Numerical simulations of dynamic crack growth along an interface

Dynamic crack growth is analyzed numerically for a plane strain bimaterial block with an initial central crack. The material on each side of the bond line is characterized by an isotropic hyperelastic constitutive relation. A cohesive surface constitutive relation is also specified that relates the tractions and displacement jumps across the bond line and that allows for the creation of new free surface. The resistance to crack initiation and the crack speed history are predicted without invoking any ad hoc failure criterion. Full finite strain transient analyses are carried out, with two types of loading considered; tensile loading on one side of the specimen and crack face loading. The crack speed history and the evolution of the crack tip stress state are investigated for parameters characterizing a PMMA/Al bimaterial. Additionally, the separate effects of elastic modulus mismatch and elastic wave speed mismatch on interface crack growth are explored for various PMMA-artificial material combinations. The mode mixity of the near tip fields is found to increase with increasing crack speed and in some cases large scale contact occurs in the vicinity of the crack tip. Crack speeds that exceed the smaller of the two Rayleigh wave speeds are also found.     

Intersonic delamination in curved thick composite laminates under quasi-static loading

Dynamic delamination in curved composite laminates is investigated experimentally and numerically. The laminate is 12-ply graphite/epoxy woven fabric L-shaped laminate subject to quasi-static loading perpendicular to one arm. Delamination initiation and propagation are observed using high speed camera and load–displacement data is recorded. The quasi-static shear loading initiates delamination at the curved region which propagates faster than the shear wave speed of the material, leading to intersonic delamination in the arms. In the numerical part, the experiments are simulated with finite element analysis and a bilinear cohesive zone model. Cohesive interface elements are used between all plies with the interface properties obtained from tests. The simulations predict a single delamination initiating at the corner under pure mode-I stress field propagating to the arms under pure mode-II stress field. The crack tip speeds transition from sub-Rayleigh to intersonic in conjunction with mode change. In addition to intersonic mode-II delamination, shear Mach waves emanating from the crack tips in the arms are observed. The simulations and experiments are found to be in good agreement at the macro-scale, in terms of load-displacement behavior and failure load, and at the meso-scale, in terms of delamination initiation location and crack propagation speeds. Finally, a mode dependent crack tip definition is proposed and observation of vibrations during delamination is presented. This paper presents the first conclusive evidence of intersonic delamination in composite laminates triggered under quasi-static loading.     

Effect of loading and geometry on the subsonic/intersonic transition of a bimaterial interface crack

An experimental investigation was conducted to study the nature of intersonic crack propagation along a bimaterial interface. A single edge notch/crack oriented along a polymer/metal interface was loaded predominantly in shear by impacting the specimen with a high velocity projectile fired from a gas gun. The stress field information around the propagating crack tip was recorded in real time by two different optical techniques--photoelasticity and coherent gradient sensing, in conjunction with high speed photography. Intersonic cracks on polymer/metal interfaces were found to propagate at speeds between the shear wave speed (c_s) and of the polymer. The nature of the crack tip fields during subsonic/intersonic transition and the conditions governing this transition were examined. Experimental observations showed the formation of a crack face contact zone as the interfacial crack speed exceeds the Rayleigh wave speed of the polymer. Subsequently, the contact zone was observed to expand in size, shrink and eventually collapse onto the intersonic crack tip. The recorded isochromatic fringe patterns showed multiple Mach wave formation associated with such a scenario. It is found that the nature of contact zone formation as well as its size and evolution differ substantially depending on the sign of the opening component of loading.     

On the stress wave induced curving of fast running cracks — a numerical study by a time-domain boundary element method

Summary Fast crack propagation in dynamically loaded plane structures is investigated. The major point of interest is the evolution of the crack trajectory under the influence of stress waves which are generated and repeatedly reflected at the specimen boundaries. Since these waves may lead to arbitrary mixed-mode and time-dependent loading of the crack tip, both the direction and speed of crack advance are determined from a fracture criterion.Starting point is a system of time-domain boundary integral equations which describes the initial boundary value problem of a linear elastic body containing an arbitrarily growing crack. The unknown displacements and/or tractions on the exterior boundary and the displacement jumps across the crack are computed numerically by a collocation method in conjunction with a time-stepping scheme. Crack growth is modelled by adding new boundary elements of constant length at the running crack tip.The method proves to be of sufficient accuracy when applied to problems treated with other numerical techniques. Moreover, the simulation of dynamic crack propagation under various geometry and loading conditions enables the reproduction and analysis of complex phenomena observed experimentally.     

Time-domain BEM analysis of a rapidly growing crack in a bi-material

Rapid propagation of a matrix crack in a bi-material system is studied with emphasis on the dynamic interaction between the crack and the interface by combining the traditional time-domain displacement boundary element method (BEM) and the non-hypersingular traction BEM. The crack growth is controlled by the fracture criterion based on the maximum circumferential stress, and is modeled by adding new elements to the moving crack tip. Detailed computation is performed for an unbounded bi-material with a crack subjected to incident impact waves and a bounded rectangular bi-material plate under dynamic wedged loading. Numerical results of the crack growth path, speed, dynamic stress intensity factors (DSIFs) and dynamic interface tractions are presented for various material combinations and geometries. The effects of the interface on the crack growth are discussed.     

Modelling of crack propagation of gravity dams by scaled boundary polygons and cohesive crack model

Crack propagation in concrete gravity dams is investigated using scaled boundary polygons coupled with interface elements. The concrete bulk is assumed to be linear elastic and is modelled by the scaled boundary polygons. The interface elements model the fracture process zone between the crack faces. The cohesive tractions are modelled as side-face tractions in the scaled boundary polygons. The solution of the stress field around the crack tip is expressed semi-analytically as a power series. It reproduces the singular and higher-order terms in an asymptotic solution, such as the William’s eigenfunction expansion when the cohesive tractions vanish. Accurate results can be obtained without asymptotic enrichment or local mesh refinement. The stress intensity factors are obtained directly from their definition and provide a convenient and accurate means to assess the zero-K condition, which determines the stability of a cohesive crack. The direction of crack propagation is determined from the maximum circumferential stress criterion. To accommodate crack propagation, a local remeshing algorithm that is applicable to any polygon mesh is augmented by inserting cohesive interface elements between the crack surfaces as the cracks propagate. Three numerical benchmarks involving crack propagation in concrete gravity dams are modelled. The results are compared to the experimental and other numerical simulations reported in the literature.     

Simulation of dynamic crack growth using the generalized interpolation material point (GIMP) method

Dynamic crack growth is simulated by implementing a cohesive zone model in the generalized interpolation material point (GIMP) method. Multiple velocity fields are used in GIMP to enable handling of discrete discontinuity on either side of the interface. Multilevel refinement is adopted in the region around the crack-tip to resolve higher strain gradients. Numerical simulations of crack growth in a homogeneous elastic solid under mode-II plane strain conditions are conducted with the crack propagating along a weak interface. A parametric study is conducted with respect to varying impact speeds ranging from 5 m/s to 60 m/s and cohesive strengths from 4 to 35 MPa. Numerical results are compared qualitatively with the dynamic fracture experiments of Rosakis et al. [(1999) Science 284:1337–1340]. The simulations are capable of handling crack growth with crack-tip velocities in both sub-Rayleigh and intersonic regimes. Crack initiation and propagation are the natural outcome of the simulations incorporating the cohesive zone model. For various impact speeds, the sustained crack-tip velocity falls either in the sub-Rayleigh regime or in the region between (c _S is the shear wave speed) and c _D (c _D is the dilatational wave speed) of the bulk material. The Burridge–Andrews mechanism for transition of the crack-tip velocity from sub-Rayleigh to intersonic speed of the bulk material is observed for impact speeds ranging from 9.5 to 60 m/s (for normal and shear cohesive strengths of 24 MPa). Within the intersonic regime, sustained crack-tip velocities between 1.66 c _S (or 0.82 c _D ) and 1.94 c _S (or 0.95 c _D ) were obtained. For the cases simulated in this work, within the stable intersonic regime, the lowest intersonic crack-tip velocity obtained was 1.66 c _S (or 0.82 c _D ).     

Finite element modelling of crack propagation in elastic-plastic media

Materials which are cyclically stressed by sliding indenters often undergo fatigue wear, as surface breaking vertical cracks and subsurface horizontal cracks propagate causing eventual loss of material. In this study, the authors model crack propagation in an elastic-plastic material using finite element techniques, and consider the influence of friction, elasticity, plasticity and degree of penetration on the J-integral at the tip of a vertical crack. Crack propagation directions are estimated using J-integral maxima as the determining variable. It is found that the J-integral values, as a measure of strain energy release rate, can be used to estimate the crack propagation angle. Its main advantage lies in the fact that it considers both modes (I, II) of crack propagation. Using the J-integral values, one finds that, in the absence of friction between the indenter and the material, the vertical crack is equally prone to propagation at both 45 and 135° angles. However, one notices that the vertical crack favours the direction opposite to the direction of rolling for non-zero values of friction, i.e. 135°. The effects of both the crack depth and the crack tip plasticity are also investigated. It is found that any experimental findings suggestive of crack orientations closer to the horizontal in the direction opposite to the sliding direction are probably a result of shallow vertical asperities or higher crack tip plasticity.     

Numerical simulation of fatigue crack propagation in friction stir welded joint made of Al 2024-T351 alloy

In this work, fatigue crack propagation in thin-walled aluminium alloy structure with two friction stir welded T joints has been simulated numerically. Crack propagation in stiffened part of the structure between two friction stir welded T joints is analysed by using the eXtended Finite Element Method (XFEM), including software ABAQUS, as well as MORFEO, for modelling and results display. Tensile fatigue loading is applied, with stress ratio R = 0, and maximum stress σ_max = 10 MPa. Material properties (Al 2024-T351, as used in aeronautical industry) in different welded joints zones are adopted from available literature data. Following results are obtained by numerical analysis: stress–strain and displacement state in the structure, position of the crack tip and value of stress intensity factor for every crack propagation step, as well as the structural life estimation, i.e. number of load cycles, N, also for each crack propagation step. Using these results the number of cycles at which the crack starts to propagate in an unstable manner is predicted.     

On the stress corrosion cracking mechanisms of austenitic stainless steels

In this paper, experimental results on stress corrosion cracking in austenitic stainless steels are described. Crack growth data in sodium chloride solution for AISI 304 steel obtained for different metallurgical conditions, acoustic emission data recorded during crack growth and fractographic observations have been discussed with a view to identifying the operating mechanism. Some of the experimental observations such as crack propagation occurring in discontinuous jumps of the order of a few microns, lowering of the threshold stress intensity andJ-integral values on sensitization and cold working, typical transgranular fractographic features, transition in mode of fracture from transgranular to intergranular in sensitized conditions and activation energies of the order of 50 to 65 kJ/mol can all be accounted by hydrogen embrittlement mechanism. Hydrogen generated at the crack tip by corrosion reaction diffuses ahead of the crack tip under hydrostatic stress and influences the deformation process at the crack tip and also leads to the brittle component of the crack advance in jumps.     

Mode II intersonic crack propagation in poroelastic media

A crack is steadily running in an elastic isotropic fluid-saturated porous solid at an intersonic constant speed c. The crack tip speeds of interest are bounded below by the slower between the slow longitudinal wave-speed and the shear wave-speed, and above by the fast longitudinal wave-speed. Biot’s theory of poroelasticity with inertia forces governs the motion of the mixture. The poroelastic moduli depend on the porosity, and the complete range of porosities n ∈ [0, 1] is investigated. Solids are obtained as the limit case n = 0, and the continuity of the energy release rate as the porosity vanishes is addressed. Three characteristic regions in the plane (n, c) are delineated, depending on the relative order of the body wave-speeds. Mode II loading conditions are considered, with a permeable crack surface. Cracks with and without process zones are envisaged. In each region, the analytical solution to a Riemann–Hilbert problem provides the stress, pore pressure and velocity fields near the tip of the crack. For subsonic propagation, the asymptotic crack tip fields are known to be continuous in the body [Loret and Radi (2001) J Mech Phys Solids 49(5):995–1020]. In contrast, for intersonic crack propagation without a process zone, the asymptotic stress and pore pressure might display a discontinuity across two or four symmetric rays emanating from the moving crack tip. Under Mode II loading condition, the singularity exponent for energetically admissible tip speeds turns out to be weaker than 1/2, except at a special point and along special curves of the (n, c)-plane. The introduction of a finite length process zone is required so that 1. the energy release rate at the crack tip is strictly positive and finite; 2. the relative sliding of the crack surfaces has the same direction as the applied loading. The presence of the process zone is shown to wipe out possible first order discontinuities.     

Dynamic fracture mechanics analysis of failure mode transitions along weakened interfaces in elastic solids

Dynamic fracture mechanics theory was employed to analyze the crack deflection behavior of dynamic mode-I cracks propagating towards inclined weak planes/interfaces in otherwise homogenous elastic solids. When the incident mode-I crack reached the weak interface, it kinked out of its original plane and continued to propagate along the weak interface. The dynamic stress intensity factors and the non-singular T-stresses of the incident cracks were fitted, and then dynamic fracture mechanics concepts were used to obtain the stress intensity factors of the kinked cracks as functions of kinking angles and crack tip speeds. The T-stress of the incident crack has a small positive value but the crack path was quite stable. In order to validate fracture mechanics predictions, the theoretical photoelasticity fringe patterns of the kinked cracks were compared with the recorded experimental fringes. Moreover, the mode mixity of the kinked crack was found to depend on the kinking angle and the crack tip speed. A weak interface will lead to a high mode-II component and a fast crack tip speed of the kinked mixed-mode crack.     

Elastic green's function for a bimaterial composite solid containing a crack inclined to the interface

An analytical closed-form expression is derived for the elastic Green's function of a bimaterial composite solid containing a planar interface and a straight crack inclined at an arbitrary angle with the interface. The crack tip is assumed to be at the interface. Both the constituent materials of the composite are assumed to anisotropic. The Green's function satisfies the interfacial boundary conditions of continuous tractions and displacements, and zero tractions at the crack surfaces. The boundary conditions are satisfied by using the virtual force technique. The determination of the virtual forces requires solutions of a Hilbert problem which is obtained by using an orthogonal complex transform. The method is illustrated by applying it to a copper/nickel composite. The Green's function should be useful in the boundary-element method of calculating the stress and the displacement field in the solid.     

A MODEL TO PREDICT THE FATIGUE LIFE OF FIBRE-REINFORCED TITANIUM MATRIX COMPOSITES UNDER CONSTANT AMPLITUDE LOADING

A model based on micro-mechanical concepts has been developed for predicting fatigue crack growth in titanium alloy matrix composites. In terms of the model, the crack system is composed of three zones: the crack, the plastic zone and the fibre. Crack tip plasticity is constrained by the fibres and remains so until certain conditions are met. The condition for crack propagation is that fibre constraint is overcome when the stress at the location of the fibre ahead of the crack tip attains a critical level required for debonding. Crack tip plasticity then increases and the crack is able to propagate round the fibre. The debonding stress is calculated using the shear lag model from values of interfacial shear strength and embedded fibre length published in the literature. If the fibres in the crack wake remain unbroken, friction stresses on the crack flanks are generated, as a result of the matrix sliding along the fibres. The friction stresses (known as the bridging effect) shield the crack tip from the remote stress, reducing the crack growth relative to that of the matrix alone. The bridging stress is calculated by adding together the friction stresses, at each fibre row bridging the crack, which are assumed to be a function of crack opening displacement and sliding distance at each row. The friction stresses at each fibre row will increase as the crack propagates further until a critical level for fibre failure is reached. Fibre failure is modelled through Weibull statistics and published experimental results. Fibre failure will reduce the bridging effect and increase the crack propagation rate. Calculated fatigue lives and crack propagation rates are compared with experimental results for three different materials (32% SCS6/Ti-15-3, 32% and 38% SCS6/Ti-6-4) subjected to mode I fatigue loading. The good agreement shown by these comparisons demonstrates the applicability of the model to predict the fatigue damage in Ti-based MMCs.     

The effect of a pre‐existing crack on a running crack in brittle material under dynamic loads

Brittle material usually contains plenty of cracks or micro‐cracks, which raises a question that how a pre‐existing crack affects a running crack as they are approaching. In order to investigate such issue, impact experiments were conducted by using double crack semi‐circle (DCSC) specimens. Polymethyl methacrylate (PMMA) was selected to make the DCSC specimens, and a modified SHPB system was used to perform the impact tests. The finite difference code AUTODYN was employed to simulate the crack propagation behavior and propagation path, and the simulated crack paths agree well with the impact test results. Meanwhile the stresses around the crack tips were analyzed and the crack propagation direction was investigated. To calculate the crack dynamic stress intensity factors (DSIFs), finite element code ABAQUS was employed. The results show that the spacing D between the vertical crack tip and the inclined crack center affects the stress distribution and fracture behavior of the vertical crack largely. As the vertical crack approaches the inclined crack, the crack speed is slow down, and tensile stress appears at the inclined crack tip. As the spacing D is small than 50 mm, the vertical crack connects with the middle area of the inclined crack. As the spacing D is 50 mm, the vertical crack connects with either the middle area or the upper tip of the inclined crack. As the spacing D is larger than 50 mm, the vertical crack coalesces with the upper crack tip.     

Homogenized mechanical behavior of composite micro-structures including micro-cracking and contact evolution

The aim of this paper is to study the effects of micro-cracking on the homogenized constitutive properties of elastic composite materials. To this end a novel micro-mechanical approach based on homogenization techniques and fracture mechanics concepts, is proposed and an original J-integral formulation is established for composite micro-structures. Accurate non-linear macroscopic constitutive laws are developed for a uniaxial and a shear macro-strain path by taking into account changes in micro-structural configuration owing to crack growth and crack face contact. Numerical results, carried out by coupling a finite element formulation and an interface model, are applied to a porous composite with edge cracks and a debonded short fiber-reinforced composite. The composite micro-structure is controlled by the macroscopic strain and the micro-to-macro transition, settled in a variational formulation, is obtained for three types of boundary conditions, i.e. linear displacements, uniform tractions and periodic fluctuations and anti-periodic tractions. The accuracy of the determined macroscopic constitutive properties to represent the failure characteristics of locally periodic defected composites is also investigated in terms of energy release rate predictions, by comparisons between a direct analysis and homogenization approaches. Results highlight the dependence of the macroscopic constitutive law for a micro-structure with evolving defects on both the macro-strain path and the type of boundary conditions and the capability of the proposed model to provide a failure model for a composite material undergoing micro-cracking and contact.     

Numerical simulation of crack deflection and penetration at an interface in a bi-material under dynamic loading by time-domain boundary element method

The hybrid time-domain boundary element method (BEM), together with the multi-region technique, is applied to simulate the dynamic process of crack deflection/ penetration at an interface in a bi-material. The whole bi-material is divided into two regions along the interface. The traditional displacement boundary integral equations (BIEs) are employed with respect to the exterior boundaries; meanwhile, the non-hypersingular traction BIEs are used with respect to the part of the crack in the matrix. Crack propagation along the interface is numerically modelled by releasing the nodes in the front of the moving crack tip and crack propagation in the matrix is modeled by adding new elements of constant length to the moving crack tip. The dynamic behaviours of the crack deflection/penetration at an interface, propagation in the matrix or along the interface and kinking out off the interface, are controlled by criteria developed from the quasi-static ones. The numerical results of the crack growth trajectory for different inclined interface and bonded strength are computed and compared with the corresponding experimental results. Agreement between numerical and experimental results implies that the present time-domain BEM can provide a simulation for the dynamic propagation and deflection of a crack in a bi-material.     

Diffraction characterization of microstructure scale fatigue crack growth in a modern Al–Zn–Mg–Cu alloy

SEM-based electron backscattered diffraction (EBSD) measurements characterize constituent-particle nucleated fatigue crack path relative to local grain orientation and crack wake defect distribution for Al–Zn–Mg–Cu alloy 7050-T7451 stressed in moist air. Crack propagation is primarily transgranular; consisting of facets parallel to {1 0 0}, {1 1 0} and high-index planes with no evidence of {1 1 1} slip-based cracking; and is also inter-subgranular involving pre-existing or fatigue process zone generated subgrain boundaries. Dislocation substructure develops close to the fatigue crack surface due to dynamic recovery of crack tip cyclic plasticity. Crack growth through subgrain structure explains the broad occurrence of crack features without a low-index orientation and is justified based on trapped-hydrogen embrittlement. A failure criterion for environmental fatigue modeling must capture a failure mechanism based on: (a) formation of localized defect structure from cumulative cyclic plasticity (perhaps H sensitive), and (b) subsequent embrittlement due to interaction of H trapped at this defect structure with microstructure-sensitive local tensile stresses normal to this weakened interface. Crack interaction with subgrain (and grain) boundaries produces local deflections and branches that arrest over a short distance. Such features should cause a distribution of microstructure-sensitive growth rates.     

Crack propagation in α-Al2O3/Mg metal matrix composites

The crack propagation characteristics of specimens of a unidirectionally reinforced α-Al₂O₃/Mg alloy metal matrix composite were investigated by means of fatigue crack propagation tests, tensile tests and fracture toughness tests. Samples were tested in longitudinal and transverse orientations. Fatigue crack propagation rates were successfully measured for each orientation. Crack propagation modes were found to be dependent upon the applied stress intensity and the fibre orientation. The crack propagation rates can vary by several orders of magnitude between nominally identical samples. In thermal cycling tests, voids were nucleated at the fibre/matrix interface: these voids decreased the load-carrying capability of the metal matrix composite but increased the work of fracture in the longitudinal orientation.