamma/gamma(') eutectic. The relationship between gamma/gamma(') eutectic and the fracture surface has not been fully determined, but it is thought that the gamma/gamma(') eutectic may serve as a possible trapping site for hydrogen.

Merrill, John M.↗

NASA NTRS1993

Evaluation of the Fracture Toughness of Nb-40Al-8Cr-1W-1Y-0.05B Intermetallic Material by Indentation Techniques

The fracture toughness of an Nb-40Al-8Cr - 1W-1Y-0.05B intermetallic material was evaluated by indentation techniques at room temperature. Two widely used indentation methods, crack size measurement and indent strength, yielded excellent agreement with a conventional fracture toughness technique using straight-through precracked specimens, despite the occasional formation of poorly configured cracks. However, the modified indentation technique, using dummy indent flaws, resulted in a low fracture toughness compared to that evaluated by the other methods. The material did not exhibit rising R-curve behavior, as evaluated from the indentation strength data. These results indicate that indentation fracture principles are applicable to this brittle intermetallic material without modification of the residual contact stress term originally calibrated for ceramic materials.

Choi, S. R.↗

NASA NTRS1994

Elastic plastic fracture mechanics methodology for surface cracks

The Elastic Plastic Fracture Mechanics Methodology has evolved significantly in the last several years. Nevertheless, some of these concepts need to be extended further before the whole methodology can be safely applied to structural parts. Specifically, there is a need to include the effect of constraint in the characterization of material resistance to crack growth and also to extend these methods to the case of 3D defects. As a consequence, this project was started as a 36 month research program with the general objective of developing an elastic plastic fracture mechanics methodology to assess the structural reliability of pressure vessels and other parts of interest to NASA which may contain flaws. The project is divided into three tasks that deal with (1) constraint and thickness effects, (2) three-dimensional cracks, and (3) the Leak-Before-Burst (LBB) criterion. This report period (March 1994 to August 1994) is a continuation of attempts to characterize three dimensional aspects of fracture present in 'two dimensional' or planar configuration specimens (Chapter Two), especially, the determination of, and use of, crack face separation data. Also, included, are a variety of fracture resistance testing results (J(m)R-curve format) and a discussion regarding two materials of NASA interest (6061-T651 Aluminum alloy and 1N718-STA1 nickel-base super alloy) involving a bases for like constraint in terms of ligament dimensions, and their comparison to the resulting J(m)R-curves (Chapter Two).

Ernst, Hugo A.↗