Development of a Fatigue Crack Growth Coupon for Highly Plastic Stress Conditions
This paper presents an analytical approach used to develop a novel fatigue crack growth coupon for a highly plastic 3-D stress field condition. The flight hardware investigated in this paper is a large separation bolt that fractures using pyrotechnics at the appointed time during the flight sequence. The separation bolt has a deep notch that produces a severe stress concentration and a large plastic zone when highly loaded. For this geometry, linear-elastic fracture mechanics (LEFM) techniques are not valid due to the large nonlinear stress field. Unfortunately, industry codes that are generally available for fracture mechanics analysis and fatigue crack growth (e.g. NASGRO (11) are limited to LEFM and are available for only a limited number of geometries. The results of LEFM based codes are questionable when used on geometries with significant plasticity. Therefore elastic-plastic fracture mechanics (EPFM) techniques using the finite element method (FEM) were used to analyze the bolt and test coupons. scale flight hardware is very costly in t e r n of assets, laboratory resources, and schedule. Therefore to alleviate some of these problems, a series of novel test coupons were developed to simulate the elastic-plastic stress field present in the bolt.