Simulating small crack growth behaviour using crystal plasticity theory and finite element analysis

Predictions of small crack growth under cyclic loading in aluminium alloy 7075 are performed using finite element analysis (FEA), and results are compared with published experimental data. A double‐slip crystal plasticity model is implemented within the analyses to enable the anisotropic nature of individual grains to be approximated. Small edge‐cracks in a single grain with a starting length of 6 μm are incrementally grown following a node‐release scheme. Crack‐tip opening displacements (CTOD) and crack opening stresses are calculated during the simulated crack growth, and da/dN against ΔK diagrams are computed. Interactions between the crack tip and a grain boundary are also considered. The computations are shown to accurately capture the magnitude and the variability normally observed in small crack fatigue data.     

Crack tip displacements of microstructurally small cracks in 316L steel and their dependence on crystallographic orientations of grains

The paper presents an analysis of the effect of the grain orientations on a short Stage I surface crack in a 316L stainless steel. The analysis is based on a plane‐strain finite element crystal plasticity model. The model consists of 212 randomly shaped, sized and oriented grains that is loaded monotonically in uniaxial tension to a maximum load of 1.12R_p0.2 (280 MPa). The influence of random grain structure on a crack is assessed by calculating the crack tip opening (CTOD) and sliding displacements (CTSD) for single crystal and polycrystal models, considering also different crystallographic orientations. In the single crystal case the CTOD and CTSD may differ by more than one order of magnitude. Near the crack tip slip is activated on all the slip planes whereby only two are active in the rest of the model. The maximum CTOD is directly related to the largest Schmid factors. For the more complex polycrystal cases it is shown that certain crystallographic orientations result in a cluster of soft grains around the crack‐containing grain. In these cases the crack tip can become a part of the localized strain, resulting in a large CTOD value. This effect, resulting from the overall grain orientations and sizes, can have a greater impact on the CTOD than the local grain orientation. On the other hand, when a localized soft response is formed away from the crack, the localized strain does not affect the crack tip directly, resulting in a small CTOD value. The resulting difference in CTOD can be up to a factor of 4, depending upon the crystallographic set. Grains as far as 6xCracklength significantly influence the crack tip parameters. It was also found that among grains with favourable orientation the CTOD increased with the size of such a grain. Finally, a significant change in CTOD and CTSD was observed when extending the crack into the second grain and placing it in the primary or the conjugate slip plane.     

Steady-state crack growth and fracture work based on the theory of mechanism-based strain gradient plasticity

Mode I steady-state crack growth is analyzed under plane strain conditions in small scale yielding. The elastic-plastic solid is characterized by the mechanism-based strain gradient (MSG) plasticity theory [J. Mech. Phys. Solids 47 (1999) 1239, J. Mech. Phys. Solids 48 (2000) 99]. The distributions of the normal separation stress and the effective stress along the plane ahead of the crack tip are computed using a special finite element method based on the steady-state fundamental relations and the MSG flow theory. The results show that during the steady-state crack growth, the normal separation stress on the plane ahead of the crack tip can achieve considerably high value within the MSG strain gradient sensitive zone. The results also show that the crack tip fields are insensitive to the cell size parameter in the MSG theory. Moreover, in the present research, the steady-state fracture toughness is computed by adopting the embedded process zone (EPZ) model. The results display that the steady-state fracture toughness strongly depends on the separation strength parameter of the EPZ model and the length scale parameter in the MSG theory. Furthermore, in order for the results of steady crack growth to be comparable, an approximate relation between the length scale parameters in the MSG theory and in the Fleck-Hutchinson strain gradient plasticity theory is obtained.     

A numerical study of crack shielding and deflection under extensive plasticity

Experimentally observed crack deflection events in multi-layered material systems, occurring even under pure mode-I loading, are here simulated and explained through elasto-plastic finite element modelling. The crack tip opening displacement is adopted as the crack driving force and estimated along crack paths whose deflection is predicted using the maximum tangential strain criterion. Shielding conditions that promote deflection and bifurcation are evaluated. It is shown that, under conditions of extended plasticity, CTOD evolution as a crack approaches an interface can reveal crack shielding and amplification, and that crack deflection and growth can be assessed from the variation of tangential strains around the crack tip.     

Applications of the element-free Galerkin method for singular stress analysis under strain gradient plasticity theories

It is known that the plasticity models affect characterization of the crack tip fields. To predict failure one has to understand the crack tip stress field and control the crack. In the present work the element-free Galerkin methods for gradient plasticity theories have been developed and implemented into the commercial finite element code ABAQUS and used to analyze crack tip fields. Based on the modified boundary layer formulation it is confirmed that the stress singularity in the gradient plasticity theories is significantly higher than the known HRR solution and seems numerically to equal to 0.78, independently of the strain-hardening exponent. The strain singularity is much lower than the known HRR one. The crack field in gradient plasticity under small-scale yielding condition consists of three zones: The elastic K-field, the plastic HRR-field dominated by the J-integral and the hyper-singular stress field. Even under gradient plasticity there exists an HRR-zone described by the known J-integral, whereas the hyper-singular zone cannot be characterized by J. The hyper-singular zone is very small (r ? J/σ₀) and contained by the HRR zone in the infinitesimal deformation framework. The finite strains under the gradient plasticity will not eliminate the stress singularity as r → 0, in contrast to the known finite strain results under the Mises plasticity. Numerically no significant changes in characterization of the stress field were found in comparison with the infinitesimal deformation theory. Since the hyper-singular stress field is much smaller than the HRR zone and in the same size as the fracture process zone, one may still use the known J concept to control the crack in the gradient plasticities. In this sense the gradient plasticity will not change characterization of the crack.     

Strip yield analysis of two collinear unequal cracks in an infinite sheet

Plastic zone sizes and crack tip opening displacements (CTODs) are obtained for two collinear cracks in an infinite sheet subjected to known remote stress. Analysis is conducted by assuming the crack accompanying plastic zones as a fictitious crack and formulating integral equations based upon traction free and no stress singularity conditions. In addition, critical remote stress, plastic zone sizes, and CTODs when the adjacent plastic zones touched are obtained by assuming the coalesced fictitious cracks as a single fictitious crack and formulating integral equations based upon no stress singularity and zero coalesced point displacement conditions. Extensive numerical results are presented.     

The influence of crystallographic orientation on crack tip displacements of microstructurally small, kinked crack crossing the grain boundary

The paper presents an analysis of the effects of grain orientations on a short, kinked surface crack in a 316L stainless steel. The kinking of the crack is assumed to take place at the boundary between two neighbouring grains. The analysis is based on a plane-strain finite element crystal plasticity model. The model consists of 212 randomly shaped, sized and oriented grains, loaded monotonically in uniaxial tension to a maximum load of 0.96R_p0.2 (240 MPa). The influence that a random grain structure imposes on a Stage I crack is assessed by calculating the crack tip opening (CTOD) displacements for bicrystal as well as for polycrystal models, considering different crystallographic orientations. Since a Stage I crack is assumed, the crack is always placed in a slip plane. Results from a bicrystal case show that the maximal CTODs are directly related to the stiffness of the grain containing the crack extension. Anisotropic elasticity and crystal plasticity both contribute to this grain stiffness, resulting in maximal CTOD when Schmid factors are the highest on two slip planes. Such crystallographic orientation results in a soft elasto-plastic response. Anisotropic elasticity can additionally increase the softness of a grain at certain crystallographic orientations. Minimal anisotropic elasticity at the crystallographic orientations with the highest Schmid factors causes the CTOD to be maximized. Presuming that the crack will preferably follow the slip plane where the crack tip opening displacement is highest, we show that the crystallographic orientation can affect the CTOD values by a factor of up to 7.7. For a given grain orientation the maximum CTOD is attained when the crack extension deflection into a second grain is between −75.141° and 34°. For the polycrystal case we show that grains beyond the first two crack-containing grains change the CTOD by a factor of up to 3.3 and that the largest CTODs are obtained when placing the crack into a slip plane with crack extension that results in a crack extension being more perpendicular to the external load.     

THE SIGNIFICANCE OF CRACK TIP DEFORMATION FOR SHORT AND LONG FATIGUE CRACKS

Abstract— The behaviour of physical short mode I cracks under constant amplitude cyclic loading was investigated both numerically and experimentally. A dynamic two-dimensional elastic-plastic finite element technique was utilised to simulate cyclic crack tip plastic deformation. Different idealisations were investigated. Both stationary and artificially advanced long and short cracks were analysed. A parameter which characterises the plastically deformed crack tip zone, the strain field generated within that zone and the opening and closure of the crack tip were considered. The growth of physically short mode I cracks under constant amplitude fully reversed fatigue loading was investigated experimentally using conventional cast steel EN-9 specimens. Based on a numerical analysis, a crack tip deformation parameter was devised to correlate fatigue crack propagation rates.     

Cyclic crystal plasticity analyses of stationary, microstructurally small surface cracks in ductile single phase polycrystals

ABSTRACT This paper explores the effects of microstructural heterogeneity on the cyclic crack tip opening and sliding displacements for stationary, microstructurally small transgranular surface cracks in a single phase metallic polycrystal using planar double slip crystal plasticity computations. Crack tip displacements are examined under plane strain conditions for stationary cracks of different lengths relative to grain size as a function of the applied nominal strain amplitude for tension-compression and cyclic shear. Nominal strain amplitudes range from well below to slightly above the nominal cyclic yield strength for each type of loading condition. Results indicate the complex nature of the crack tip sliding and opening displacements as functions of nominal strain amplitude and orientation of the nearest neighbour grains, the influence of the free surface in promoting the cyclic opening displacement even for cracks in the first surface grain, the rather restricted limits of applicability of linear elastic fracture mechanics, and very interesting crack tip plasticity effects which include crack tip displacement ratcheting or progressive accumulation, even for completely reversed, proportional applied loading. Results are compared for cases with and without crack face friction.     

Crack tip displacements of microstructurally small surface cracks in single phase ductile polycrystals

A planar double slip crystal plasticity model is applied to the evaluation of crack tip opening (CTOD) and sliding (CTSD) displacements for microstructurally small stationary cracks under monotonic loading for a material with nominal stress-strain behavior that is representative of a relatively high strength helicopter rotor hub material. Two-dimensional plane strain finite element calculations are presented for CTSD and CTOD of microstructurally small transgranular surface cracks in a polycrystal subjected to monotonic loading. The effects of crack length relative to grain size, orientation distribution of nearest neighbor grains, stress state and stress level are considered for nominal stress levels below the macroscopic yield strength. The CTOD and CTSD are computed for stationary crystallographic surface cracks with various realizations of crystallographic orientations of surrounding grains. It is found that (i) the opening displacement is dominant for remote tension even for crystallographic cracks oriented along the maximum shear plane in the first surface grain, (ii) there is a strong dependence of the CTOD on the proximity to grain boundaries, but lesser dependence of the CTSD, and (iii) that the elastic solutions for CTOD and CTSD are valid below about 30% of the 0.2% offset-defined yield strength.     

Mechanisms and modeling of low cycle fatigue crack propagation in a pressure vessel steel Q345

The fatigue process near crack is governed by highly concentrated strain and stress in the crack tip region. Based on the theory of elastic–plastic fracture mechanics, we explore the cyclic J-integral as breakthrough point, an analytical model is presented in this paper to determine the CTOD for cracked component subjected to cyclic axial in-plane loading. A simple fracture mechanism based model for fatigue crack growth assumes a linear correlation between the cyclic crack tip opening displacement (ΔCTOD) and the crack growth rate (da/dN). In order to validate the model and to calibrate the model parameters, the low cycle fatigue crack propagation experiment was carried out for CT specimen made of Q345 steel. The effects of stress ratio and crack closure on fatigue crack growth were investigated by elastic–plastic finite element stress–strain analysis of a cracked component. A good comparison has been found between predictions and experimental results, which shows that the crack opening displacement is able to characterize the crack tip state at large scale yielding constant amplitude fatigue crack growth.     

CRACK CLOSURE AND PLASTIC ZONE SIZES IN FATIGUE

Abstract— An elastic-plastic finite element simulation of growing fatigue cracks which accounts for plasticity-induced crack closure is used to study the size of the forward and reversed plastic zones at the crack tip. Forward plastic zone widths for fatigue cracks and stationary, monotonically loaded cracks are compared and found to be similar. The width of the forward plastic zone at the tip of a fatigue crack is not significantly influenced by closure. The traditional Irwin-Rice estimate for crack tip plastic zone size in plane stress is found to be generally consistent with the finite element results. The width of the reversed plastic zone at the tip of a growing fatigue crack in plane stress is found to be considerably less than one-fourth the size of the forward plastic zone, the traditional Rice estimate. This decrease appears to be due to fatigue crack closure. A simple model is developed which permits estimation of the reversed plastic zone size for any stress ratio from information about maximum and minimum stresses and the closure stress. The predictions of this model agree closely with plastic zone sizes calculated by the finite element analysis. These observations appear to be consistent with experimental measurements of forward and reversed plastic zones sizes reported in the literature.     

A numerical analysis of the mechanisms behind plasticity induced crack closure: Application to variable amplitude loadings

The effect of loading parameters on fatigue crack growth has been explained using the concept of crack closure. Plasticity induced crack closure (PICC) is linked to the crack tip plastic deformation, which becomes residual with crack propagation. The objective here is to identify the main mechanisms behind PICC, and for that different loading cases were considered namely overloads and load blocks. An analytical model was used to isolate the effect of residual plastic deformation on PICC, however significant differences were obtained relatively to finite element results. A second mechanism, which is crack tip blunting, was used to explain the transient behaviour observed after overloads and load blocks. For overloads and low–high load sequences there is a sudden increase of crack tip blunting with load increase which explains the sudden decrease of crack opening level. For high–low load sequences there is a sudden decrease of crack tip blunting which enhances the effect of residual plastic wake. Finally, the partial closure concept was tested looking to non-linear crack tip parameters but no evidences of Donald’s effect were found for the material studied.     

Microstructural effects on crack closure and propagation thresholds of small fatigue cracks

The crack closure behaviour of microstructurally small fatigue cracks was numerically simulated by combining the crack-tip slip band model with the plasticity-induced crack closure model. A Stage II crack started to propagate from an initiated Stage I crack. When the plastic zone was constrained by the grain boundary or the adjacent grain with higher yield stresses, the crack opening stress increased with crack extension, and the effective component of the stress range decreased. The crack-tip opening displacement range (Δ CTOD ), first decreased with crack extension due to the development of the residual stretch, then increased until the tip of the plastic zone reached the neighbouring grain boundary. When the plastic zone was blocked by the grain boundary, Δ CTOD began to decrease. The arrest condition of cracks was given by the threshold value of Δ CTOD . At the fatigue limit, the arrest of small cracks takes place just after the Stage II crack crosses the grain boundary when the grain boundary does not act as a barrier. Only when the grain boundary has a blocking strength and the yield stress of adjacent grains is not so high, the arrest of Stage II cracks takes place before the crack reaches the grain boundary. The fatigue limit decreases with the mean stress. The predicted relation between the fatigue limit and the mean stress is close to the modified Goodman relation.     

Crack tip opening displacement of a Dugdale crack in a three-phase cylindrical model composite material

The analytical investigation of the plastic zone size of a crack in three-phase cylindrical model composite material was carried out. The physical problem is simulated as a crack near a circular inclusion (a single fiber) in the composite matrix, while the three-phase cylindrical composite model is used to represent the composite matrix. In the solution procedure, the crack is simulated as a continuous distribution of edge dislocations. With the Dugdale model of small scale yielding, a thin strip of yielded plastic zone is introduced at each crack tip. Using the solution for a three-phase model with a single dislocation in the matrix phase as the Green’s function, the physical problem is formulated into a set of singular integral equations. By employing Erdogan and Gupta’s method, as well as iterative numerical procedures, the singular integral equations are solved numerically for the plastic zone sizes and crack tip opening displacements.     

Numerical simulations of crack tip fields in polycrystalline plastic solids

In this paper, modes I and II crack tip fields in polycrystalline plastic solids are studied under plane strain, small scale yielding conditions. Two different initial textures of an Al-Mg alloy, viz., continuous cast AA5754 sheets in the recrystallized and cold rolled conditions, are considered. The former is nearly-isotropic, while the latter displays distinct anisotropy. Finite element simulations are performed by employing crystal plasticity constitutive equations along with a Taylor-type homogenization as well as by using the Hill quadratic yield theory. It is found that significant texture evolution occurs close to the notch tip which profoundly influences the stress and plastic strain distributions. Also, the cold rolling texture gives rise to higher magnitude of plastic strain near the tip.     

Application of the distributed dislocation technique for calculating cyclic crack tip plasticity effects

This paper describes a method for modelling cyclic crack tip plasticity effects based on the distributed dislocation technique (DDT). A strip‐yield model is utilised to allow for the determination of the crack opening displacement, size of the plastic zones and in the case of a fatigue crack, the wake of plasticity. The DDT can be easily implemented for a wide range of cracked geometries with reliable control over the accuracy and convergence. Thickness effects can also be incorporated through a recently obtained solution for an edge dislocation in an infinite plate of finite thickness. Results for finite length cracks that have had limited growth, such that there is no plastic wake, are presented for a range of applied loads and R‐ratios. Further results are provided for a steady‐state fatigue crack in a plate of finite thickness. The present results are compared with analytical solutions and they show an excellent agreement.     

Analysis of the plastic zone size ahead of repaired cracks with bonded composite patch of metallic aircraft structures

In this study, the three-dimensional and non-linear finite element method is used to estimate the performance of the bonded composite repair of metallic aircraft structures by analyzing the plastic zone size ahead of repaired cracks. Several calculations have been realized to extract the plasticized elements around the crack tip of repaired crack. The obtained results show that the presence of the composite patch reduces considerably the size of the plastic zone ahead of the crack. The effects of the adhesive properties and the patch thickness on the plastic zone size ahead of repaired cracks were analyzed.     

Towards a new model of crack tip stress fields

This work introduces a novel mathematical model of the stresses around the tip of a fatigue crack, which considers the effects of plasticity through an analysis of their shielding effects on the applied elastic field. The ability of the model to characterize plasticity-induced effects of cyclic loading on the elastic stress fields is assessed and demonstrated using full-field photoelasticity. The focus is on determining the form of the shielding stress components (induced by compatibility requirements at the elastic–plastic interface along the crack flank and via the crack tip plastic zone) and how they influence the crack tip elastic stress fields during a load cycle. The model is successfully applied to the analysis of a fatigue crack growing in a polycarbonate CT specimen.