Experimental investigation on low cycle fatigue and fracture behaviour of a notched Ni‐based superalloy at elevated temperature

In order to investigate the effects of stress concentration on low cycle fatigue properties and fracture behaviour of a nickel‐based powder metallurgy superalloy, FGH97, at elevated temperature, the low cycle fatigue tests have been conducted with semi‐circular and semi‐elliptical single‐edge notched plate specimens at 550 and 700 °C. The results show that the fatigue life of the notched specimen decreases with the increase of stress concentration factor and the fatigue crack initiation life evidently decreases because of the defect located in the stress concentration zone. Moreover, the plastic deformation induced by notch stress concentration affects the initial crack occurrence zone. The angle α of the crack occurrence zone is within ±10° of notch bisector for semi‐circular notched specimens and ±20° for semi‐elliptical notched specimens. The crack propagation rate decreases to a minimum at a certain length, D, and then increases with the growth of the crack. The crack propagation rate of the semi‐elliptical notched specimen decelerates at a faster rate than that of the semi‐circular notched specimen because of the increase of the notch plasticity gradient. The crack length, D, is affected by both the applied load and the notch plasticity gradient. In addition, the fracture mechanism is shown to transition from transgranular to intergranular as temperature increases from 550 to 700 °C, which would accelerate crack propagation and reduce the fatigue life.     

Analysis of elastoplastic sharp notches

In this paper the elastoplastic solutions with higher-order terms for apex V-notches in power-law hardening materials have been discussed. Two-term expansions of the plane strain and the plane stress solutions have been obtained. It has been shown that the leading-order singularity approaches the value for a crack when the notch angle is not too large. In plane strain cases the elasticity does not enter the second-order solutions when the notch opening angle is too small. For a large notch angle, the two-term expansions of the plane strain near-tip fields are described by a single amplitude parameter. The plane stress solutions generally contain the elasticity terms. The boundary layer formulations based on the small-strain plasticity theory confirm that a dominance zone exists ahead of the notch tip. Finite element results give good agreement to the asymptotic solutions under both plane strain and plane stress conditions. The second-order terms cannot improve the predictions significantly. The near-tip fields are dominated by a single parameter. Finite element calculations under the finite strain J ₂-flow plasticity theory revealed that the finite strains can only affect local characterization of the asymptotic solution. The asymptotic solution has a large dominance zone around the notch tip. For an apex notch bounded to a rigid substrate the leading-order singularity falls with the notch angle significantly more slowly than in the homogeneous material. It vanishes at the notch angle about 135° for all power-hardening exponents. The elasticity effects enter the second-order solutions when the notch angle becomes large enough. The tip fields are characterized by the hydrostatic stress and the shear stress ahead of the notch.     

Influences of non-singular stresses on plane-stress near-tip fields for pressure-sensitive materials and applications to transformation toughened ceramics

In this paper, we investigate the effects of the non-singular stress (T stress) on the mode I near-tip fields for elastic perfectly plastic pressure-sensitive materials under plane-stress and small-scale yielding conditions. The T stress is the normal stress parallel to the crack faces. The yield criterion for pressure-sensitive materials is described by a linear combination of the effective stress and the hydrostatic stress. Plastic dilatancy is introduced by the normality flow rule. The results of our finite element computations based on a two-parameter boundary layer formulation show that the total angular span of the plastic sectors of the near-tip fields increases with increasing T stress for materials with moderately large pressure sensitivity. The T stress also has significant effects on the sizes and shapes of the plastic zones. The height of the plastic zone increases substantially as the T stress increases, especially for materials with large pressure sensitivity. When the plastic strains are considered to be finite as for transformation toughened ceramics, the results of our finite element computations indicate that the phase transformation zones for strong transformation ceramics with large pressure sensitivity can be approximated by those for elastic-plastic materials with no limit on plastic strains. When the T stress and the stress intensity factor K are prescribed in the two-parameter boundary layer formulation to simulate the crack-tip constraint condition for a single-edge notch bend specimen of zirconia ceramics, our finite element computation shows a spear shape of the phase transformation zone which agrees well with the corresponding experimental observation.     

Effect of martensite transformation on fracture behavior of shape memory alloy NiTi in a notched specimen

In this paper, the finite element calculation of the stress–strain distribution in front of a notch tip were carried out for two materials. One is a shape memory alloy NiTi with the stress-induced martensite transformation, and another is a fully transformed martensite NiTi without the transformation. Based on the results obtained, and combining a model of the fracture process zone, effect of martensite transformation on the fracture behavior of the shape memory alloy NiTi in a notched specimen of plane stress state is comparably analyzed. The results show that the martensite transformation increases the load to produce plastic deformation in the transformed martensite at the notch tip and decreases the maximum normal stress and plastic strain near the notch tip, and tends to suspend the crack nucleation and propagation in the fully transformed martensite in front of the notch tip, and thus increases the fracture load and improves the toughness. A quantitative analysis based on the model of the fracture process zone shows that the martensite transformation in the SMA NiTi causes about 47% increase in the apparent fracture toughness.     

Analysis of the wedge-shaped damage zone in edge-notched polypropylene

The irreversible deformation behaviour of polypropylene during sharp single-edge-notched tension testing has been studied as a function of temperature. Specimens were tested at room temperature, –20, –40, and –60 °C with photographs taken of the notch tip area during testing. BelowT _g, a narrow wedge-shaped damage zone grew from the notch tip with increased stress. The damage zone length correlated with the ratio of applied stress to yield stress in agreement with the Dugdale model. The crack tip opening displacement (CTOD) was found to follow the predicted Dugdale CTOD when modified by using the secant modulus to account for viscoelasticity. The shape of the damage zone did not agree with the Dugdale model near the notch tip, but instead was found to follow a path of the minor principal stress trajectory. AboutT _g, the damage zone had a lower length-to-width ratio which no longer resembled the Dugdale model.     

Failure of a Porous Solid from a Deep Notch

A finite strain finite element method is used to examine the stress state near the tip of a deep notch in an elastic-plastic porous solid. The notch is loaded in mode I plane strain tension and small scale yielding is assumed. Two rate independent strain hardening material models are used: a version of the Gurson model (1977) and the more recent FKM model developed by Fleck, Kuhn and McMeeking (1992). Under increasing K _I, void growth is initially stable and independent of mesh dimension. Localization of plastic flow sets in at a finite value K _i, and the deformation field is mesh-size dependent thereafter. The initiation of crack growth at the notch root is assumed to occur when a critical level of porosity is attained. The results show that the shape of the plastic zone for both the Gurson and the FKM material is highly dependent on the initial porosity. In the case of low initial porosity, the plastic zone shape is similar to that of a fully dense material; at higher initial porosities the plastic zone is concentrated ahead of the notch tip. The effect of the initial void volume fraction on the porosity field and the critical stress intensity factor is studied, and the mesh-size dependence of the results is discussed. The analysis is useful for prediction of the notched strength of porous metals. This revised version was published online in August 2006 with corrections to the Cover Date.     

Predicting failure from the initiation stage of slow crack growth in polyethylene

The crack opening displacement against time was measured in linear polyethylene as a function of stress, notch depth, and temperature for three-point bending under plane strain conditions. The experimental conditions were accurately controlled so that the scatter in the rate of damage was within ±20%. Microscopic observations showed that the shape of the damaged zone was triangular for stresses less than one-half the yield point and that the length was predictable from measurements of the crack opening displacement. The initial rate of damage prior to crack growth was constant up to crack opening displacement = 15 to 25Μm. The entire shape of the crack opening displacement-time curve and the time to complete failure could be predicted from the initial damage rate. A theory based on the observed microcrazing is presented which explains the dependence of damage rate on stress intensity and microstructural parameters.     

Effect of lattice orientation on crack tip constraint in ductile single crystals

In this work, the effect of lattice orientation on the fields prevailing near a notch tip is investigated pertaining to various constraint levels in FCC single crystals. A modified boundary layer formulation is employed and numerical solutions under mode I, plane strain conditions are generated by assuming an elastic–perfectly plastic FCC single crystal. The analysis is carried out corresponding to different lattice orientations with respect to the notch line. It is found that the near‐tip deformation field, especially the development of kink or slip shear bands is sensitive to the constraint level. The stress distribution and the size and shape of the plastic zone near the notch tip are also strongly influenced by the level of T ‐stress. The present results clearly establish that ductile single crystal fracture geometries would progressively lose crack tip constraint as the T ‐stress becomes more negative irrespective of lattice orientation. Also, the near‐tip field for a range of constraint levels can be characterized by two‐parameters such as K–T or J–Q as in isotropic plastic solids.     

Study of the effects of stress and strain on martensite transformation: Kinetics and transformation plasticity*

In this paper, the effects of stress and strain on the kinetics and plasticity during martensitic transformation are studied. The mathematical models of transformation kinetics and plasticity under stress are developed. According to experimental results, the transformation plasticity parameter k is concluded not to be a constant, but it varies with the stresses.     

Plasticity spread in mild steel pre-cracked charpy bars

During dynamic service loading, small fatigue cracks are normally seen to emanate from the root of sharp machined stress concentration region. In a recent authors' paper at ICF4, the fracture strength of a charpy type notched beam has been studied in three different engineering materials, when a small fatigue crack emanates from the notch root. Fracture tests on these medium and high strength materials demonstrate the presence of a large size plastic zone near the crack tip [1–6]. To understand the mechanism of fracture for such complex geometry. it is important to know the size and shape of these plastically yielded regions. The present paper is mainly on the experimental measurement of plasticity spread as well as the stress intensity factor (S.I.F.) for such short cracks. Firstly, the S.I.F. is approximately measured by plain transmission photoelasticity on model castolite specimens. Secondly, plastic zones around crack tip are measured for a wide range of notch root radii and crack-length, by using photo-stress PS-3B coating on mild steel pre-cracked charpy type notched specimens. It is observed that for small scale yielding at the crack tip, the plasticity spread is around 60–65° angle to the line of crack-extension. On the contrary, as the gross applied stress approaches the yield strength of the material, the maximum plasticity spreads around 45° angle. Finally, it is noticed that at high stress level, the plastic zone boundary (for short crack) touches the free machined notch surface. These experimental observations explain the nature and degree of non-linearity in a load—C.O.D. diagram during the fracture test of a short cracked-notched specimen. These data are also useful to predict the crack-extension load for an elastic-plastic material.     

Damage zone development in PVC under a multiaxial tensile stress state

The irreversible deformation mechanisms of poly(vinyl chloride) with a semicircular notch under slow tensile loading have been studied as a function of sheet thickness. Initially, core yielding was observed in the optical microscope as two families of slip lines growing from the notch surface in the centre of the specimen. The size and shape of the core yielding zone could be described by plasticity analysis. A stress-whitened zone subsequently initiated near the tip of the slip line zone. The stress whitening was caused by 1 m voids that were visible in the scanning electron microscope. The mean stress for stress whitening was calculated to be 43.0±1.5 MPa by a plastic stress analysis of a pressure-dependent yield material. By assuming a constant mean stress along the boundary of the stress-whitened zone, the one-dimensional shift of the elastic stress distribution was obtained. At higher stresses, hinge shear and intersecting shear were observed for thick and thin sheet, respectively.     

Propagation of fatigue cracks from notches

Abstract

The traditional design approaches to fatigue at notches, based on stress level–endurance relationships, are briefly reviewed. It is shown, by considering crack propagation from notches and invoking a change in control mode from notch plasticity to crack-tip plasticity, that a critical stress condition can be obtained which must be exceeded if the crack is to propagate to failure. The traditional techniques are then reinterpreted and explained by this propagation method. An example is given of crack growth from a sharp defect at a weld toe. It is shown that the integration of an elastic fracture mechanics growth law can reproduce stress range–cycles to failure data for this situation. There are, however, complexities of stress analysis and crack shape. A simple treatment of residual stresses affecting the threshold and slow–growth regimes, shows some promise as a technique for accounting for residual stresses.

MST/70     

Effects of grain size and specimen geometry on the transformation and R-curve behaviour of 9Ce-TZP ceramics

Transformation and R-curve behaviour have been investigated in 9 mol% Ce-TZP ceramics with different grain sizes. Both single-edge notched beam and short double-cantilever beam specimens were tested to measure the crack-resistance curves. The size and shape of the transformation zone not only depend on grain size, but are also strongly influenced by the specimen geometry. This different transformation behaviour has led to different crack-resistance curves. These experimental results are discussed in terms of the thermodynamics of transformation, the effect of autocatalytic transformation, and fracture mechanics.     

Effects of notch length,specimen thickness,ply thickness and type of defect on the fracture behaviour of angle-ply graphite-epoxy composites

An experimental study was carried out on the effects of notch length, specimen thickness, ply thickness and type of defect (centre-notch or hole) on the fracture toughness of graphite-epoxy composites with lay-up sequences of 0/±45°/0 and 0/90°. Three fracture-mechanical concepts were applied: the Waddoups-Eisenmann-Kaminski (WEK) model, the Whitney-Nuismer model (point and average stress cirteria) and the K _R-curve method. An increase of notch length as well as an increase of ply thickness led to a higher toughness, whereas a change in specimen thickness did not noticeably affect the toughness. Furthermore, the hole caused a smaller strength reduction than a notch. The applicability of the above-mentioned concepts is probably restricted mainly because of the fact that they do not, or do only insufficiently, regard the damage zone near the border of the defect, if a large damage zone usually leads to larger material parameters of the investigated concepts, namely the inherent flaw size, the characteristic lengths of the point and average stress criterions and the K _R -value at fracture.     

Stress concentration formulae useful for any shape of notch in a round test specimen under tension and under bending

In this work stress concentration factors, K_t , for a round bar with a circular-arc or V-shaped notch are considered on the basis of exact solutions for special cases and accurate numerical results. Then, a set of K_t formulae useful for any shape of notch is proposed. The conclusions can be summarized as follows. (i) For the limiting cases of deep (d) and shallow (s) notches, the body force method is used to calculate the K_t values. Then, the formulae are obtained as K_td and K_ts . (ii) On the one hand, upon comparison of K_t and K_td it is found that K_t is nearly equal to K_td if the notch is deep or blunt. (iii) On the other hand, if the notch is sharp or shallow, K_t is mainly controlled by K_ts and the notch depth. (iv) The notch shape is classified into several groups according to the notch radius and notch depth. Then, the least-squares method is applied for the calculation of K_t /K_td and K_t /K_ts . (v) Finally, a set of convenient formulae is proposed that are useful for any shape of notch in a round test specimen. The formulae give SCFs with <1% error for any shape of notch.     

Fracture mechanics and notch sensitivity

A diagram valid for the analysis of the fatigue limit of cracks and notches centred in an infinite plate was recently proposed by the authors of the present work with the aim to make explicit the bridging at the fatigue limit between defect sensitivity (correlated to the length parameter a₀, according to El Haddad–Topper–Smith's definition) and notch sensitivity (correlated to a*, where a* is a particular notch depth corresponding to the intersection between the ΔK_th and Δσ₀/K_t curves). The expression being valid, defect sensitivity and notch sensitivity were seen as two sides of the same medal. Such a diagram is now extended to finite size components by simply introducing the shape factor α commonly used in fracture mechanics. The obtained critical defect size is termed a_D, which is a material and geometry dependent parameter, in order to distinguish it from a₀, which is a material parameter. As a consequence the critical notch depth a_N is introduced, such that . This results in the proposal of a ‘universal’ diagram able to summarize experimental data related to different materials, geometry and loading conditions. The diagram, the validity of which is checked by means of several results available in the literature, is applied both to the interpretation of the scale effect and to the surface finishing effect.     

Theoretical investigation of elastoplastic notch fields under triaxial stress constraint

In this paper, an exact elastic-plastic solution has been obtained based on the J ₂-deformation theory of plasticity for a plate having a circular hole under biaxial tension and triaxial stress constraint in linear elastic strain-hardening materials. The theoretical solution shows that a linear elastic solution of the equivalent strain can be used to linear elastic-power hardening plastic situation just by a simple variable replacement. Then a strain equivalent rule (SER) is proposed to predict the elastoplastic notch fields by use of the elastic solution. Validations against theoretical analyses and finite element calculation for various combinations of material properties, triaxial stress constraints, load levels show that the SER can be used to predict stress-strain distributions in the whole plastic zone effectively and conveniently.     

Fatigue limit evaluation of notches,small cracks and defects: an engineering approach

In this paper, the average stress method for the fatigue limit evaluation of stress raising geometrical features is revised and extended. In particular, an analytical close‐form approach was used and the linear elastic stress equations were modified by taking into account the effect of nominal stress on the local stress distribution. Hence, the average tangential stress was correctly evaluated over a distance of 2a₀, where a₀ was El Haddad's short crack constant, for long and small notches as well as for crack‐like notches. When this model is applied to a wide range of geometrical features subjected to mode I fatigue loading, the classical shape of the curves of the Kitagawa–Takahashi diagram was obtained for changes in crack‐like notch size. Similarly, notch sensitivity was estimated by reducing the notch tip radius. The accuracy of the proposed method in predicting fatigue limits was then checked by using experimental data taken from the literature and generated on testing specimens weakened by rounded and sharp notches as well as by small artificial defects.     

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.     

Effect of notches on creep–fatigue behavior of a P/M nickel-based superalloy

A study was performed to determine and model the effect of high temperature dwells on notch low cycle fatigue (NLCF) and notch stress rupture behavior of a fine grain LSHR powder metallurgy (P/M) nickel-based superalloy. It was shown that a 90 second (s) dwell applied at the minimum stress (“min dwell”) was considerably more detrimental to the NLCF lives than similar dwell applied at the maximum stress (“max dwell”). The short min dwell NLCF lives were shown to be caused by growth of small oxide blisters which caused preferential cracking when coupled with high concentrated notch root stresses. The cyclic max dwell notch tests failed mostly by creep accumulation, not by fatigue, with the crack origin shifting internally to a substantial distance away from the notch root. The classical von Mises plastic flow model was unable to match the experimental results while the hydrostatic stress profile generated using the Drucker–Prager plasticity flow model was consistent with the experimental findings. The max dwell NLCF and notch stress rupture tests exhibited substantial creep notch strengthening. The triaxial Bridgman effective stress parameter was able to account, with some limitations, for the notch strengthening by collapsing the notch and uniform gage geometry test data into a singular grouping.