Digital image correlation measurement of near‐tip fatigue crack displacement fields: constant amplitude loading and load history effects

Recent work by de Matos and colleagues employed digital image correlation to measure near tip displacement fields for fatigue cracks in 6082 T6 aluminium alloy. The main focus of this work was to directly measure fatigue crack closure, but the measurements can also be used to examine conditions at and ahead of the crack tip. In this paper, the results are re‐analysed and compared to two crack‐tip deformation models. The first assumes simple elastic deformation (according the Westergaard solution). This allows the history of crack‐tip stress intensity to be examined. Reasonable agreement with the elastic model is obtained, although there is a residual stress intensity caused by the plastic wake, which gives rise to crack closure. The second model examined is a simple elastic–plastic assumption, proposed by Pommier and colleagues. This can be applied to constant amplitude loading, although the results obtained here are very similar to the elastic case. A slightly more complex load case (a single overload in an otherwise constant amplitude variation of load) gives a much more complicated crack‐tip history. Here, the importance of crack‐tip plastic displacement, represented by the second term in Pommier's model becomes much clearer. Load history effects are captured by the residual value of this term and its associated displacement fields as well as by stress intensity factor. The implications for further modelling and experimental work are discussed.     

On improved crack tip plastic zone estimates based on T‐stress and on complete stress fields

Cracked ductile structures yield locally to form a plastic zone (pz) around their crack tips, which size and shape controls their structural behaviour. Classical pz estimates are based solely on stress intensity factors (SIF), but their precision is limited to very low σ_n/S_Y nominal stress to yield strength ratios. T‐stresses are frequently used to correct SIF‐based pz estimates, but both SIF and SIF plus T‐stress pz estimates are based on truncated linear elastic (LE) stress fields that do not satisfy boundary conditions. Using Griffith's plate complete LE stress field to avoid such truncated pz estimates, the influence of its Williams’ series terms on pz estimation is evaluated, showing that T‐stress improvements are limited to medium σ_n/S_Y values. Then, corrections are proposed to introduce equilibrium requirements into LE pz estimates. Finally, these improved estimates are compared with pz calculated numerically by an elastic–plastic finite element analysis.     

Mixed mode fatigue crack growth: A literature survey

The applications of fracture mechanics have traditionally concentrated on crack growth problems under an opening or mode I mechanism. However, many service failures occur from growth of cracks subjected to mixed mode loadings. This paper reviews the various criteria and parameters proposed in the literature for predictions of mixed mode crack growth directions and rates. The physical basis and limitations for each criterion are briefly reviewed, and the corresponding experimental supports are discussed. Results from experimental studies using different specimen geometries and loading conditions are presented and discussed. The loading conditions discussed consist of crack growth under mode II, mode III, mixed mode I and II, and mixed mode I and III loads. The effects of important variables such as load magnitudes, material strength, initial crack tip condition, mean stress, load non-proportionality, overloads and crack closure on mixed mode crack growth directions and/or rates are also discussed.     

Can pure mode III fatigue loading contribute to crack propagation in metallic materials?

The possibility of pure mode III crack growth is analysed on the background of theoretical and experimental results obtained in the last 20 years. Unlike for modes I and II, there is no plausible micromechanistic model explaining a pure mode III crack growth in ductile metals. In order to realize 'plain' mode III fracture surface, we propose the propagation of a series of pure mode II cracks along the crack front. Fractographical observations on crack initiation and propagation in a low alloy steel under cyclic torsion support such a model. The authors have not seen any clear indication of a pure mode III crack growth micromechanism in metals until now.     

Mode III crack growth in linear hardening materials with strain gradient effects

The flow-theory version of couple stress strain gradient plasticity is adopted for investigating the asymptotic fields near a steadily propagating crack-tip, under Mode III loading conditions. By incorporating a material characteristic length, typically of the order of few microns for ductile metals, the adopted constitutive model accounts for the microstructure of the material and can capture the strong size effects arising at small scales. The effects of microstructure result in a substantial increase in the singularities of the skew-symmetric stress and couple stress fields, which occurs also for a small hardening coefficient. The symmetric stress field turns out to be non-singular according to the asymptotic solution for the stationary crack problem in linear elastic couple stress materials. The performed asymptotic analysis can provide useful predictions about the increase of the traction level ahead of the crack-tip due to the sole contribution of the rotation gradient, which has been found relevant and non-negligible at the micron scale.     

Crack kinking under high pressure in an elastic-plastic material

Directional crack growth criteria in compressed elastic–plastic materials are considered. The conditions at the crack tip are evaluated for a straight stationary crack. Remote load is a combined hydrostatic stress and pure shear, applied via a boundary layer assuming small scale yielding. Strains and deformations are assumed to be small. Different candidates for crack path criteria are examined. Maximum non-negative hoop stress to judge the risk of mode I and maximum shear stress for mode II extension of the crack are examined in some detail. Crack surfaces in contact are assumed to develop Coulumb friction from the very beginning. Hence, a condition of slip occurs throughout the crack faces. The plane in which the crack extends is calculated using a finite element method. Slip-line solutions are derived for comparison with the numerically computed asymptotic field. An excellent agreement between numerical and analytical solutions is found. The agreement is good in the region from the crack tip to around halfway to the elastic–plastic boundary. The relation between friction stress and yield stress is varied. The crack is found to extend in a direction straight ahead in shear mode for sufficiently high compressive pressure. At a limit pressure a kink is formed at a finite angle to the crack plane. For lower pressures the crack extends via a kink forming an angle to the parent crack plane that increases with decreasing pressure.     

A hybrid approach to determine fracture resistance for mode I and mixed‐mode I and II fracture specimens

This paper proposes a hybrid approach to determine the fracture resistance for mode I and mixed‐mode I and II fracture specimens, combining both numerically computed and experimentally measured load (P) versus load‐line displacement (LLD or Δ) relationships for metallic fracture specimens. The hybrid approach predicates on the same principle as the conventional, multiple‐specimen experimental method in determining the energy release rate. The hybrid method computes the P–Δ curves from multiple finite element (FE) models, each with a different crack depth. The experimental procedure measures the P–Δ curve from a standard fracture specimen with a growing crack. The intersections between the experimental P–Δ curve and the numerical P–Δ curves from multiple FE models dictate the LLD levels to compute the strain energy (U) using the area under the numerical P–Δ curves. This method provides accurate estimates of the J resistance data for both SE(B) specimen under mode I loading and single‐edge notched specimens under mixed‐mode I and II loading.     

The effect of T‐stress on crack‐tip plastic zones under mixed‐mode loading conditions

In this paper, the influence of T‐stress on crack‐tip plastic zones under mixed‐mode I and II loading conditions is examined. The crack‐tip stress field is defined in terms of the mixed‐mode stress intensity factors and the T‐stress using William's series expansion. The crack‐tip stress field is incorporated into the Von Mises yield criteria to develop an expression that determines the crack‐tip plastic zone. Using the resultant expression, the plastic zone is plotted for various combinations of mode II to mode I stress intensity factor ratios and levels of T‐stress. The properties of the plastic zone affected by T‐stress and mixed‐mode phase angle are discussed. The observations obtained on plastic zones variations are important for further fatigue and fracture analyses for defects in engineering structures under mixed‐mode loading conditions.     

Reduction of measured toughness due to out‐of‐plane constraint in ductile fracture of aluminium alloy specimens

It is generally believed that a lower bound on the fracture toughness of a material is obtained from a standard test, particularly in metals where yielding occurs prior to fracture. The understanding is that in such a test the material around the crack tip is highly constrained hence reducing the extent of yielding. In this paper, we report the results of fracture tests where a tensile load is applied to a biaxial aluminium alloy specimen in the direction parallel to the crack front in addition to the fracturing load normal to the crack surface. We show that in this case a lower fracture toughness is measured than that obtained from a standard test. Indeed, for the highest value of tensile load used in our tests the J‐integral at fracture was half the value measured in a standard test. It is also shown that the volume of the plastic region can be used to measure the effect of constraint, irrespective of the manner in which the constraint arises. This approach suggests an even lower fracture toughness may be obtained than that measured here in certain loading conditions.     

A J-integral estimation method for C(T) specimens using the Common Format Equation

A new estimation scheme based on the Common Format Equation (CFE) is laid out for Compact Tension (C(T)) specimens. In this context, the CFE constraint factor Ω*, originally given only for the two limits plane stress, and plane strain, is discussed. A nonlinear finite element analysis of the behaviour of blunt notched C(T) specimens with varying crack length was performed. The specimen thickness B has been varied from 3.125 up to 25 mm. Furthermore the special cases plane stress and plane strain have been considered. Considering a linear elastic – ideal plastic material, a limit load analysis has been performed numerically from which Ω* has been obtained as a function of the ligament-to-thickness-ratio B/b. The -integral as a function of the load line displacement v has been determined for isotropic, nonlinear hardening material, where has been calculated using its definition as contour or surface integral, respectively. It is shown that if the obtained curves are normalized according to the Common Format Methodology, all curves fall approximately into one single curve. This allows to estimate J(v) curves for C(T) specimens using the CFE.     

A comparative numerical study of combined cold expansion and local torsion on fastener holes

Cold expansion and local torsion processes provide controllable strengthening mechanisms for a fastener hole and therefore have engineering significance. They rely on the residual stress and the accumulated shearing strain, respectively, which are difficult to measure. Due to the complex closed form solutions for these mechanisms, their numerical study is of great importance. In this work, a combination of the cold expansion and the local torsion on a fastener hole has been investigated numerically to evaluate the amount and nature of the total accumulated residual stresses around a fastener hole. Different cases of the cold expansion and the local torsion processes were modelled and studied by finite element simulation to investigate the existence of a loading case which produces a beneficial compressive residual stress field in the vicinity of a hole. Sensitivity of the final residual stress with respect to a range of process parameters including adequate diametral interference and angle of rotation was investigated.