Residual tensile strength in the presence of through cracks or surface cracks
Residual tensile strength in presence of through cracks or surface cracks
Kuhn, P.↗
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Crack-mouth displacements for semielliptical surface cracks subjected to remote tension and bending loads
The exact analytical solution for an embedded elliptical crack in an infinite body subjected to arbitrary loading was used in conjunction with the finite element alternating method to obtain crack-mouth-opening displacements (CMOD) for surface cracks in finite plates subjected to remote tension. Identical surface-crack configurations were also analyzed with the finite element method using 20-noded element for plates subjected to both remote tension and bending. The CMODs from these two methods generally agreed within a few percent of each other. Comparisons made with experimental results obtained from surface cracks in welded aluminum alloy specimens subjected to tension also showed good agreement. Empirical equations were developed for CMOD for a wide range of surface-crack shapes and sizes subjected to tension and bending loads. These equations were obtained by modifying the Green-Sneddon exact solution for an elliptical crack in an infinite body to account for finite boundary effects. These equations should be useful in monitoring surface-crack growth in tests and in developing complete crack-face-displacement equations for use in three-dimensional weight-function methods.
Raju, Ivatury S.↗
The effects of crack surface friction and roughness on crack tip stress fields
A model is presented which can be used to incorporate the effects of friction and tortuosity along crack surfaces through a constitutive law applied to the interface between opposing crack surfaces. The problem of a crack with a saw-tooth surface in an infinite medium subjected to a far-field shear stress is solved and the ratios of mode I stress intensity to mode II stress intensity are calculated for various coefficients of friction and material properties. The results show that tortuosity and friction lead to an increase in fracture loads and alter the direction of crack propagation.
Ballarini, Roberto↗
The effects of crack surface friction and roughness on crack tip stress fields
A model is presented which can be used to incorporate the effects of friction and tortuosity along crack surfaces through a constitutive law applied to the interface between opposing crack surfaces. The problem of a crack with a saw-tooth surface in an infinite medium subjected to a far-field shear stress is solved and the ratios of Mode-I stress intensity to Mode-II stress intensity are calculated for various coefficients of friction and material properties. The results show that tortuosity and friction lead to an increase in fracture loads and alter the direction of crack propagation.
Ballarini, Roberto↗
Working toward a three-dimensional fatigue closure model for surface cracks
The first reliable elastic fracture mechanics solutions for a surface crack in a plate were obtained by Newman and Raju. The authors, both from the Mechanics of Materials Branch at NASA-Langley, used a highly detailed finite element solution requiring substantial computational resources. Computers have since become more powerful and available; however, many important related problems remain computationally expensive. The problem of three-dimensional fatigue crack growth taking into account plasticity-induced crack closure is one such problem. It is the goal of this research to provide an efficient method to account for three-dimensional crack closure in fatigue. Newman developed a two-dimensional plasticity-induced crack closure model for center cracked specimens. This model requires iterations to determine both the contact solution at each growth step and the extent of the plastic zone at the crack tip. A three-dimensional version of this model would require obtaining these nonlinear variables all along the crack front. This model must be efficient so that repeated calculations can be performed during crack growth simulations. The highly versatile line spring model (LSM) with contact, fatigue, and plasticity will form the basis of the closure model. There are several required additions to past work to address the three-dimensional crack closure problem. Initially, these additions will include (1) an improved LSM to more accurately obtain the crack opening displacement, stress intensity factors, and elastic T-stress near the ends of the surface crack; (2) a method to determine the extent of the plastic zone all along the crack front; (3) a method to determine the contact zone given a perfectly plastic layer of material on the crack surfaces; (4) a method to determine the magnitude of the compressive contact stress; and (5) a way to implement the degree of constraint along the curved crack front. During the summer ASEE program an enhanced LSM was developed. A method similar to that of 'strip synthesis' first introduced by Fujimoto was used. Briefly, the crack opening displacements of 'slices' of the surface crack in a direction parallel to the plate surface are considered in addition to the standard LSM approach that makes use of springs obtained from slices perpendicular to the plate surface. This enhancement is necessary so that an accurate three-dimensional representation of quantities such as contact zone size, plastic zone size, stress intensity factors, T-stress, and crack opening displacement can be determined. By combining results of previous investigations with the LSM, the problem of three-dimensional crack closure will be addressed. In addition to a closure model, the enhanced LSM can be used for many other problems including interacting surface cracks and fatigue crack growth of a through crack with a curved crack front.
Joseph, Paul F.↗
Stress-intensity factors for a wide range of semi-elliptical surface cracks in finite-thickness plates
Surface cracks are among the more common flaws in aircraft and pressure vessel components. Several calculations of stress-intensity factors for semi-elliptical surface cracks subjected to tension have appeared in the literature. However, some of these solutions are in disagreement by 50-100%. In this paper, stress-intensity factors for shallow and deep semi-elliptical surface cracks in plates subjected to tension are presented. To verify the accuracy of the three-dimensional finite-element models employed, convergence was studied by varying the number of degrees of freedom in the models from 1500 to 6900. The 6900 degrees of freedom used here were more than twice the number used in previously reported solutions. Also, the stress-intensity variations in the boundary-layer region at the intersection of the crack with the free surface were investigated.
Raju, I. S.↗
A review of surface-crack fracture testing
A brief historical review of surface-crack testing and analysis is given together with some examples of service failures due to surface cracks. The factors which complicate the analysis and interpretation of surface-crack fracture data are discussed. Current efforts to develop consensus recommendations for tensile testing of surface-crack specimens are summarized.
Orange, T. W.↗
A review of surface-crack fracture testing
A brief historical review of surface-crack testing and analysis is given together with some examples of service failures due to surface cracks. The factors which complicate the analysis and interpretation of surface-crack fracture data are discussed. Current efforts to develop consensus recommendations for tensile testing of surface-crack specimens are summarized.
Orange, T. W.↗
Surface-crack growth: Models, experiments, and structures; Proceedings of the Symposium, Sparks, NV, Apr. 25, 1988
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.
Reuter, Walter G.↗
Microwave detection of surface cracks on metals.
Metal surface cracks detection by microwave techniques resulting in noncontacting, nonfocusing and high sensitivity self illuminating system
Feinstein, L.↗
An empirical stress-intensity factor equation for the surface crack
This paper presents an empirical stress-intensity factor equation for a surface crack as a function of parametric angle, crack depth, crack length, plate thickness and plate width for tension and bending loads. The stress-intensity factors used to develop the equation were obtained from a previous three-dimensional, finite-element analysis of semielliptical surface cracks in finite elastic plates subjected to tension or bending loads. A wide range of configuration parameters was included in the equation. The ratios of crack length to plate thickness and the ratios of crack depth to crack length ranged from 0 to 1.0. The effects of plate width on stress-intensity variations along the crack front were also included. The equation was used to predict patterns of surface-crack growth under tension or bending fatigue loads. 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.
Newman, J. C., Jr.↗
Crack-surface displacements for two symmetric cracks emanating from a circular hole in an infinite plate
An analytical model is presented for the surface displacement associated with two symmetric cracks radiating from a circular hole in a plate undergoing remote uniform stress. The model equations account for the stress intensity factor (Kic), the boundary conditions enveloping the hole, and the effects of symmetric forces concentrated around the hole. The displacement(s) of the surface are calculated at a given distance from the hole along the crack(s).
Mall, S.↗
Fracture Analysis of Semi-Elliptical Surface Cracks in Ductile Materials
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.
Daniewicz, S. R.↗
Analytical Round Robin for Elastic-Plastic Analysis of Surface Cracked Plates, Phase II Results
The second phase of an analytical round robin for the elastic-plastic analysis of surface cracks in flat plates was conducted under the auspices of ASTM Interlaboratory Study 732. The interlaboratory study (ILS) had 10 participants with a broad range of expertise and experience, and experimental results from a surface crack tension test in 4142 steel plate loaded well into the elastic-plastic regime provided the basis for the study. The participants were asked to evaluate a surface crack tension test according to the version of the surface crack initiation toughness testing standard published at the time of the ILS, E2899-13. Data were provided to each participant that represent the fundamental information that would be provided by a mechanical test laboratory prior to evaluating the test result. Overall, the participant’s test analysis results were in good agreement and constructive feedback was received that has resulted in an improved published version of the standard E2899-15.
Allen, P. A.↗
Measurements of mixed-mode crack surface displacements and comparison with theory
A theoretical and an experimental technique is used to determine crack surface displacements under mixed-mode conditions. Crack surface displacements proved to be quite useful in mode 1 fracture analysis in that they are directly related to strain energy release rate and stress intensity factor. It is felt that similar relationships can be developed for the mixed-mode case. A boundary-integral method was developed for application to two-dimensional fracture mechanics problems. This technique was applied to the mixed-mode problem. A laser interferometry technique, for measurement of crack surface displacements under mixed-mode conditions, is presented. The experimental measurements are reported and the results of the two approaches are compared and discussed.
Altiero, N. J., Jr.↗
Stress Intensity Factors for Part-Through Surface Cracks in Hollow Cylinders
Flaws resulting from improper welding and forging are usually modeled as cracks in flat plates, hollow cylinders or spheres. The stress intensity factor solutions for these crack cases are of great practical interest. This report describes some recent efforts at improving the stress intensity factor solutions for cracks in such geometries with emphasis on hollow cylinders. Specifically, two crack configurations for cylinders are documented. One is that of a surface crack in an axial plane and the other is a part-through thumb-nail crack in a circumferential plane. The case of a part-through surface crack in flat plates is used as a limiting case for very thin cylinders. A combination of the two cases for cylinders is used to derive a relation for the case of a surface crack in a sphere. Solutions were sought which cover the entire range of the geometrical parameters such as cylinder thickness, crack aspect ratio and crack depth. Both the internal and external position of the cracks are considered for cylinders and spheres. The finite element method was employed to obtain the basic solutions. Power-law form of loading was applied in the case of flat plates and axial cracks in cylinders and uniform tension and bending loads were applied in the case of circumferential (thumb-nail) cracks in cylinders. In the case of axial cracks, the results for tensile and bending loads were used as reference solutions in a weight function scheme so that the stress intensity factors could be computed for arbitrary stress gradients in the thickness direction. For circumferential cracks, since the crack front is not straight, the above technique could not be used. Hence for this case, only the tension and bending solutions are available at this time. The stress intensity factors from the finite element method were tabulated so that results for various geometric parameters such as crack depth-to-thickness ratio (a/t), crack aspect ratio (a/c) and internal radius-to-thickness ratio (R/t) or the crack length-to-width ratio (2c/W) could be obtained by interpolation and extrapolation. Such complete tables were then incorporated into the NASA/FLAGRO computer program which is widely used by the aerospace community for fracture mechanics analysis.
Mettu, Sambi R.↗
Surface-crack shape change in bending fatigue using an inexpensive resonant fatiguing apparatus
An inexpensive device for producing surface cracks of controlled size and shape is described along with results of its use which show how the shape of the surface crack changes as it grows in bending fatigue from a variety of crack starter shapes. The growth pattern for any crack is uniquely defined by the crack starter configuration and appears to be independent of alloy. Shape changes are substantial and all growth curves tend toward a common growth curve. Circular cracks tend to become elliptical with an associated increase in stress intensity factor. This increase accelerates the crack growth rate and proximity to the critical flaw size. Through-cracks produced by the extension of a surface crack in a bending stress field will have length ten times the section thickness. The results demonstrate the necessity of taking into account changing crack shape in the calculation of structural life when bending is a significant component of the stress field.
Pierce, W. S.↗
Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier
In this paper, surface cracking and interface reactions of a ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions that were largely enhanced by the coating surface cracking in the water vapor environment were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions. The coating design issues will also be discussed based on the observed failure mechanisms under the high-heat-flux test conditions.
Zhu, Dongming↗