Characterization of Loading Rate Effects on the Interactions between Crack Growth and Inclusions in Cementitious Material

The microcapsule-enabled cementitious material is an appealing building material and it has been attracting increasing research interest. By considering microcapsules as dissimilar inclusions in the material, this paper employs the discrete element method (DEM) to study the effects of loading rates on the fracturing behavior of cementitious specimens containing the inclusion and the crack. The numerical model was first developed and validated based on experimental results. It is then used to systematically study the initiation, the propagation and the coalescence of cracks in inclusion-enabled cementitious materials. The study reveals that the crack propagation speed, the first crack initiation stress, the coalescence stress, the compressive strength and the ultimate strain increase with the loading rate. The initiation position, the propagation direction, the cracking length and the type of the initiated cracks are influenced by the loading rates. Two new crack coalescence patterns are observed. It is easier to cause the coalescence between the circular void and a propagating crack at a slow loading rate than at a fast loading rate.     

EFFECT OF NON-METALLIC INCLUSIONS ON CORROSION FATIGUE RESISTANCE OF P/M DUPLEX STAINLESS STEELS

Abstract— The effect of non-metallic inclusions on high-cycle fatigue resistance of powder metallurgically (P/M) fabricated and hot isostatically pressed (HIP) duplex stainless steels (DSSs) was investigated with axial fatigue test specimens in a chloride and sulphate containing aqueous solution at room temperature. The inclusion content of the studied materials was analysed with bulk oxygen content measurements as well as with optical and digital inclusion analysis methods. Fatigue crack initiation was observed to take place at material defects, i.e., on contaminated prior powder-particle boundaries or, especially, at oxide inclusions. Localised corrosion was not noticed at the initiation sites. Material defects had an especially pronounced effect on fatigue properties, when the stress ratio was R =0, but their effect decreased, when the calculated stress intensity factor was reduced below a certain value. Moreover, the change of the stress ratio from R =0 to R =-1 decreased the difference in high-cycle corrosion fatigue properties between P/M-HIP DSSs with different inclusion contents.     

Effect of non-metallic inclusions on butterfly wing initiation,crack formation,and spall geometry in bearing steels

Non-metallic inclusions such as sulfides and oxides are byproducts of the bearing steel manufacturing process. Stress concentrations due to such inclusions can originate cracks that lead to final failure. This paper proposes a model to simulate subsurface crack formation in bearing steel from butterfly-wing origination around non-metallic inclusions until final failure. A 2D finite element model was developed to obtain the stress distribution in a domain subjected to Hertzian loading with an embedded non-metallic inclusion. Continuum Damage Mechanics (CDM) was used to introduce a new variable called Butterfly Formation Index (BFI) that manifests the dependence of wing formation on depth. The value of critical damage inside the butterfly wings was obtained experimentally and was used to simulate damage evolution. Voronoi tessellation was used to develop the FEM domains to capture the effect of microstructural randomness on butterfly wing formation, crack initiation and crack propagation. Then, the effects of different inclusion characteristics such as size, depth, and stiffness on RCF life are studied. The results show that stiffness of an inclusion and its location have a significant effect on the RCF life: stiffer inclusions and inclusions located at the depth of maximum shear stress reversal are more detrimental to the RCF life. Stress concentrations are not significantly affected by inclusion size for the cases investigated; however, a stereology study showed that larger inclusions have a higher chance to be located at the critical depth and cause failure. Crack maps were recorded and compared to spall geometries observed experimentally. The results show that crack initiation locations and final spall shapes are similar to what has been observed in failed bearings.     

Fatigue crack growth through particulate clusters in polycarbonate material

The interaction of a crack with a perfectly bonded inclusion or a cluster of inclusions in polycarbonate matrix was investigated through both numerical simulations and fatigue tests. Stress intensity factors (K_I) were evaluated by boundary element method for several particle sizes, position and finally for inclusion cluster as a precursor study for the experiments. The numerical simulation has shown the crack tendency to circumvent the inclusions with consequential reduction of the growth rate. Fatigue crack growth tests were carried out on several particle-filled specimens at constant value of the applied stress intensity factor range (ΔK_Iapp) highlighting the crack delay due to the presence of the stiff second phase. The experiments demonstrated that the inclusion effect on the crack growth rate can be explained with a model based on the crack shielding effect in which the particle would act to reduce the effective stress intensity factor at crack tip (K_Ieff). Finally, the crack growth rate was predicted with an analytical model, and then compared to that obtained by the fatigue testing. Possible explanations for differences are discussed.     

About inclusion shape effect on the endurance limit of ductile matrix materials

The theory describing fatigue mechanism in elastoplastic material containing pores or inclusions of different shape and size has been developed. The paper is a continuation of the analysis presented in J. Mat. Sc. 31 (1996) 2475 where the effect of only circular inclusion shape was investigated. An attempt at quantitative determination of the effect of endurance limit reduction by plastic zones size formed near the inclusions, and their cracking has been done. The geometrical configuration, consisting of round inclusion, horizontal, vertical and angular elliptical inclusions, from which a nucleating crack emerged, as well as sharp cracks was considered, and the stress intensity factors of such configurations were analysed. Based on threshold value of K below which crack propagation ceases, the critical value of loading stress was determined for different shapes and sizes of pores using an equivalent ellipse concept. Theoretical results were compared with results from experiments, showing quite good agreement. For plastic zones size determination finite elements technique and photo-stress experimental method were applied. Surprisingly it was found that circular shape of the pores is the most dangerous which explains why so many earlier investigations using circular pore shape model are, so well supported by the experiment.     

基体裂纹-异型夹杂相互作用焦散线实验研究

该文通过透射式静态焦散线方法利用三点弯曲梁断裂实验对异型夹杂与基体裂纹的相互作用进行研究。首先得到不同夹杂情况下I型裂纹尖端的焦散斑图,引入焦散斑纵横轴长之比β反映焦散斑在夹杂作用下的畸变特性;其次,提取相应的焦散斑特征尺寸,并得到I型裂纹的应力强度因子K_I;最后,基于不同夹杂情况下裂尖焦散斑、裂尖应力强度因子与裂尖和夹杂之间距离的关系,揭示不同夹杂对裂纹尖端应力场奇异性影响规律。实验研究结果为含异型夹杂结构的强度设计和断裂性能评估提供实验依据。     

Detrimental effect of nitride and aluminium oxide inclusions on fatigue life in rotating bending of bearing steels

Abstract

Rotating bending fatigue tests were performed on hardened AISI type 52100 bearing steel. Fracture surfaces after testing at a stress amplitude of 950 MPa showed that the Ti(C,N) inclusions which caused fatigue failure were significantly smaller than the corresponding alumina inclusions. The smallest crack initiating Ti(C,N) inclusion had a size of 3 μm and the smallest alumina inclusion was 17 μm. It was also shown that fatigue life was significantly shorter for a steel which showed cracked alumina inclusions on the fracture surfaces than for a steel which had non-cracked inclusions. Finite element calculations were performed to determine the driving forces of short cracks at Ti(C,N) and alumina inclusions. Two configurations were studied in each case, based on both non-cracked and cracked inclusions. The calculations incorporated heat treatment simulation and cyclic loading with successive growth of cracks. It was found that the Ti(C,N) configurations gave the highest driving forces for crack growth. The alumina configuration with a non-cracked inclusion gave the lowest driving force. It was concluded based both on experimental evidence and theoretical considerations that Ti(C,N) inclusions are more detrimental to fatigue life than alumina inclusions of the same size. It is their shape and thermal properties which make Ti(C,N) inclusions more detrimental than alumina inclusions. Internal cracking of alumina inclusions leads to reduced fatigue life.     

Initiation and early growth of short fatigue cracks at inclusions

In this study, the initiation and early growth behaviour of short fatigue cracks in En 7A steel with a high content of elongated MnS inclusions was investigated, by generating and evaluating data on the growth of short fatigue cracks under various stress levels and stress ratios for the six principal specimen orientations. Short cracks usually initiated at the debonded interfaces between the matrix and the inclusions. If there was no debonding, cracking sometimes occurred in the inclusions. In the early stages, short cracks propagated by a mechanism of inclusion influenced growth. Under low stress levels, usually one short crack was initiated which dominated most of the fatigue life, while under high stress levels there was multicrack interaction.

MST/3249A     

Three-dimensional Fe speciation of an inclusion cloud within an ultradeep diamond by confocal μ-X-ray absorption near edge structure: evidence for late stage overprint

A stream of 1-20 μm sized mineral inclusions having the negative crystal shape of its host within an "ultra-deep" diamond from Rio Soriso (Juina area, Mato Grosso State, Brazil) has been studied with confocal μ-X-ray absorption near edge structure (μXANES) at the Fe K and Mn K edges. This technique allows the three-dimensional nondestructive speciation of the Fe and Mn containing minerals within the inclusion cloud. The observed Fe-rich inclusions were identified to be ferropericlase (Fe,Mg)O, hematite and a mixture of these two minerals. Confocal μ-X-ray fluorescence (μXRF) further showed that Ca-rich inclusions were present as well, which are spatially separated from or in close contact with the Fe-rich inclusions. The inclusions are aligned along a plane, which most likely represents a primary growth zone. In the close vicinity of the inclusions, carbon coated planar features are visible. The three-dimensional distribution indicates a likely fluid overprint along an open crack. Our results imply that an imposed negative diamond shape of an inclusion alone does not exclude epigenetic formation or intense late stage overprint.     

Numerical analysis of the effect of microstructures of particle-reinforced metallic materials on the crack growth and fracture resistance

This paper presents a systematical computational study of the effect of microstructures of materials reinforced with brittle hard particles on their fracture behavior and toughness. Crack growth in particle-reinforced materials (here, in high speed steels) with various artificially designed arrangements of brittle inclusions is simulated using microstructure-based finite element meshes and an element elimination method. The following types of brittle inclusions arrangements are considered: (simple microstructures) net-like continuous, band-like, random with different inclusion sizes, and (complex microstructures) layered and clustered arrangements, with different inclusion sizes and orientations. Crack paths, force-displacement curves, fracture toughness and fractal dimension of fracture surfaces are determined numerically for each microstructure of the materials. It is demonstrated that extensive crack deviations from the initial cracking directions and an increase in the fracture toughness can most efficiently be achieved by using complex microstructures, such as alternated layers of fine and coarse inclusions.     

Experimental study on effects of freeze‐thaw fatigue damage on the cracking behaviors of sandstone containing two unparallel fissures

This paper investigates the effects of freeze‐thaw (FT) fatigue damage on the cracking behaviors of sandstone specimens containing two unparallel fissures under uniaxial compression. First, the effects of FT fatigue damage and fissure angle on the mechanical properties of sandstone specimens are analyzed. Second, the real‐time cracking process of sandstone specimens is captured by a high‐speed digital video camera system. Seven crack coalescence patterns are observed in this experiment. Local strong fatigue‐damaged zones, which are visualized as white zones, are observed in the specimens subjected to FT cycles during loading. Finally, scanning electron microscopy (SEM) observations show that the local strong fatigue‐damaged zones mainly consisted of microcracks and micropores induced by the FT fatigue damage. These experimental results are helpful for improving the understanding of the cracking process in cold‐region engineering.     

Corrosion fatigue crack initiation and growth in 18 Ni maraging steel

Nucleation of fatigue cracks in air and 3.5 wt% NaCl solution has been studied in an 18 wt% Ni maraging steel. Specimens tested on reverse bending fatigue machine showed a marked decrease in fatigue strength of the steel in NaCl solution reducing the 10⁷ cycles endurance limit from 410 MPa in air to 120 MPa. Microscopic studies revealed crack initiation to be predominantly associated with non-metallic silicate inclusions in both cases. In air, initiation is caused by decohesion of the inclusion/matrix interface, while in NaCl solution complete detachment of inclusions from the matrix results due to the dissolution of the interface. 70% more inclusions are quantitatively shown to be associated with cracks in NaCl solution than in air at the same stress levels. Experimental and theoreticalS-N curves and inclusion cracking sensitivity data are consistent with the mechanism suggested. The final fracture occurs by the main crack consuming the inclusions ahead of it by the “unzipping” of the shear band produced between the crack tip and the inclusion ahead.     

A PROBABILISTIC MODEL FOR PREDICTION OF LCF SURFACE CRACK INITIATION IN PM ALLOYS

The Low Cycle Fatigue (LCF) life of PM Ni-base superalloys is commonly reduced by surface crack initiation at ceramic inclusions. For this reason, a probabilistic model has been developed that predicts the size of surface crack initiation sites from the inclusion size distribution. For the experimental correlation of the model two sets of alloys were examined: a “standard” (i.e. as-received) alloy, and a second material of identical composition to which a known distribution of ceramic inclusions was incorporated (or seeded). Model predictions were found to be in excellent agreement with the results obtained from the seeded materials in which the defect size distribution is larger and better characterized, and were satisfactory for the unseeded material in which two types of surface defects (pores and ceramic inclusions) initiate LCF cracks. The results of these experiments were employed in LCF simulations of both test specimens and full scale components. These indicated that differences exist between the site preference for LCF crack initiation in small test specimens and large scale components due to a scale effect. Such results demonstrate the utility of seeding experiments for generation of LCF test data used in component design.     

3D modeling of subsurface fatigue crack nucleation potency of primary inclusions in heat treated and shot peened martensitic gear steels

A computational strategy is developed to characterize the driving force for fatigue crack nucleation at subsurface primary inclusions in carburized and shot peened C61^® martensitic gear steels. Experimental investigation revealed minimum fatigue strength to be controlled by subsurface fatigue crack nucleation at inclusion clusters under cyclic bending. An algorithm is presented to simulate residual stress distribution induced through the shot peening process following carburization and tempering. A methodology is developed to analyze potency of fatigue crack nucleation at subsurface inclusions. Rate-independent 3D finite element analyses are performed to evaluate plastic deformation during processing and service. The specimen is subjected to reversed bending stress cycles with R = 0.05, representative of loading on a gear tooth. The matrix is modeled as an elastic–plastic material with pure nonlinear kinematic hardening. The inclusions are modeled as isotropic, linear elastic. Idealized inclusion geometries (ellipsoidal) are considered to study the fatigue crack nucleation potency at various subsurface depths. Three distinct types of second-phase particles (perfectly bonded, partially debonded, and cracked) are analyzed. Parametric studies quantify the effects of inclusion size, orientation and clustering on subsurface crack nucleation in the high cycle fatigue (HCF) or very high cycle fatigue (VHCF) regimes. The nonlocal average values of maximum plastic shear strain amplitude and Fatemi–Socie (FS) parameter calculated in the proximity of the inclusions are considered as the primary driving force parameters for fatigue crack nucleation and microstructurally small crack growth. The simulations indicate a strong propensity for crack nucleation at subsurface depths in agreement with experiments in which fatigue cracks nucleated at inclusion clusters, still in the compressive residual stress field. It is observed that the gradient from the surface of residual stress distribution, bending stress, and carburized material properties play a pivotal role in fatigue crack nucleation and small crack growth at subsurface primary inclusions. The fatigue potency of inclusion clusters is greatly increased by prior interfacial damage during processing.     

THE EFFECT OF CATHODIC POLARIZATION ON CORROSION FATIGUE OF A HIGH STRENGTH STEEL IN SALT WATER

Abstract— Corrosion fatigue crack growth rates in high strength steel are often increased when a large cathodic polarization is applied. The corrosion fatigue mechanism in this case is generally considered to be due to hydrogen embrittlement. In the present study the crack growth process was carefully monitored by taking replicas from initially smooth specimens of a high strength steel under fully reversed push-pull loading while: (1) exposed to laboratory air, (2) immersed in a 0.6 M sodium chloride (NaCl) solution at open circuit potential (OCP) and (3) with an applied cathodic potential of —1250 mV (SCE). It is shown that the effect of cathodic polarization is dependent on the applied stress level and the nature of the cracking process, which in turn, is related to the sue of the crack. For stress levels at or below the in-air fatigue limit, failure did not occur for cathodically polarised specimens despite the number of loading cycles being 10 times that of the lifetime of identical tests in solution at the open circuit potential. At stress levels above the in-air fatigue limit the reduction in fatigue endurance caused by the presence of the corrosive environment can be partially recovered through cathodic polarization. The role of non-metallic inclusions in the cracking process under various exposure conditions is discussed, and a cracking mechanism is proposed.     

Extended FEM modeling of crack paths near inclusions

The extended FEM is applied to model crack growth near inclusions. A procedure to handle different propagation rates at different crack tips is presented. The examples considered investigate uniform tension as well as equibiaxial tension under plane strain conditions. A parameter study analyzes the effects on the crack path when changing the relative stiffness between inclusion and matrix material, the relative distance between initial crack and inclusion, and the size of the inclusion. Both edge cracks and internal cracks are studied. An example with an internal crack near an inclusion is presented, where both crack tips propagate at different growth rates until one crack tip eventually stops growing, as the related energy release rate drops below the critical value. In another example, only one crack tip propagates initially, but eventually, the energy release rate of the second crack tip becomes critical, and both crack tips propagate. Finally, an example of two cracks near an inclusion is presented in which up to four crack tips propagate simultaneously. Copyright © 2011 John Wiley & Sons, Ltd.     

Effect of embedded optical fiber sensors on transverse crack spacing of smart composite structures

In this study the effect of the presence of embedded optical fiber sensors on the transverse cracking of cross-ply laminates was investigated. The transverse crack spacing of cross-ply laminates with embedded optical fiber sensors was predicted using modified shear-lag analysis considering the presence of optical fibers and compared with experimental results. The effect of the orientation and quantity of optical fibers was evaluated and the effect of the coating of optical fiber was also investigated. Specimens were made with transparent glass/epoxy prepreg because the transverse crack and other damages such as delamination, splitting and bleeding of laser can be examined directly and visually. It has been found that the transverse crack spacing was not affected significantly by the embedding of optical fibers at low volume fraction of optical fibers. However, the cracks of specimens with embedded optical fibers which were initiated at a slightly lower stress level showed smaller spacing at the same stress level than those of specimens without embedded optical fibers. The theoretical crack spacing evaluated from the shear lag analysis showed good agreements with experimental results.     

The role of inclusions in the fracture of ceramic materials

The stress concentrations that occur at inclusions due to thermal expansion and elastic modulus mismatch are discussed and the stress intensity factors at interface cracks that result from these stresses are calculated. It is shown that conservative failure prediction based on an equivalence between inclusion size and crack size is usually acceptable if the shear modulusμ or thermal expansion coefficientα for the inclusion is larger than the matrix values. If, however,μ andα are smaller for the inclusion than the matrix, extensive cracking can develop at the inclusions which may lead to premature failure. For this case the only effective methods for failure prediction are techniques which give directly the maximum stress intensity factor, i.e., proof testing and/or acoustic emission.     

THE AIR FATIGUE AND CORROSION FATIGUE OF A 13% Cr TURBINE BLADE STEEL

Abstract— Reasons for data scatter from fatigue tests on a high strength 13% Cr steel are discussed and data is presented for corrosion fatigue of this steel in a condensing steam environment. Rotating bend tests were performed at 50 and 3 Hz and tension-tension fatigue tests at 0.016 Hz and R =0.1. Some specimens were periodically inspected to identify sites of fatigue crack initiation. The role of inclusions in initiating fatigue cracks was investigated and it was found that the population of larger inclusions in the steel matched that at fatigue crack initiation sites. Comparison of fatigue lives from polished and abraded specimens indicated that there is little point in producing highly polished surfaces for this steel to try and improve fatigue life unless the inclusion content can be reduced in size and number. Corrosion fatigue data is presented indicating the magnitude of the reduction of fatigue life caused by condensing pure steam and condensing chlorinated steam.     

Fatigue crack growth behaviour of A533B steel in pressurized water at 288 and 28 °C

Fatigue crack growth behaviour of A533B steel was investigated in pressurized water at 288 °C using specimens machined from four different orientations. When inclusions were oriented along the direction of crack propagation, fatigue crack growth rate (FCGR) was enhanced compared to when they were perpendicular to the direction of crack propagation. At low ΔK levels FCGR in ambient water was slightly higher than that in 288 °C water. This may be attributed to the occurrence of intergranular cracking in ambient water tested specimen. Though mainly ductile striations were observed on the fracture surfaces, isolated intergranular facets (in a specimen tested in ambient water) and fan shaped features were also present. Hydrogen induced damage was clearly evident in the ambient water tested specimen in the form of isolated intergranular facets.