Fully plastic J-integral solutions for surface cracked plates under biaxial loading

In this paper, surface cracked plates under biaxial tension are studied. Three-dimensional elastic-plastic finite element analyses have been carried out to calculate the J-integral for surface cracked plate for a wide range of geometry, biaxiality and material properties. Fully plastic J-integral solutions along the front of the surface cracks are presented for Ramberg-Osgood power law hardening material of n = 3, 5, 10 and 15. Geometries considered are a/c = 0.2, 1.0 and a/t = 0.2, 0.4, 0.6 and 0.8 and the biaxial ratios of 0, 0.5 and 1. Based on these results, the J-integral along the crack front for general elastic-plastic loading conditions can be estimated using the EPRI scheme. These solutions are suitable for fracture analyses for surface cracked plates under biaxial loading.     

Two-parameter characterization of elastic-plastic crack front fields: Surface cracked plates under tensile loading

In this paper the J-Q two-parameter characterization of elastic-plastic crack front fields is examined for surface cracked plates under uniaxial and biaxial tensile loadings. Extensive three-dimensional elastic-plastic finite element analyses were performed for semi-elliptical surface cracks in a finite thickness plate, under remote uniaxial and biaxial tension loading conditions. Surface cracks with aspect ratios a/c = 0.2, 1.0 and relative depths a/t = 0.2, 0.6 were investigated. The loading levels cover from small-scale to large-scale yielding. In topological planes perpendicular to the crack fronts, the crack stress fields were obtained. In order to facilitate the determination of Q-factors, modified boundary layer analyses were also conducted. The J-Q two-parameter approach was then used in characterizing the elastic-plastic crack front stress fields along these 3D crack fronts. Complete distributions of the J-integral and Q-factors for a wide range of loading conditions were obtained. It is found that the J-Q characterization provides good estimate for the constraint loss for crack front stress fields. It is also shown that for medium load levels, reasonable agreements are achieved between the T-stress based Q-factors and the Q-factors obtained from finite element analysis. These results are suitable for elastic-plastic fracture mechanics analysis of surface cracked plates.     

A new constraint based fracture criterion for surface cracks

A new methodology for predicting the location of maximum crack extension along a surface crack front in ductile materials is presented. Three-dimensional elastic-plastic finite element analyses were used to determine the variations of a constraint parameter (α_h) based on the average opening stress in the crack tip plastic zone and the J-integral distributions along the crack front for many surface crack configurations. Monotonic tension and bending loads are considered. The crack front constraint parameter is combined with the J-integral to characterize fracture, the critical fracture location being the location for which the product Jα_h is a maximum. The criterion is verified with test results from surface cracked specimens.     

Comparison of methods for fracture toughness testing of thin low carbon steel plates

Abstract

The fracture toughness of double edge notched tension (DENT) specimens of a low carbon steel sheet was evaluated using experimental and numerical methods. The concepts of critical J integral J_c critical crack tip opening displacement δ_c, essential work of fracture We_e, and essential work of fracture and initiation we^init were compared. The numerical methods were based on finite strain, three-dimensional finite element simulations of the tensile straining of the DENT specimens. Good agreement was found between numerical and experimental J_c values. Fair agreement was also found between J_c and we^init. The essential work of fracture W_e was ～20% lower than J_c. This discrepancy is attributed to inaccuracy in the detection of cracking initiation. The Shih factor derived from the measured J_c and δ_c values closely corresponds with the plane stress prediction.     

Tunneling radial cracks in layered structures from contact loading

Glass/epoxy laminates glued onto a compliant substrate are indented with a hard ball. The damage is characterized by a set of transverse cracks which pop out from the subsurface of the glass layers due to flexure and propagate stably in the radial direction with load in a bell-shape front under a diminishing stress field. Compliant interlayers, even extremely thin ones, are effective in inhibiting crossover fracture. This leads to crack tunneling and crack multiplication in the hard layers, which enhances energy dissipation and reduces the spread of damage relative to the basic bilayer configuration. The experiments show that the fracture in a given layer is well approximated by a power-law relation of the form c^3/2K_C/P = δ, where P, c, and K_C are the indentation load, crack length and fracture toughness, in that order, and δ an implicit function of the layer position and material and geometric variables, derived with the aid of available tunnel crack solutions.The model specimen studied provides a useful insight into the fracture behavior of natural, biological and synthetic layered structures from concentrated loading. The analysis shows that the crack arrest capability of a thin interlayer increases in proportion to the modulus misfit ratio between the layer and interlayer, and that the spread of radial cracks in a laminate of given thickness reduces in proportion to n^1/3, where n is the number layers in the laminate.     

3-D stress intensity factors for arrays of inner radial lunular or crescentic cracks in a typical spherical pressure vessel

Many spherical pressure vessels are manufactured by methods such as the integrated hydro-bulge forming (IHBF) method, where the sphere is composed of a series of double curved petals welded along their meridional lines. Such vessels are susceptible to multiple radial cracking along the welds. For fatigue life assessment and fracture endurance of such vessels one needs to evaluate the stress intensity factors (SIFs) distribution along the fronts of these cracks. However, to date, only two 3-D solutions for the SIF for one inner semi-elliptical crack in thin or thick spheres are available, as well as 2-D SIFs for one through-the-thickness crack in thin spherical shells. In the present paper, mode I SIF distributions for a wide range of lunular and crescentic cracks are evaluated. The 3-D analysis is performed, via the FE method employing singular elements along the crack front, for a typical spherical pressure vessel with outer to inner radius ratios of η = R_o/R_i = 1.1. SIFs are evaluated for arrays containing n = 1-20 cracks; for a wide range of crack depth to wall thickness ratio, a/t, from 0.025 to 0.95; and for various ellipticities of the crack, i.e., the ratio of crack depth to semi crack length, a/c, from 0.2 to 1.5. The obtained results clearly indicate that the SIFs are considerably affected by the three-dimensionality of the problem, and the following parameters: the number of cracks in the array-n, the relative crack depth a/t, and the crack ellipticity a/c.     

J integral solution for semi-elliptical surface crack in high density poly-ethylene pipe under bending

The goal of this work is to analyse the severity of semi-elliptical crack defects and to study the degree of damage in the poly-ethylene pipe in bending during the crack propagation. The semi-elliptical cracks are considered in this work located in different position in the wall of the pipe. The three finite element method based on the computation of the J integral was used to analyse the fracture behaviour of these structures. The effect of the position, shape and size of the crack on the J integral values was highlighted. The effects of strain rate and the temperature on the J integral values were also examined. The obtained results show that the strain rates have a strong influence on the J integral values especially for circumferential crack at higher bending moment. However, the energy for circumferential crack is more important compared to axial crack. The effect of the depth of the crack becomes important when the ratio (a/t) reaches a critical value of 0.6 (a/t = 0.6), especially when the ratio a/c is weak (semi-elliptical crack, a/c = 0.2) where the J integral values becomes independently of the crack depth, this conclusion is opposite to the above for the poly-ethylene pipe subjected to internal pressure. We recall finally, that the temperature effect on circumferential cracks behaviour is more important compared to the axial cracks at critical crack size (a/c = 0.2 and a/t = 0.6). It is also shown that in the wall of pipe, the internal cracks are more dangerous than the external cracks.     

Essential work of fracture analysis of the tearing of a ductile polymer film

The fracture behaviour of a 0.5 mm thick ethylene-propylene block copolymer, previously evaluated using the essential work of fracture method, has been analyzed again in more detail, using different plots, allowing the determination of the crack initiation displacement and stress. In such plots is evidenced that the specific essential work of fracture, w_e, corresponds to the energy just up to crack initiation value that can be related with J₀. Also, it has been found a novel relationship between the plastic term, βw_p and the crack initiation stress, σ_i.     

Fracture behaviour of chemical vapour deposited and hot isostatically pressed zinc sulphide ceramics

Fracture behaviour of zinc sulphide ceramics prepared by chemical vapour deposition (CVD) followed by hot isostatic pressing (CVD + HIP) was investigated in terms of flexural strength (σ_f), plane-strain fracture toughness (K_Ic), even conditional fracture toughness (K_IQ), R-curve behaviour (variation of total fracture energy release rate, J_c with crack extension, δ/δ_c) and fracture mode. The corresponding Knoop Hardness number (KHN) and its correlations to flexural strength (σ_f) are also evaluated and reported. The present study showed that the zinc sulphide (ZnS) ceramics processed by CVD exhibited higher fracture resistance compared to ZnS processed by CVD + HIP condition. This observation is principally attributed to higher grain size associated with post-CVD HIPing process. In both conditions, the ZnS materials exhibited conditional fracture toughness (K_IQ) that decreased moderately with increased crack length due to the change in fracture mode form grossly tensile to predominant shear. A constantly rising R-curve behaviour was indicated in both the materials with significant increase in total fracture energy release rate (J_c with the normalised displacement (δ/δ_c), a parameter representing crack extension.     

Three finite element analysis of semi-elliptical crack in high density poly-ethylene pipe subjected to internal pressure

The principal objective of this work is to analyze the severity of semi-elliptical crack defects and to study the degree of damage in the equipment under internal pressure during the crack propagation. The semi-elliptical cracks are considered in this work located in different position in the wall of poly-ethylene pipe. The tree finite element method based on the computation of the J integral was used to analyze the fracture behaviour of these structures. The effect of the position shape and size of the crack on the J integral was highlighted. The effects of strain rate and the temperature on the J integral values were also examined. The obtained results show that, whatever the material (strain rate) for a semi-elliptical crack, the J integral value has not an important variation with respect to the crack size. However, the energy for axial crack is more important compared to circumferential crack. The effect of the depth of the crack becomes important when the ratio (a/t) reaches a critical value of 0.6 (a/t = 0.6), especially when the ratio a/c is weak (semi-elliptical crack). We recall finally, that the temperature effect on circumferential cracks behaviour is more important compared to the axial cracks. It is also shown that in the wall of pipe, the internal cracks are more dangerous than the external cracks.     

Methods for calculating stress intensity factors in anisotropic materials: Part II—Arbitrary geometry

The problem of a crack in a general anisotropic material under conditions of linear elastic fracture mechanics (LEFM) is examined. In Part I, three methods were presented for calculating stress intensity factors for various anisotropic materials in which z = 0 is a symmetry plane and the crack front is along the z-axis. These included displacement extrapolation, the M-integral and the separated J-integrals.In this study, general material anisotropy is considered in which the material and crack coordinates may be at arbitrary angles. A three-dimensional treatment is required for this situation in which there may be two or three modes present. A three-dimensional M-integral is extended to obtain stress intensity factors. It is applied to several test problems, in which excellent results are obtained. Results are obtained for a Brazilian disk specimen made of isotropic and cubic material. Two examples for the latter are examined with material coordinates rotated with respect to the crack axes.     

Determination of higher order coefficients and zones of dominance using a singular integral equation approach

A method to determine higher order coefficients from the solution of a singular integral equation is presented. The coefficients are defined by , which gives the radial stress at a distance, r, in front of the crack tip. In this asymptotic series the stress intensity factor, k₀, is the first coefficient, and the T-stress, T₀, is the second coefficient. For the example of an edge crack in a half space, converged values of the first 12 mode I coefficients (k_n and T_n, n = 0, … , 5) have been determined, and for an edge crack in a finite width strip, the first six coefficients are presented. Coefficients for an internal crack in a half space are also presented. Results for an edge crack in a finite width strip are used to quantify the size of the k-dominant zone, the kT-dominant zone and the zones associated with three and four terms, taking into account the entire region around the crack tip.     

Finite element simulations of crack propagation in functionally graded materials under flexural loading

Cracks in stepped and continuously graded material specimens under flexural loading were investigated via finite element analysis. Calculation of mechanical energy release rates and propagation angles with crack-opening displacement correlation and the local symmetry (K_II = 0) criterion, respectively, provided results most efficiently and accurately, as compared with compliance and J-integral approaches and other deflection criteria. A routine was developed for automatic crack extension and remeshing, enabling simulation of incremental crack propagation. Effects of gradient profile and crack geometry on crack-tip stresses and crack propagation path are examined, and implications of these for optimal design of graded components against failure by fast fracture are discussed.     

Limitations of elastic definitions in Al-Si-Mg cast alloys with enhanced plasticity: linear elastic fracture mechanics versus elastic-plastic fracture mechanics

Linear elastic fracture mechanics describes the fracture behavior of materials and components that respond elastically under loading. This approach is valuable and accurate for the continuum analysis of crack growth in brittle and high strength materials; however it introduces increasing inaccuracies for low-strength/high-ductility alloys (particularly low-carbon steels and light metal alloys). In the case of ductile alloys, different degrees of plastic deformation precede and accompany crack initiation and propagation, and a non-linear ductile fracture mechanics approach better characterizes the fatigue and fracture behavior under elastic-plastic conditions.To delineate plasticity effects in upper Region II and Region III of crack growth an analysis comparing linear elastic stress intensity factor ranges (ΔK_el) with crack tip plasticity adjusted linear elastic stress intensity factor ranges (ΔK_pl) is presented. To compute plasticity corrected stress intensity factor ranges (ΔK_pl), a new relationship for plastic zone size determination was developed taking into account effects of plane-strain and plane-stress conditions (“combo plastic zone”). In addition, for the upper part of the fatigue crack growth curve, elastic-plastic (cyclic J based) stress intensity factor ranges (ΔK_J) were computed from load-displacement records and compared to plasticity corrected stress intensity factor ranges (ΔK_pl). A new cyclic J analysis was designed to compute elastic-plastic stress intensity factor ranges (ΔK_J) by determining cumulative plastic damage from load-displacement records captured in load-control (K-control) fatigue crack growth tests. The cyclic J analysis provides the true fatigue crack growth behavior of the material. A methodology to evaluate the lower and upper bound fracture toughness of the material (J_IC and J_max) directly from fatigue crack growth test data (ΔK_FT(JIC) and ΔK_FT(Jmax)) was developed and validated using static fracture toughness test results. The value of ΔK_FT(JIC) (and implicitly J_IC) is determined by comparing the plasticity corrected elastic fatigue crack growth curve with the elastic-plastic fatigue crack growth curve. A most relevant finding is that plasticity adjusted linear elastic stress intensity factor ranges (ΔK_pl) are in remarkably good agreement with cyclic J analysis results (ΔK_J), and provide accurate plasticity corrections up to a ΔK corresponding to J_IC (i.e. ΔK_FT(JIC)). Towards the end of the fatigue crack growth test (above ΔK_FT(JIC)) when plasticity is accompanied by significant tearing, the cyclic J analysis provides a more accurate way to capture the true behavior of the material and determine ΔK_FT(Jmax). A procedure to decouple and partition plasticity and tearing effects on crack growth rates is given.Three cast Al-Si-Mg alloys with different levels of ductility, provided by different Si contents and heat treatments (T61 and T4) are evaluated, and the effects of crack tip plasticity on fatigue crack growth are assessed. Fatigue crack growth tests were conducted at a constant stress ratio, R = 0.1, using compact tension specimens.     

Three-dimensional stress state around quarter-elliptical corner cracks in elastic plates subjected to uniform tension loading

Detailed full-field three-dimensional (3D) finite element analyses have been conducted to study the out-of-plane stress constraint factor T_z around a quarter-elliptical corner crack embedded in an isotropic elastic plate subjected to uniform tension loading. The distributions of T_z are studied in the forward section (0° ? θ ? 90°) of the corner cracks with aspect ratios a/c of 0.2, 0.4, 0.5, 0.6, 0.8 and 1.0. In the normal plane of the crack front line, T_z drops radially from Poisson’s ratio at the crack tip to zero beyond certain radial distances. Strong 3D zones (T_z > 0) exist within a radial distance r/a of about 4.6-0.7 for a/c = 0.2-1.0 along the crack front, despite the stress-free boundary conditions far away. At the same radial distance along the crack front in the 3D zones, T_z increases from zero on one free surface to a peak value in the interior, and then decreases to zero on another free surface. The distributions of T_z near the corner points are also discussed. Empirical formulae describing the 3D distributions of T_z are obtained by fitting the numerical results, which prevail with a sufficient accuracy in the valid range of 0.2 ? a/c ? 1.0 and 0° ? θ ? 90° except very near the free surfaces where T_z is extremely low. Combined with the K-T solution, the transition of approximate plane-stress state near the surfaces to plane-strain state in the interior can be characterized more accurately.     

Surface planarization and masked ion-beam structuring of YBa2Cu3O7 thin films

Surface planarization and masked ion-beam structuring (MIBS) of high-T_c superconducting (HTS) YBa₂Cu₃O_7-δ (YBCO) thin films grown by pulsed-laser deposition (PLD) method is reported. Chemical-mechanical polishing, plasma etching, and oxygen annealing of YBCO films strongly reduce the particulate density (~ 10^-2 ×) and surface roughness (~ 10^-1 ×) of as-grown PLD layers. The resistivity, critical temperature T_c ≈ 90 K and critical current density J_c (77 K) > 1 MA/cm² of films are not deteriorated by the planarization procedure. The YBCO films are modified and patterned by irradiation with He⁺ ions of 75 keV energy. Superconducting tracks patterned by MIBS without removal of HTS material and, for comparison, by wet-chemical etching show same T_c and J_c(T) values. Different micro- and nano-patterns are produced in parallel on planarized films. The size of irradiated pattern depends on the mask employed for beam shaping and features smaller than 70 nm are achieved.     

A simplified expression for low cleavage probability calculation

This article describes an analysis made to develop a simplified stress-based criterion for brittle fracture focussed on the lowest probability of failure. For that, on the basis of fine numerical interpretation of two series of fracture-tests on 16MND5 reactor vessel steel, a number of variables were proposed:

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A stress threshold σ_th below which cleavage cannot occur. This stress is determined by testing on notch tensile specimen at low temperature.

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A minimum toughness K_min(T) required to make a crack unstable. The originality is here to consider this parameter depends on temperature.

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For K_J > K_min(T), a volume susceptible to cleavage, defined as the volume of material subjected to stress exceeding the threshold stress and noted V_th, representative of the fracture probability.

These three variables are explained in the article then used to establish a tentative criterion for expressing the risk of brittle fracture, in the presence or absence of a crack.     

A through interface crack between a transversely isotropic pair of materials (+30°/−60°, −30°/+60°)

This study focuses on a delamination between two layers of a fiber-reinforced composite material oriented in the directions θ/(θ − 90°). Two specific interfaces are examined: the +30°/−60° interface and −30°/+60° interface. The delamination in these cases is treated effectively as a crack between two monoclinic materials. The behavior of the stress and displacement fields near the crack tip is studied. The first term of the asymptotic expansion for the stress and displacement fields are found by means of the Stroh and Lekhnitskii formalisms. A general solution is obtained for an interface crack in the x₂ = 0 plane. The crack is between two monoclinic materials with x₂ = 0 a symmetry plane.In order to calculate the stress intensity factors, a three-dimensional interaction energy or conservative M-integral is extended and implemented in conjunction with the finite element method. For the M-integral, the auxiliary fields used are particular cases of the stress and displacement fields obtained earlier. The displacement extrapolation method is also extended for this case. The crack surface displacements obtained from a finite element analysis are employed. The methods are independent of each other; hence, they may be used for validation of the results determined.Three test cases are analyzed to examine the accuracy of the results obtained by means of the M-integral method. In addition, two problems of a central crack in a symmetric composite under different loadings are solved. Those loadings are tension and in-plane shear. Stress intensity factors and the interface energy release rate are obtained along the crack front for all cases.     

Magnetic-field angle dependent critical current densities and flux pinning in commercial YBCO tapes at liquid nitrogen temperatures

The magnetic-field angle dependence of critical current densities J_c(H,θ) in commercial YBCO tapes grown by MOCVD and MOD was examined at liquid nitrogen temperatures. We first measured J_c(H,θ) in MOCVD-YBCO tapes at 70 and 77.3 K in fields up to 2 T using both transport and inductive (the third harmonic voltage) methods and compared the results. It was observed that, in low magnetic fields, the transport measurements gave higher J_c than the inductive ones; however, in high fields they agreed well, which is well explained by the effects of weak links due to low-angle grain boundaries. We then investigated J_c(H,θ) in MOCVD- and MOD-YBCO tapes at 77.3 K in fields up to 2 T. All the tapes exhibited peaks at H//ab in the shape of Mount Fuji, which shows that small random pinning plays a major role. However, an anisotropic scaling analysis showed that the flux pinning mechanisms in those tapes were different, resulting in distinctive angular behaviors of J_c(H,θ). It is suggested that the difference in the flux pinning mechanisms of the two types of tapes came from the different sizes of point defects originating from the growing processes.     

Methods for calculating stress intensity factors in anisotropic materials: Part I—z = 0 is a symmetric plane

The problem of a crack in general anisotropic material under LEFM conditions is presented. In Part I, three methods are presented for calculating stress intensity factors for various anisotropic materials in which z = 0 is a plane of symmetry. All of the methods employ the displacement field obtained by means of the finite element method. The first one is known as displacement extrapolation and requires the values of the crack face displacements. The other two are conservative integrals based upon the J-integral. One employs symmetric and asymmetric fields to separate the mode I and II stress intensity factors. The second is the M-integral which also allows for calculation of K_I and K_II separately.All of these methods were originally presented for isotopic materials. Displacement extrapolation and the M-integral are extended for orthotropic and monoclinic materials, whereas the J_I- and J_II-integrals are only extended for orthotropic material in which the crack and material directions coincide. Results are obtained by these methods for several problems appearing in the literature. Good to excellent agreement is found in comparison to published values. New results are obtained for several problems.In Part II, the M-integral is extended for more general anisotropies. In these cases, three-dimensional problems must be solved, requiring a three-dimensional M-integral.