THE INFLUENCE OF PLASTIC PRESTRAINING ON BRITTLE FRACTURE RESISTANCE OF METALLIC MATERIALS WITH CRACKS

Abstract The purpose of the present work was to study the influence of different regimes of overloading of pressure vessel steels in different states which correspond to the steel properties at the beginning of a reactor operation and at different degrees of embrittlement (simulated by heat treatment). The experiments were performed on 25, 50 and 150 mm thick specimens with short and long cracks of various shape in the temperature range from 293 to 623 K corresponding to the service temperature range of those steels. The following factors were investigated contribution of different effects (residual stresses, strain hardening, crack tip blunting) into the enhancement of the brittle fracture resistance of steels after warm prestressing, stability of the positive warm prestressing effect during subsequent exposure of the steels to different service loading conditions; size effect on optimal regimes of thermo-mechanical prestressing and on the brittle fracture resistance characteristics of the steels studied after warm-prestressing. An approach is proposed to predict the increase in the brittle fracture resistance of steels with cracks after warm prestressing.     

INVESTIGATION OF THE ROLE OF RESIDUAL STRESSES IN THE WARM PRESTRESS (WPS) EFFECT. PART I—EXPERIMENTAL

Abstract— The role of residual stresses in the warm prestress (WPS) effect has been investigated. Three types of specimen have been tested in this investigation: smooth uniaxial tensile specimens, blunt notched single edge notched bend (SENB) specimens and sharply precracked SENB specimens. Room temperature prestraining of uniaxial tensile specimens leads to a dramatic decrease in the measured nominal fracture stress at — 196°C. Such an embrittling effect may be expected to reduce the beneficial increase in subsequent fracture toughness commonly observed in WPS sequences. The blunt-notched specimens were prestressed in tension and compression. Compressive prestressing was found to lead to a decrease in subsequent fracture load whereas tensile prestressing leads to an increase. The load decrease following a compressive WPS was greater than the load increase following a tensile WPS. Various sequences of loading, unloading and cooling have been investigated and the differences in the subsequent fracture behaviour of specimens have been explained qualitatively by superposition arguments. The theories of Chell and Curry have been supported by the general trend of results.     

A calculation-experimental study of crack-tip opening displacement and residual stresses upon warm prestressing

For a reactor pressure vessel steel 15Kh2MFA(III) experiments and calculations have been carried out to study the factors that have an influence on the increase of the lower-shelf fracture toughness in the temperature dependence diagrams upon warm prestressing. Stereoscopic fractography and numerical investigation have demonstrated that after the warm prestressing the crack tip remains blunt. This reduces the stress singularity during subsequent loading and raises the material fracture toughness. The paper gives the calculated data on residual stresses and crack-tip opening displacement during warm prestressing and upon relief. The calculated results are shown to agree well with the known analytical relations and experimental data.     

THE EFFECT OF SPECIMEN SIZE ON THE J R-CURVE BEHAVIOUR OF A TITANIUM ALLOY

Abstract— —This paper presents preliminary results from a large experimental programme to study geometry and size effects in J R-curves, The results presented were obtained from unloading compliance R-curve tests performed at room temperature on different sized single-edge-notch-bend specimens made from Ti-3Al–2V alloy. The crack growth resistance was measured in terms of the standard fracture resistance J (i.e. not corrected for crack growth), J corrected for crack growth, and the J modified parameter proposed by Ernst. It was found that the best agreement was exhibited by the R-curves based on the standard fracture resistance J , which displayed reasonable size independence up to, and in many cases beyond crack growths corresponding to 50% of the initial uncracked ligament.     

Fem prediction of the influence of warm prestressing on fracture toughness of heat-resistant steel

We present a procedure of prediction of the influence of warm prestressing combined with cycling on the brittle strength of steel 15Kh2MFA. Using a finite-element method, the effect of the combined warm prestressing on the stress-strain state at a fatigue crack tip is studied in an elastic-plastic statement. Electron microscopic observations of fracture surfaces have revealed that fracture is initiated at some distance from the fatigue crack front. Based on the pattern of influence of the plastic prestrain level on the cleavage stress of steel 15Kh2MFA and the experimental CID value, a method is put forward for finite-element modeling of the stress-strain state at a crack tip during the specimen fracture. Using the results of the finite-element modeling, the relevant curves have been plotted and an approximating formula has been proposed to represent the influence of the combined warm prestress level on the fracture toughness of steel 15Kh2MFA.     

INVESTIGATION OF THE ROLE OF RESIDUAL STRESSES IN THE WARM PRESTRESS (WPS) EFFECT. PART II—ANALYSIS

Abstract— Curry's model of the WPS effect has been applied to the results of a previous paper, and is extended to treat warm prestressing in blunt notched test-pieces. The effect of more complex prestress cycles is also predicted by an extrapolation of the model. The effects of the load-cool-fracture, LCF, cycle can be reasonably predicted for both sharply precracked and blunt notched specimens. For the sharply precracked specimens the effects of the load-unload-cool-fracture, LUCF, cycle at — 196°C are consistently overpredicted and this may be due to a decrease in the cleavage fracture stress at — 196°C of the material at the crack tip which has been subjected to repeated plastic straining by the combination of loading cycles. Modifications to the model are suggested which reduce the overproduction but a wide degree of scatter is observed in the experimental observations. Blunt notched specimens show a reasonable correlation between prediction and theory for the tensile LUCF cycle. Problems have been found in predicting the effect of various prestress cycles in different specimens due to the inherent variability in baseline fracture behaviour of the weld metal. It is concluded that the general trend of results is adequately explained by superposition models but that a greater understanding of local flow properties at a crack tip is required to achieve reasonable predictive success for weld metals such as A533BW.     

A STUDY OF SPECIMEN SIZE ON J-R CURVE BEHAVIOUR

This paper presents results from an experimental programme to study size effects in J-R curves. Results are presented from unloading compliance R curve tests on different sized single edge notch bend specimens of nickel aluminium bronze and compared with previously published R curve data on a Ti3A1-2.5V titanium and an HY 100 steel alloy. The crack growth resistance was measured in terms of the standard fracture resistance J, J corrected for crack growth and the J modified parameter proposed by Ernst. It was observed that following a region of size independence small specimen J-R curves could fall either above or below the large specimen curve. It was found that although the limit to J controlled crack growth could be extended the limit is not unique but dependent on material type.     

Prediction of the Warm Prestressing Effect on an Increase in the Brittle Strength of Crack-Containing Heat-Resistant Structural Steels. Part 1. Model and Procedure of Calculating the Warm Prestressing Effect

The physicomechanical model of warm prestressing and the procedure of calculating this effect for heat-resistant steels are proposed. The procedure is based on the analysis of stress-strain state variations in the elementary volume of the material near the crack tip during warm prestressing and further loading. This procedure takes account of such factors as crack tip blunting, residual stresses, and strain hardening of the material near the crack tip, which determine the effect of warm prestressing on the brittle strength of heat-resistant steels.     

THE EFFECTS OF CRACK DEPTH ON THE J-INTEGRAL AND CTOD FRACTURE TOUGHNESS FOR WELDED BEND SPECIMENS

This work deals with the influence of crack depth on the fracture toughness at initiation of crack growth and the constraint factor in relationship between the J-integral and the crack tip opening displacement (CTOD). A series of tests were performed on high strength low alloyed HT80 steel welds, and the critical J-integral and CTOD were determined using the load versus load point displacement record from three-point bend specimens with 0.05 < a/W < 0.5. It was found that the fracture toughness for shallow cracks at the onset of crack growth was larger than that for deep cracks for the steel welds tested, but it is felt that there is no fixed relationship between these values in the welds tested. The constraint factor is also a function of crack depth, and values of the factor increase from 0.5 to 1.5 when a/W increases from about 0.05 to 0.5. The factors are not very sensitive to the crack tip materials (HAZ or weld metal) in the welds tested.     

THE WARM PRESTRESSING EFFECT IN STEELS UNDERGOING INTERGRANULAR FRACTURE

Abstract— The warm prestressing (WPS) effect has been studied in three different steels. One of these, a Cr-Ni steel (EN36), was heat treated to cause fracture to occur either intergranularly, by cleavage, or by a mixture of cleavage and intergranular fracture. A plain carbon steel (EN3) was also used for experiments involving cleavage fracture and thermally aged A533B was used for additional experiments involving intergranular fracture. A significant WPS effect was found for each fracture mode. There were slight differences in the magnitude of the effect for different groups of specimens but, except in certain special cases, these were not considered significant. Experiments involving stress relieving treatments following warm prestressing were also carried out. They indicated that the WPS effect was not completely eliminated by stress relieving. Crack blunting during warm prestressing has been proposed to account for this and for certain other aspects of the results.     

Fracture-induced photon emission of aluminium oxide and its application to fracture mechanical investigations

Mechanically-stimulated luminescence is generated during sub-critical crack growth prior to macroscopic bending fracture of sintered alumina, fusion-cast Al₂O₃, sapphire, and ruby. At similar toughness, K _Ic, the measured intensity increases with the hardness of the tested specimens, it does not depend on the macroscopic fracture strength.     

Slow crack growth in cellulose fibre cements

Slow stable crack growth is a prominent feature of the fracture behaviour of cellulose fibre cements. It is shown that this characteristic can be described by crack growth resistance against crack extension curves based on linear elastic fracture mechanics. Double-cantilever-beam specimens with side grooves are used to obtain such crack resistance curves for a commercial cellulose cement containing approximately 8% mass fraction of bleached fibres. Both dry and wet samples are tested. Compliances measured during slow crack growth by the unloading/reloading technique at successive crack increments are less than those obtained for saw-cut notches with similar crack lengths. Residual displacements due to either mismatch fracture surfaces or a large inelastic process zone at the crack tip are also observed at zero load. A modified elastic potential energy release rate (G _R ^* ), and hence its equivalentK _R ^* [= (EG _R ^* )^1/2], must be used to include this residual displacement effect in order to yield the true crack growth resistance curves. This is found to be necessary for the wet samples due to their large residual displacements. The crack growth resistances of the wet samples are superior to those of the dry samples: this is explained in terms of the improved ductility and toughness of the wet cellulose fibres.     

THE EFFECTS OF MICROSTRUCTURE AND FRACTURE SURFACE ROUGHNESS ON NEAR THRESHOLD FATIGUE CRACK PROPAGATION CHARACTERISTICS OF A TWO-PHASE CAST STAINLESS STEEL

In this study, the effects of stress ratio, microstructure and fracture surface roughness on the fatigue properties of a two-phase cast stainless steel were investigated. This behaviour was examined by means of the fracture mechanics approach and fractography. The fatigue crack growth rate decreased with decreasing stress ratio. The stress ratio markedly influenced the fatigue crack growth rate as ΔK approached the ΔK_th value. The roughness of the fracture surface was greater in the as-cast material than in the heat-treated material. Analysis of the crack growth data using ΔK_eff showed that the effect of R ratio could be explained but that the effect of microstructure on crack growth rate could not.     

An energy analysis of crack initiation and arrest in epoxy

The objective of this work is to study fracture processes such as crack initiation and arrest in epoxy. A compact tension specimen with displacement-controlled loading is employed to observe multiple crack initiations and arrests. The energy release rate at crack initiation is significantly higher than that at crack arrest, as has been observed elsewhere. In this study the difference between these energy release rates is found to depend on specimen size (scale effect), and is quantitatively related to the fracture surface morphology. The scale effect, similar to that in strength theory, is conventionally attributed to the statistics of defects which control the fracture process. Triangular shaped ripples, deltoids, are formed on the fracture surface of the epoxy during the slow sub-critical crack growth, prior to the smooth mirror-like surface characteristic of fast cracks. The deltoids are complimentary on the two crack faces which excludes any inelastic deformation from consideration. The deltoids are analogous to the ripples created on a river surface downstream from a small obstacle. However, in spite of our expectation based on this analogy and the observed scale effect, there are no defects at the apex of the deltoids detectable down to the 0.1 micron level. This suggests that the formation of deltoids during the slow process of sub-critical crack growth is an intrinsic feature of the fracture process itself, triggered by inhomogeneity of material on a sub-micron scale. This inhomogeneity may be related to a fluctuation in the cross-link density of the epoxy.     

A FINITE ELEMENT TECHNIQUE TO SIMULATE THE STABLE SHAPE EVOLUTION OF PLANAR CRACKS WITH AN APPLICATION TO A SEMI-ELLIPTICAL SURFACE CRACK IN A BIMATERIAL FINITE SOLID

This paper describes a numerical procedure to model the crack front evolution of initially arbitrary shaped planar cracks in a three-dimensional solid. The influence of a bimaterial interface on the fracture path of a semi-elliptical surface crack in a three-dimensional structure is examined. The analysis is based on the assumption that fracture is controlled by small-scale yielding and linear elastic fracture mechanics. The finite element method and the crack-tip contour J-integral in a volume domain representation are utilized to calculate the crack front energy release rate. The computed values of the energy release rate are used with a crack-tip velocity growth law to model crack growth increment. The progress of the crack growth evolution is brought forward by successive iterations. Examples of computed crack evolution are given for an embedded circular crack, a semi-elliptical surface crack in a finite plate, and a configuration that defines an isotropic homogeneous material layer with a surface crack located between two material layers. © 1997 by John Wiley & Sons, Ltd.     

SENSITIVITY ANALYSIS OF THE DOUBLE CLIP GAUGE METHOD

During fracture toughness testing, the stable crack growth measurement is necessary for the construction of the R-curves of J vs Δa or CTOD vs Δa. One possible measurement technique uses the Double Clip Gauge Method, which is based on the assumption that the specimen is deformed like two rigid arms that rotate around an apparent centre of rotation located in front of the crack tip. This apparent centre moves as the crack grows in a stable way, and its position can be estimated through the measurement of two crack opening displacements located at different heights. As a consequence the crack growth can be calculated. In this paper the behaviour of the equations that govern the Double Clip Gauge Method are described, and the zones of greatest sensitivity for the location of the clip gauges are determined. A sensitivity analysis of the most influential intervening variables is also made.     

Preparation,microstructure and mechanical properties of dense polycrystalline hydroxy apatite

Hydroxy apatite ceramic blocks of varying density have been prepared from a commercial powder. The elastic properties, fracture toughness, strength and sub-critical crack growth of these materials have been investigated. Young's modulus for the nearly fully dense material is 112 GPa while the compressive strength is about 800 MPa. For the same material the strength and fracture toughness under dry conditions are 115 MPa and 1.0 MPa m^1/2, respectively. Substantial slow crack growth was found under these conditions. Under wet conditions the values for strength and fracture toughness drop to about 75% of their “dry” values. In this case very serious slow crack growth is present.     

Enhancement of delamination fatigue resistance in carbon nanotube reinforced glass fiber/polymer composites

We show that the addition of small volume fractions of multi-walled carbon nanotubes (CNTs) to the matrix of glass–fiber composites reduces cyclic delamination crack propagation rates significantly. In addition, both critical and sub-critical inter-laminar fracture toughness values are increased. These results corroborate recent experimental evidence that the incorporation of CNTs improve fatigue life by a factor of two to three in in-plane cyclic loading. We show that in both the critical and sub-critical cases, the degree of delamination suppression is most pronounced at lower levels of applied cyclic strain energy release rate, ΔG. High-resolution scanning electron microscopy of the fracture surfaces suggests that the presence of the CNTs at the delamination crack front slows the propagation of the crack due to crack bridging, nanotube fracture, and nanotube pull-out. Further examination of the sub-critical fracture surfaces shows that the relative proportion of CNT pull-out to CNT fracture is dependent on the applied cyclic strain energy, with pull-out dominating as ΔG is reduced. The conditions for crack propagation via matrix cracking and nanotube pull-out and fracture are studied analytically using fracture mechanics theory and the results compared with data from the experiments. It is believed that the shift in the fracture behavior of the CNTs is responsible for the associated increase in the inter-laminar fracture resistance that is observed at lower levels of ΔG relative to composites not containing CNTs.     

A local approach to cleavage fracture in ferritic steels following warm pre-stressing

Quantification of the enhancement in cleavage fracture toughness of ferritic steels following warm pre‐stressing has received great interest in light of its significance in the integrity assessment of such structures as pressure vessels. A Beremin type probability distribution model, i.e., a local stress‐based approach to cleavage fracture, has been developed and used for estimating cleavage fracture following prior loading (or warm pre‐stressing, WPS) in two ferritic steels with different geometry configurations. Firstly, the Weibull parameters required to match the experimental scatter in lower shelf toughness of the candidate steels are identified. These parameters are then used in two‐ and three‐dimensional finite element simulations of prior loading on the upper shelf followed by unloading and cooling to lower shelf temperatures (WPS) to determine the probability of failure. Using both isotropic hardening and kinematic hardening material models, the effect of hardening response on the predictions obtained from the suggested approach has been examined. The predictions are consistent with experimental scatter in toughness following WPS and provide a means of determining the importance of the crack tip residual stresses. We demonstrate that for our steels the crack tip residual stress is the pivotal feature in improving the fracture toughness following WPS. Predictions are compared with the available experimental data. The paper finally discusses the results in the context of the non‐uniqueness of the Weibull parameters and investigates the sensitivity of predictions to the Weibull exponent, m, and the relevance of m to the stress triaxiality factor as suggested in the literature.     

A review of the J and I integrals and their implications for crack growth resistance and toughness in ductile fracture

The application of the J and the I-integrals to ductile fracture are discussed. It is shown that, because of the finite size of the fracture process zone (FPZ), the initiation value of the J-integral is specimen dependent even if the plastic constraint conditions are constant. The paradox that the I-integral for steady state elasto-plastic crack growth is apparently zero is examined. It is shown that, if the FPZ at the crack tip is modelled, the I-integral is equal to the work performed in its fracture. Thus it is essential to model the fracture process zone in ductile fracture. The I-integral is then used to demonstrate that the breakdown in applicability of the J-integral to crack growth in ductile fracture is as much due to the inclusion in the J-integral of progressively more work performed in the plastic zone as it is to non-proportional deformation during unloading behind the crack tip. Thus J _R -curves combine the essential work of fracture performed in the FPZ with the plastic work performed outside of the FPZ. These two work terms scale differently and produce size and geometry dependence. It is suggested that the future direction of modelling in ductile fracture should be to include the FPZ. Strides have already been made in this direction.