Determination of thermal stress intensity factors for an interface crack in a graded orthotropic coating-substrate structure

The thermal fracture problem of an interface crack between a graded orthotropic coating and the homogeneous substrate is investigated by two different approaches. For the case that most of the material properties in the graded orthotropic coating are assumed to vary as an exponential function, the integral transform and singular integral equation technique is used to obtain some analytical results. In order to analyze the case with more complex material distribution, an interaction integral is presented to evaluate the thermal stress intensity factors of cracked functionally graded materials (FGMs), and then the element-free Galerkin method (EFGM) is developed to obtain the final numerical results. The good agreement is obtained between the numerical results and the analytical ones. In addition, the influence of material gradient parameters and material distribution on the thermal fracture behavior is also presented.     

Stress intensity factor analysis for an interface crack between dissimilar isotropic materials under thermal stress

Thermal stresses, one of the main causes of interfacial failure between dissimilar materials, arise from different coefficients of linear thermal expansion. Two efficient numerical procedures in conjunction with the finite element method (FEM) for the stress intensity factor (SIF) analysis of interface cracks under thermal stresses are presented. The virtual crack extension method and the crack closure integral method are modified using the superposition method. The SIF analyses of some interface crack problems under mechanical and thermal loads are demonstrated. Very accurate mode separated SIFs are obtained using these methods.     

Contour integral method for stress intensity factors of interface crack

A general Betti's reciprocal work theorem with interface cracks of a bimaterial is established in this paper, and a path independent contour integral method for the stress intensity factor (SIF) of the interface crack was obtained. When the stress and displacement fields in a specimen are calculated by the finite element method, the SIF K _I and K _II of interface cracks can be obtained immediately by a contour integral. Some solutions of interesting examples, such as two collinear interface cracks, are also given.Presented at the Far East Fracture Group (FEFG) International Symposium on Fracture and Strength of Solids, 4–7 July 1994 in Xi'an China.     

On the three-dimensional problem of an interface crack under uniform heat flow in a bimaterial periodically-layered space

This paper deals with the study of thermal stresses due to a plane crack lying on an interface in a microperiodic two-layered composite under a uniform perpendicular heat flow. An approximate analysis is carried out within the framework of linear stationary thermoelasticity with microlocal parameters. Taking this approach, a general method of solving the resulting boundary-value problem is presented. Effective results have been achieved through the use of suitable potential solutions and reducing the thermal crack problem to its skew-symmetric isothermal mechanical counterpart. An illustrative example is given in the paper by considering an insulated stress-free penny-shaped crack. For this problem the solution is obtained in terms of elementary functions and discussed from the point of view of fracture theory.     

Stress intensity factors for an interface crack along an elliptical inclusion

The problem of a crack along the interface of an elliptical elastic inclusion embedded in an infinite plate subjected to uniform stresses at infinity is analyzed by the body force method. The crack tip stress intensity factors are calculated for various inclusion geometries and material combinations. Based on numerical results, the effect of the inclusion geometry on the stress intensity factors is investigated. It is found that for small interface cracks the stress intensity factors are mainly determined by the stresses, occurring at the crack center point before the crack initiation, and interface curvature radius alone.     

An experiment on stress intensity factors for an interface crack between epoxy and aluminum plates

A teflon tape (0.07 mm thickness) is placed at the center of an edge of an epoxy plate. The plate is used to fabricate a mold, and epoxy resin is cast in the mold so as to produce a cracked epoxy plate. A tensile test is conducted so as to determine the fracture toughness value of the epoxy plate. Next, a mold is fabricated from an aluminum plate having a teflon tape placed along its edge, and epoxy resin is cast in the mold so as to produce an epoxy-aluminum composite weakened by an interface crack. Tensile testing reveals that the crack always propagates into the epoxy plate at an angle measured from the interface. The stress intensity factor for an interface crack is defined in a manner similar to that for a crack in a homogeneous material, and is obtained for several values of a/h, 2a being the crack length and 2h being the width of the epoxy-aluminum composite.     

Rotation at the crack tip under uniform heat flow in an infinite medium

A complex analysis of rigid body rotation is presented. The crack-tip rotation for a line crack subjected to steady uniform heat flow is obtained in terms of thermal stress intensity factor in shear mode of the crack, the material and thermal parameters and coordinates of points close to the crack tip. The shear strip configuration is analysed on the basis of rotation and displacement at the end of the shear strip.     

The stress intensity factor for a flat elliptical crack in an elastic solid under uniform tension

Making use of simple results concerning 2-dimensional Fourier transforms an expression is derived for the stress-intensity factor at the rim of a flat elliptical crack in an infinite elastic solid under uniform tension.     

On the numerical evaluation of stress intensity factors for an interface crack of a general shape

A numerical algorithm is presented for the problem of a crack along the interface of an elastic inclusion embedded in an elastic plane subjected to uniform stress at infinity. The algorithm is based on a Fredholm integral equation of the second kind and allows for fast and accurate solutions to geometries of great complexity. In an example crack opening displacement and stress intensity factors are computed for a crack in the interface of an inclusion with nineteen protruding arms. Copyright © 1999 John Wiley & Sons, Ltd.     

Dynamic stress intensity factors analysis of interface crack using line-spring model

In this study, a new method for calculating the dynamic stress intensity factors of a bimaterial bending specimen with an interface crack is proposed by making use of a line-spring model. A pre-cracked bending specimen is modeled by one-dimensional beam finite elements and a line-spring representing the stiffness or compliance of a cracked part. The proposed method enables the one-dimensional analysis of a two-dimensional crack problem; thus the time variations of the dynamic stress intensity factors of a bimaterial bending specimen with an interface crack can be obtained by making use of a personal computer within a few minutes. The results obtained by the proposed method agree reasonably well with those obtained by the two-dimensional finite element method, although a slight difference in period can be found. The proposed method enables rapid evaluation of dynamic stress intensity factors. So a rapid evaluation system of the dynamic fracture toughness of a bimaterial with an interface crack can be achieved by combining an instrumented impact test apparatus with a computer program based on the proposed method which runs on a personal computer.     

Transient thermal stress intensity factors for an internal longitudinal semi-elliptical crack in a thick-walled cylinder

In this paper, the stress intensity factors are derived for an internal semi-elliptical crack in a thick-walled cylinder subjected to transient thermal stresses. First, the problem of transient thermal stresses in a thick-walled cylinder is solved analytically. Thermal and mechanical boundary conditions are assumed to act on the inner and outer surfaces of the cylinder. The quasi-static solution of the thermoelasticity problem is derived analytically using the finite Hankel transform and then, the stress intensity factors are extracted for the deepest point and the surface points of the semi-elliptical crack using the weight function method. The results show to be in accordance with those cited in the literature in the special case of steady-state problem. Using the closed-form relations extracted for the transient thermal stress intensity factors, some conclusive results are drawn.     

Thermal stress singularities at tips of a crack in a semi-infinite medium under uniform heat flow

In the framework of plane thermoelastic problems is discussed the thermal stress field near the tips of an arbitrarily inclined crack in an isotropic semi-infinite medium with the thermally insulated edge surface under uniform heat flow. The crack is replaced by continuous distributions of quasi-Volterra dislocations corresponding to line heat sources and edge dislocations, and we obtain a set of simultaneous singular integral equations for dislocation density functions, whose solution is given in the forms of series in terms of Tchebycheff polynomials of the first kind. By means of this method, the thermal stress singularities at the crack tips are estimated exactly and the stress intensity factors can be readily evaluated. Numerical results are given for the particular case where the surface of the inclined crack is maintained at constant temperature and the heat supplied across the surface of the crack vanishes as a whole. The effects of the distance from the crack tip to the edge surface of the semi-infinite medium and the angle of inclination of the crack on the stress intensity factors and the initial direction of crack extension are shown graphically.     

Stress intensity factor analysis of an interface crack between dissimilar anisotropic materials under thermal stress using the finite element analysis

New numerical methods were presented for stress intensity factor analyses of two-dimensional interfacial crack between dissimilar anisotropic materials subjected to thermal stress. The virtual crack extension method and the thermal M-integral method for a crack along the interface between two different materials were applied to the thermoelastic interfacial crack in anisotropic bimaterials. The moving least-squares approximation was used to calculate the value of the thermal M-integral. The thermal M-integral in conjunction with the moving least-squares approximation can calculate the stress intensity factors from only nodal displacements obtained by the finite element analysis. The stress intensity factors analyses of double edge cracks in jointed dissimilar isotropic semi-infinite plates subjected to thermal load were demonstrated. Excellent agreement was achieved between the numerical results obtained by the present methods and the exact solution. In addition, the stress intensity factors of double edge cracks in jointed dissimilar anisotropic semi-infinite plates subjected to thermal loads were analyzed. Their results appear reasonable.     

Stress intensity factors of a surface crack near an interface end

Due to the singular behavior of the stress field near the interface edge of bonded dissimilar materials, fracture generally initiates near the interface edge, or just from the interface edge point. In this paper, an edge crack near the interface, which can be considered as being induced by the edge singularity and satisfying two conditions, is analyzed theoretically, based on the singular stress field near the interface edge and the superposition principle. It is found that the stress intensity factor can be expressed by the stress intensity coefficient of the edge singular stress field, the crack length, the distance between the interface and the crack, as well as the material combination. Boundary element method analysis is also carried out. It is found that the theoretical result coincides well with the numerical result when the crack length is small. Therefore, the theoretical representation obtained by this study can be used to simply evaluate the stress intensity factor of an edge singularity induced crack for this case. However, when the crack length becomes larger than a certain value, a significant difference appears, especially for the case with large edge singularity.     

Calculation of mixed mode stress intensity factors for an elliptical subsurface crack under arbitrary normal loading

Normal loading causes mixed fracture modes in an elliptical subsurface crack because of the nonsymmetrical geometry with respect to the crack face. In this paper, mixed mode weight functions (MMWFs) for elliptical subsurface cracks in an elastic semi‐infinite space under normal loading are derived. Reference mixed mode stress intensity factors (MMSIFs), calculated by finite element analysis, under uniform normal loading are used to derive MMWFs. The cracks have aspect ratios and crack depth to crack length ratios of 0.2–1.0 and 0.05 to infinity, respectively. MMWFs are used to calculate MMSIFs for any point of the crack front under linear and nonlinear two‐dimensional (2D) loadings. So, in order to evaluate the fatigue crack growth phenomenon under complicated 2D stress distributions, MMWFs can be easily used. The comparison between the MMSIFs obtained from the MMWFs and finite element analysis indicates high accuracy.     

Determination of stress intensity factors for surface cracks using fatigue crack growth data

The fatigue growth of semi-elliptical surface cracks in a structural steel under constant amplitude tensile cycling loading is investigated. The AC potential technique is used for sizing and monitoring the profile development of the cracks. The data are used to determine the stress intensity factors along the entire crack front at different stages of crack growth where the effects of front face, finite thickness and finite width are continuously changing. Various numerical solutions are compared with the experimental results     

Boundary element analysis of thermal stress intensity factors for interface griffith and cusp cracks

The thermal stress intensity factors for interface cracks of Griffith and symmetric lip cusp types under vertical uniform heat flow in a finite body are calculated by the boundary element method. The boundary conditions on the crack surfaces are insulated or fixed to constant temperature. The relationship between the stress intensity factors and the displacements on the nodal point of a crack-tip element is derived. The numerical values of the thermal stress intensity factors for an interface Griffith crack in an infinite body are compared with the previous solutions. The thermal stress intensity factors for a symmetric lip cusp interface crack in a finite body are calculated with respect to various effective crack lengths, configuration parameters, material property ratios and the thermal boundary conditions on the crack surfaces. Under the same outer boundary conditions, there are no appreciable differences in the distribution of thermal stress intensity factors with respect to each material property. However, the effect of crack surface thermal boundary conditions on the thermal stress intensity factors is considerable.     

Thermal stresses in a periodic two-layer space with an interface rigid inclusion under uniform heat flow

This paper investigates the three-dimensional thermal stress distribution that arises when a uniform heat flow is disturbed by an insulated rigid interface sheet-like inclusion in a periodically layered bimaterial space. An approximate general analysis is carried out within the framework of linear stationary thermoelasticity with microlocal parameters. The resulting boundary-value problems are reduced to classical mixed problems of potential theory. As an illustration, a complete solution in elementary functions is given and discussed for the case of a rigid circular inclusion.     

Thermal stresses near tips of an insulated line crack in a semi-infinite medium under uniform heat flow

On the basis of the two-dimensional theory of thermoelasticity, the thermal stress field near the tips of a thermally insulated line crack in a semi-infinite medium under steady-state uniform heat flow is discussed. The crack is replaced by continuous distributions of sources of temperature discontinuity and edge dislocations. Then we obtain a set of simultaneous singular integral equations for density functions. The solution is given in the form of the product of the series of Tchebycheff polynomials of the first kind and their weight function. By means of this method, the thermal stress singularities at the crack tips are estimated exactly and the stress intensity factors can be readily evaluated. The effects of the distance from the crack tip to the bounding plane surface of the semi-infinite medium and the angle of inclination of the line crack on the stress intensity factors are shown graphically.