A simple model of stress intensity range threshold and crack closure stress

The cyclic stress intensity threshold (Δ$\text{K}{}_{\mathrm{TH}}$) below which cracks will not propagate varies with length for short cracks. A model is proposed which relates Δ$\text{K}{}_{\mathrm{TH}}$ to the crack closure stress arising from fracture surface roughness. This is used to predict a variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length for surface cracks in Ti 6Al-2Sn-4Zn-6Mo alloy, based upon measured values of crack opening displacement arising from roughness. The predicted variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length is found to be similar to that obtained from the empirical model of Δ$\text{K}{}_{\mathrm{TH}}$ proposed by El Haddad et al.[5]. The application of the new model to estimate the value of crack closure stress arising from crack tip plasticity for short surface cracks is also discussed.     

Fatigue crack propagation from a crack inclined to the cyclic tensile axis

Cyclic stresses with stress ratio R = 0.65 were applied to sheet specimens of aluminium which have an initial crack inclined to the tensile axis at angles of 30°, 45°, 72° or 90°. The threshold condition for the non-propagation of the initial crack was found to be given by a quadratic form of the ranges of the stress intensity factors of modes I and II. The direction of fatigue crack extension from the inclined crack was roughly perpendicular to the tensile axis at stress ranges just above the threshold value for non-propagation. On the other hand, at stress ranges 1.6 times higher than the threshold values the crack grew in the direction of the initial crack. The rate of crack growth in the initial crack direction was found to be expressed by the following function of stress intensity factor ranges of mode I, K₁, and mode II, K₂: $\text{dc}\text{dN}\text{= C(K}{}_{\mathrm{eff}}\text{)sum}$, where $\text{K}{}_{\mathrm{eff}}\text{= [K}{}_1{}^4\text{+ 8K}{}_2{}^4\text{]}{}^{\mathrm{<mtext>1</mtext><mtext>4</mtext>}}$. This law was derived on the basis of the fatigue crack propagation model proposed by Weertman.     

Dynamic stress distribution around the tip of a running crack

The stress distribution is obtained around the tip of a crack running in a brittle material. The stresses are written as the sum of the associated static solution and the wave-effect terms which depend upon the crack speed. The results obtained clearly reduce to the associated static solutions if the crack speed vanishes.Near the tip of the crack, the dynamic stress-intensity factor for the circumferential stress, $\text{σ}{}_{\mathrm{\theta \theta }}$, is written as the product of the associated static stress-intensity factor and the dynamic correction factor which is a nondimensional function of the crack speed, $\text{V}$, the angle from the crack plane, θ, and Poisson's ratio, ν. The value of the correction factor is computed for various values of $\text{V}$ and θ at $\text{ν = 0.25}$. It is shown that the maximum tensile value of $\text{σ}{}_{\mathrm{\theta \theta }}$, occurs on the crack plane for $\text{V}$ less than 0.7 time shear wave speed, $\text{c}{}_2$, and suddenly shifts to the plane of $\text{θ = 55°}$ for $\text{V}$ slightly larger than 0.7 $\text{c}{}_2$. For $\text{V > 0.7}$$\text{c}{}_2$, the angle θ for the maximum $\text{σ}{}_{\mathrm{\theta \theta }}$, θ being larger than 55°, varies continuously with the crack speed, $\text{V}$. The results obtained are used to discuss the growth of branching crack.     

Influence of stress state on static crack growth in AlZnMgCuO·5

To investigate the influence of stress state on the $\text{R-}\text{curve}$ the electric potential method was used to determine $\text{R-}\text{curves}$ for specimens with different thicknesses. The maximum thickness was greater than 2.5 ($\text{K}{}_{\mathrm{Ic}}\text{/δ}{}_{\mathrm{Y}}$)². A formula developed by H.H. Johnson was used to compute the crack length increase from the measured potential drop.The investigation showed a marked influence of specimen thickness on the crack propagation resistance. This influence increases with increasing crack propagation. Transition from plane strain to plane stress causes an increase of the crack propagation resistance. The $\text{R-}\text{curve}$ is also dependent on specimen orientation with respect to rolling direction whereas a twofold variation of initial crack length did not show any influence on the $\text{R-}\text{curve}$. Furthermore, the experimental $\text{R-}\text{curve}$ data are compared with analytical $\text{R-}\text{curve}$ expressions.     

Cyclic analysis of a propagating crack and its correlation with fatigue crack growth

Stress and strain field of a propagating fatigue crack and the resulting crack opening and closing behavior were analysed. It was found that a propagating fatigue crack was closed at tensile external loads due to the cyclically induced residual stresses. Strain range value $\text{Δ?}{}_{\mathrm{y}}$ in the vicinity of the crack tip was found to be closely related with the effective stress intensity factor range $\text{ΔK}{}_{\mathrm{eff}}$ which was determined on the basts of the analytical crack opening and closing behavior at its tip. Application of this analysis to the non-propagating fatigue crack problem and the fatigue crack propagation problems under variable stress amplitude conditions revealed that both $\text{Δ?}{}_{\mathrm{y}}$ and $\text{ΔK}{}_{\mathrm{eff}}$ were essential parameters governing fatigue crack growth rate.     

Crack tip closure and environmental crack propagation

Crack propagation rate, da/dN, and crack tip closure stress, σ_cc, in part-through crack fatigue specimens of aluminum alloys are drastically affected by gaseous environments. The present studies indicate that the crack closure reflects the influence of the environment on the plastic deformation at the crack tip, and, therefore, on the crack propagation rates. Postulating that da/dN is mainly determined by $\text{ΔK}{}_{\mathrm{eff}}\text{∝ (σ}{}_{\max }\text{?σ}{}_{\mathrm{cc}}\text{)}$ (instead of $\text{ΔK ∝ (σ}{}_{\max }\text{?σ}{}_{\min }\text{)}$, as is done traditionally) leads to the relationship $\text{da/dN = A(ΔK}{}_{\mathrm{eff}}\text{)}{}^{\mathrm{n}}$ in which $\text{A}$ and $\text{n}$ are virtually independent of the gaseous environment. The exponents are $\text{n ≈ 3.3}$ for Al 7075 T651 and $\text{n ≈ 3.1}$ for Al 2024 T351, respectively.     

Fatigue crack propagation in steels

From previous investigations of the mechanisms of both fracture and fatigue crack propagation, the static fracture model proposed by Lal and Weiss may be thought as reasonable for describing fatigue crack propagation in metals at both low and intermediate stress intensity factor ranges $\text{ΔK}$. Recent progress in fatigue crack propagation indicates that it is not only possible, but also necessary, to modify this static fracture model. Based on the modified static fracture model, the effective stress intensity factor range $\text{ΔK}{}_{\mathrm{eff}}$, which is defined as the difference between $\text{ΔK}$ and the fatigue crack propagation threshold value $\text{Δ}{}_{\mathrm{th}}$, is taken as the governing parameter for fatigue crack propagation. Utilising the estimates of the theoretical strengths of metals employed in industry, a new expression for fatigue crack propagation, which may be predicted from the tensile properties of the metals, has been derived. The correlation between the fatigue crack propagation rate and the tensile properties is thus revealed. The new expression fits the test results of fatigue crack propagation of steels below 10^?3 mm/cycle and indicates well the effect of stress ratio on the fatigue crack propagation rate.     

Mechanism of corrosion fatigue crack propagation in high strength steels

The crack propagation velocity in corrosion fatigue $\text{(d a/d N)}{}_{\mathrm{c}}$ were measured on the Ni-Cr-Mo steel quenched and tempered at 473 or 773 K.The steel with high sensitivity to delayed failure reveals the largest $\text{(d a/d N)}{}_{\mathrm{c}}$ under square load and the smaller $\text{(d a/d N)}{}_{\mathrm{c}}$ under positive saw tooth load. The frequency dependency of crack propagation characteristics indicates that the interaction between hydrogen atoms and the cyclic moving of triaxial position at crack tip acts an important role in the crack propagation mechanism, i.e. hydrogen concentration process controls the crack propagation of the steel.The steel with low susceptibility to delayed failure reveals, on the other hand, the largest $\text{(d a/d N)}{}_{\mathrm{c}}$ under the positive saw tooth load but the smallest $\text{(d a/d N)}{}_{\mathrm{c}}$ under the square load, i.e. the stress increasing time is important and the hydrogen invasion process is the controlling factor for the crack propagation.     

Effect of stress wave shape on the crack propagation velocity in cyclic delayed failure

Crack propagation velocity in delayed failure under superposed repeating load, ($\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{R}}$, was compared with that under static load, ($\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{S}}$Two peaks appear on the relation between decreasing rate of crack propagation velocity, $\text{1-β = 1 ? (}\text{d}\text{a/}\text{d}\text{t))}{}_{\mathrm{R}}\text{/(}\text{d}\text{a/}\text{d}\text{t)}{}_{\mathrm{S}}$ and frequency, ?, both under sinusoidal and square load. By changing the ratio of holding time at maximum stress intensity factor to that at minimum stress intensity factor in square load, it was deduced that the existence of two peaks on the 1 ? β vs $\text{f}$ curve was caused by an asymmetric interaction between hydrogen atoms and cyclic moving of the position with triaxial tensile stress at crack tip. Moreover, the relation between 1 ? β and $\text{f}$ under the positive or negative saw tooth load could be well explained by the interaction model.     

Experimental research on surface crack propagation laws for low alloy steel

Surface crack propagation experiments were performed for low alloy steel. The testing result shows that the data for the crack propagation rate in the surface in the direction of the width may be treated by using Paris and Erdogan formula [1] for the crack propagation rate, and Shah and Kobayashi's formula for the stress intensity factor[2]. For the crack propagation rate in the direction of the depth, the data obtained cannot be treated in this way.It has been found that the data can also be treated by using the experimental formula suggested by Kawahara et al.[3].In addition, a test for investigating through-thickness crack propagation was made. It was found that the propagation rate of the through-thickness crack is much greater than those of the surface crack both in the direction of the width and in the direction of the depth. When $\text{ΔK(= 100 Kg/mm}{}^{\mathrm{<mtext>3</mtext><mtext>2</mtext>}}$) is the same, the propagation rate of through-thickness crack da/dN is five times as great as that of surface crack in the direction of the width.During the propagation of the crack, the relationship between the crack length b and the crack depth a is $\text{a}\text{b}\text{= A?B}\text{a}\text{h}$, where A = 0.97, B = 1.29.With db/dN determined, the prediction of fatigue life can be calculated by

$\text{N=}\text{∫}\text{a}{}_0\text{a}\text{A}\text{A?B}\text{a}\text{h}{}^2\text{d}\text{N}\text{d}\text{b}\text{d}\text{a}$

.     

Effect of mechanical properties of material on rate of fatigue crack propagation

Many experimental and analytical equations on a rate of a fatigue crack propagation have been proposed. However, it seems that they can not fully express its complex behavior. There are still many problems remaining to be solved in order to clarify its mechanism. One of them is to clarify the relation between the rate of the crack propagation and the mechanical properties of material. In this paper, the rate of the crack propagation is analysed to clarify this problem. This analysis is based on the observation results of the fatigue crack propagation behavior previously by the authors. The analytical result is compared with the experimental one to make sure that they agree with each other. The conclusion obtained is; the rate of fatigue crack propagation is expressed by using the stress intensity factors as

$\text{dl}\text{dN}\text{= {}\text{c}\text{[Y}{}^2\text{F}{}^{\mathrm{a}}\text{E}{}^{\mathrm{a(1?n)}}\text{]}\text{} (K}{}_{\max }\text{)}{}^2\text{(K}{}_{\mathrm{a}}\text{)}{}^{\mathrm{a(2?n)}}$

. where C is a constant; E, Young's modulus; F, plastic coefficient; Y, yield stress; K_max and K_a, maximum and amplitude of the stress intensity factor, and α and n, exponents of the Manson-Coffin's law and work-hardening.     

The effects of load ratio on environmentally assisted fatigue crack growth

A modification to the model of Weir et al. for surface reaction and transport controlled fatigue crack growth has been developed to explicitly account for the effect of load ratio on environmentally assisted fatigue crack growth. Load ratio was found to affect principally gas transport to the crack tip, and therefore affected only transport controlled crack growth response. Experimental verification of the modified model was made by studying the room temperature fatigue crack growth responses at different load ratios for a 2219-T851 aluminum alloy exposed to water vapor.The results show that the effects of load ratio can be attributed to two different sources—one relating to its effect on local deformation at the crack tip and is reflected through the mechanical component, (d$\text{a}$/d$\text{N}$)₀ and the other on its role in modifying environmental effect and is manifested through the corrosion fatigue component, $\text{(da/dN)}{}_{\mathrm{cf}}$ Furthermore, the results show that the saturation value of corrosion fatigue component, $\text{(da/dN)}{}_{\mathrm{cf,s}}$, is essentially independent of $\text{R}$, and that the exposure needed to produce “saturation response” ($\text{P}{}_0\text{/2f)}{}_{\mathrm{s}}$, as a function of load ratio can be predicted from the modified model. The modified model, therefore, allows one to predict the corrosion fatigue crack growth response for any load ratio on the basis of measurements made at a single load ratio, provided that the values of ($\text{da/dN}$), are known.     

On crack opening stress level in fatigue by Eddy current technique

Linear elastic fracture mechanics relates fatigue crack growth with the stress intensity factor at the crack tip. Presence of residual deformations at the tip of a fatigue crack reduces the crack tip stress intensification such that effective stress intensity range $\text{ΔK}{}_{\mathrm{e}}\text{= U · ΔK}$. In this paper use of eddy current technique is exhibited to find the values of test value of effective stress range factor $\text{U}{}_{\mathrm{test}}$. A reasonable comparison between computed and experimental results of $\text{U}{}_1$ and $\text{U}{}_{\mathrm{test}}$ on two Al alloys 6061-T6 and 6063-T6 has recommended the Eddy Current Technology for finding out the values of crack opening stress level under given loading conditions.     

Effect of specimen thickness on the crack propagation and crack branching in delayed failure

The crack propagation and crack branching behaviors in delayed failure have been investigated on the specimens with various thickness ($\text{B = 1.5–10}\text{mm}$).The crack propagation velocity reveals a maximum value at a medium specimen thickness ($\text{B = 5}\text{mm}$). This fact can be understood by assuming the compound effect of two factors that the triaxiality of stress at crack tip as a driving force for hydrogen diffusion increases with increase of specimen thickness $\text{B}$, and that the invasion of hydrogen atoms from specimen surface increases with decrease of $\text{B}$.The stress intensity factor at crack branching, $\text{K}{}_{\mathrm{IB}}$, increases with decrease of specimen thickness $\text{B}$, and when B is 1.5 mm, the specimen fractures without showing the crack branching. The latter fact can be explained by connecting the necessary and sufficient conditions for crack branching with the decrease in height of plastic region at the crack tip in thin specimens.     

The influence of environment and stress ratio on fatigue crack growth at near threshold stress intensities in low-alloy steels

Fatigue crack propagation at low stress intensities has been studied in two low alloy steels in a variety of environments with particular emphasis being placed on the influence of stress ratio and strength level. It was found that fatigue crack growth rates are lower and threshold stress intensities ($\text{ΔK}{}_0$) are higher in vacuum than in humid, laboratory air but, in dry gaseous environments (argon, hydrogen and air) and at low stress ratio ($\text{R ~ 0.1}$), crack growth rates are faster and $\text{ΔK}{}_0$ values are lower than in laboratory air. However, the influence of stress ratio is considerably greater in laboratory air than in dry gaseous environments with the result that, at high stress ratio ($\text{R ~ 0.8}$) $\text{ΔK}{}_0$ values are similar in all environments examined. Increasing material strength level resulted in higher, near-threshold crack growth rates and a reduction in $\text{ΔK}{}_0$ in both dry and humid air environments. The results are discussed in terms of the influence of crack closure and environmental effects on fatigue crack growth behaviour. The importance of corrosion debris produced in fatigue cracks at low stress intensities is also discussed.     

The form of crack tip plastic zones

The “radius” of the plastic zone at a crack tip is a parameter that has numerous applications in fracture mechanics. However, attention is drawn here to the confusion that is apparent, even in text-books, concerning the calculation of the plastic zone “radius” under plane strain conditions. The aim of this work has been to resolve this point, to determine the actual shape and size of the zone and to investigate the influence of stress state and other factors.The plastic zone dimensions have been simply calculated, over a range of values of Poisson's ratio, for isotropic materials subjected to loading under plane stress and plane strain conditions; the analysis has been further extended to cover some effects of anisotropy. It has been demonstrated that, for isotropic materials, the maximum extent of the plastic zone directly ahead of, and in the plane of, a crack is ($\text{K}{}_{\mathrm{I}}\text{/Y)}{}^2\text{18π}$ under plane stress loading and is ($\text{K}{}_{\mathrm{I}}\text{/Y)}{}^2\text{18π}$ under plane strain loading. This latter result is smaller, by a factor of $\text{1}\text{3}$ than the plastic zone “radius” under plane strain conditions that is widely quoted in fracture mechanics texts. That “radius”, ($\text{K}{}_{\mathrm{I}}\text{/Y)}{}^2\text{6π}$ is, in fact, the maximum size of the zone parallel to, but not in, the plane of the crack, if Poisson's ratio is taken to be $\text{1}\text{3}$.A lower value of Poisson's ratio or an increased material anisotropy can lead to an enlarged plastic zone; this latter conclusion suggests that test-pieces for valid fracture toughness measurements on anisotropic materials could be required to be larger than defined in the relevant British Standard.     

An experimental study of crack tip plastic flow in mild steel

The paper deals with an experimental study on the nature of plastic flow at the root of a crack in mild steel beams, for the non-valid $\text{K}{}_{\mathrm{IC}}$ test regime, under three point hending loads. Photoelastic coating technique has been used to measure the plasticity spread ahead of the tip in relation to the load-COD record. It is observed that in all cases there is a sudden increase in specimen compliance near the maximum linear load due to an abrupt increase in plastic zone size on some preferential planes ahead of the crack tip. This abrupt increase in plastic flow was seen to occur along the 45° planes (with respect to the plane of the crack) for thicker beams and/or with longer cracks. In contrast, the plastic zone extended more on the plane of the crack for thin section beams with relatively shorter cracks. The stress intensity factor required to cause this sudden loss of resistance to localized deformation is found to be remaining constant beyond a certain crack length for a given specimen thickness. These observations suggest that a critical stress intensity factor () concept can be introduced to describe the abrupt flow localization ahead of the crack tip. This () can be taken as a new parameter in addition to those commonly used in characterising the overall “fracture” behaviour of large scale yielding materials like mild steel, especially in the non-valid $\text{K}{}_{\mathrm{IC}}$ test regime.     

Strain rate effects on viscoelastic crack bifurcation

The effects of applied strain rate on the viscoelastic crack bifurcation phenomenon in Polymethyl Methacrylate (PMMA) were investigated. It was still verified that the product $\text{σ}{}_{\mathrm{f}}\text{C}{}_{\mathrm{b}}{}^{\mathrm{<mtext>1</mtext><mtext>2</mtext>}}$ was constant, as was already observed by Congleton and Petch, and Anthony, Chubb and Congleton, for brittle elastic materials, for any strain rate, where σ_f = the gross fracture stress and C_b= the main crack length until the bifurcation starts. However, it was found that the higher strain rate increases the main crack length C_b resulting in the decrease in the gross fracture stress σ_f and vice versa. This might be interpreted that the higher stress concentration at the initiation crack tip, which is realized by becoming more brittle due to the higher strain rate owing to the predominance of the elastic element in the viscoelastic material, decreases the gross fracture stress leading to the longer main crack length.