Interface crack initiation at V-notches along adhesive bonding in weakly bonded polymers subjected to mixed-mode loading

In this paper, interface crack initiation at V-notches along adhesive in bonded Polycarbonate (PC) and Poly Methyl Methacrylate (PMMA) subjected to mixed-mode loading conditions was investigated based on a combined experimental, finite element and matched asymptotic analysis. The V-notch specimens with an adhesive interface starting from its tip made at different notch angles were tested under three-point bending conditions. The experimental observations show that the specimens mainly fail by cracks along the interface. Also, the load at the crack initiation increases when the notch angle increases. The computational results are then used to explain and to correlate with the experimental data. A two-fold criterion developed by Leguillon (Eur J Mech A/Solids 21:61?C72 2002) that requires a simultaneous satisfaction of both Griffith energy and stress conditions for the crack initiation at a notch in the specimen made of a homogeneous brittle material is first extended for V-notch specimens under mixed-mode loading conditions and then used to estimate the crack initiation load. The estimated loads appear to agree well with the experimental data. Finally, an inverse method is proposed to estimate the values of fracture toughness at different mode mixity ratios.     

Fatigue thresholds of holed components under in‐phase and out‐of‐phase torsional and axial loadings

The resistance‐curve (R‐curve) method was applied to the prediction of the fatigue thresholds of notched components under in‐phase and out‐of‐phase combinations of cyclic torsion and axial loadings. The prediction was compared with the experimental data obtained from thin‐walled tubular specimen of medium‐carbon steel with a hole. The stress was completely reversed and the mean stress was zero. The crack was nucleated at the position of the maximum range of the circumferential stress on the periphery of a hole, and propagated almost straight for all cases examined. The experimental data of the thresholds for crack initiation and fracture agreed well with the predictions for in‐phase and for out‐of‐phase loadings with 45° phase difference. For out‐of‐phase loading with 90°, the threshold for fracture was close to the crack initiation limit, because of the reduction of crack closure due to crack face rubbing by mode II shear cycling.     

Experimental investigation on low cycle fatigue and fracture behaviour of a notched Ni‐based superalloy at elevated temperature

In order to investigate the effects of stress concentration on low cycle fatigue properties and fracture behaviour of a nickel‐based powder metallurgy superalloy, FGH97, at elevated temperature, the low cycle fatigue tests have been conducted with semi‐circular and semi‐elliptical single‐edge notched plate specimens at 550 and 700 °C. The results show that the fatigue life of the notched specimen decreases with the increase of stress concentration factor and the fatigue crack initiation life evidently decreases because of the defect located in the stress concentration zone. Moreover, the plastic deformation induced by notch stress concentration affects the initial crack occurrence zone. The angle α of the crack occurrence zone is within ±10° of notch bisector for semi‐circular notched specimens and ±20° for semi‐elliptical notched specimens. The crack propagation rate decreases to a minimum at a certain length, D, and then increases with the growth of the crack. The crack propagation rate of the semi‐elliptical notched specimen decelerates at a faster rate than that of the semi‐circular notched specimen because of the increase of the notch plasticity gradient. The crack length, D, is affected by both the applied load and the notch plasticity gradient. In addition, the fracture mechanism is shown to transition from transgranular to intergranular as temperature increases from 550 to 700 °C, which would accelerate crack propagation and reduce the fatigue life.     

Three‐dimensional mixed‐mode (I and II) crack‐front fields in ductile thin plates — effects of T‐stress

It has been well‐established that the non‐singular T‐stress provides a first‐order estimate of geometry and loading mode (e.g. tension versus bending) effects on elastic–plastic crack‐front field under mode I loading conditions. The objective of this paper is to exam the T‐stress effect on three‐dimensional (3D) crack‐front fields under mixed‐mode (modes I and II) loading. To this end, detailed 3D small strain, elastic–plastic simulations are carried out using a 3D boundary layer (small‐scale yielding) formulation. Characteristics of near crack‐front fields are investigated for a wide range of T‐stresses (T/σ₀ = ?0.8, ?0.4, 0.0, 0.4, 0.8). The plastic zones and thickness and angular and radial variations of the stresses are studied, corresponding to two values of the remote elastic mixity parameters M_e = 0.3 and 0.7, under both low and high levels of applied loads. It is found that different T‐stresses have a significant effect on the plastic zones size and shapes, regardless of the mode mixity and load level. The thickness, angular and radial distributions of stresses are also affected markedly by T‐stress. It is important to include these effects when investigating the mixed‐mode ductile fracture failure process in thin‐walled structural components.     

Low‐cycle fatigue/high‐cycle fatigue interactions in notched Ti‐6Al‐4V*

Combined low‐cycle fatigue/high‐cycle fatigue (LCF/HCF) loadings were investigated for smooth and circumferentially V‐notched cylindrical Ti–6Al–4V fatigue specimens. Smooth specimens were first cycled under LCF loading conditions for a fraction of the previously established fatigue life. The HCF 10⁷ cycle fatigue limit stress after LCF cycling was established using a step loading technique. Specimens with two notch sizes, both having elastic stress concentration factors of K_t = 2.7, were cycled under LCF loading conditions at a nominal stress ratio of R = 0.1. The subsequent 10⁶ cycle HCF fatigue limit stress at both R = 0.1 and 0.8 was determined. The combined loading LCF/HCF fatigue limit stresses for all specimens were compared to the baseline HCF fatigue limit stresses. After LCF cycling and prior to HCF cycling, the notched specimens were heat tinted, and final fracture surfaces examined for cracks formed during the initial LCF loading. Fatigue test results indicate that the LCF loading, applied for 75% of total LCF life for the smooth specimens and 25% for the notched specimens, resulted in only small reductions in the subsequent HCF fatigue limit stress. Under certain loading conditions, plasticity‐induced stress redistribution at the notch root during LCF cycling appears responsible for an observed increase in HCF fatigue limit stress, in terms of net section stress.     

Induced out‐of‐plane mode at the tip of blunt lateral notches and holes under in‐plane shear loading

As it is well known the Poisson's effect in a cracked plate subjected to anti‐symmetric plane loading leads to the generation of a coupled out‐of‐plane singular mode. Recent theoretical and numerical analyses have shown that this effect is present also in plates weakened by sharp V‐notches and might play a role in failure initiation phenomena of notched plates subjected to Mode II loading, especially in the presence of a large notch opening angle. Dealing with blunt notches with a large notch radius, and not just with sharp notches, the presence or not of an out‐of‐plane mode does not appear to have been systematically investigated in the past. The main aim of this work is to confirm the existence of the stress field associated with the out‐of‐plane mode (Mode O) and to describe its main features in the presence of a notch radius significantly different from zero. The analyses include U‐notches, as well as circular and elliptic holes. The strain energy density in a 3D control volume is utilized to identify the most critical zone (with respect to failure initiation) through the plate thickness at the notch tip.     

The role of first non‐singular stress terms in mixed mode brittle fracture of V‐notched components: an experimental study

This paper investigates the effects of the first non‐singular stress terms on the fracture assessment of sharp V‐notches under mixed mode loading. First, numerical studies have been performed on a fracture test configuration called single V‐notched ring (SVR) specimen. Then, the notch stress intensity factors as well as the coefficients of the first non‐singular stress terms, which are vital parameters in brittle fracture of V‐notched components, were calculated via a finite element over‐deterministic algorithm for a wide range of loading and geometry conditions. The obtained results demonstrate that the SVR specimen is able to provide a complete range of mode mixities from pure mode I to pure mode II loading conditions. The numerical results, next, have been converted to dimensionless parameters and are illustrated in several graphs. Indeed, these graphs can be easily employed by the engineers for rapid calculation of the corresponding notch stress intensity factors and the coefficients of the first non‐singular stress terms in the SVR specimen. The obtained fracture parameters are then submitted to the maximum tangential stress criterion to assess the effects of the first non‐singular terms on fracture behaviour of the specimen. Finally, an experimental study has been performed on the SVR specimen made of Nayriz Marble rock for two notch angles with a complete range of mode mixities. The obtained experimental data confirm the significant role of the first non‐singular stress terms. In fact, these results show that considering only the singular stress terms may induce an average error of 38% in the predicted fracture loads, which can be decreased to about 12% just by adding the contribution of the first non‐singular terms to the maximum tangential stress criterion.     

7050铝合金Ⅰ-Ⅱ复合型疲劳裂纹研究

为研究7050铝合金在Ⅰ-Ⅱ型复合加载下疲劳裂纹扩展规律,在Amsler HFP5000高频试验机上利用Richard加载装置,完成紧凑拉剪(CTS)试样疲劳裂纹扩展试验,利用有限元对Ⅰ-Ⅱ复合型裂纹进行数值模拟,采用APDL命令流计算不同裂纹长度的应力强度因子,并引入最大周向应力准则计算裂纹扩展角,用有限元计算等效应...     

Fatigue crack propagation under in‐phase and out‐of‐phase biaxial loading

Fatigue damage characteristics of aluminium alloy under complex biaxial loads such as in‐phase and out‐of‐phase loading conditions and different biaxiality ratios have been investigated. The effects of microscale phenomena on macroscale crack growth were studied to develop an in‐depth understanding of crack nucleation and growth. Material characterization was conducted to study the microstructure variability. Scanning electron microscopy was used to identify the second phase particles, and energy dispersive X‐ray spectroscopy was performed to analyse their phases and elements. Extensive quasi‐static and fatigue tests were conducted on Al7075‐T651 cruciform specimens over a wide range of load ratios and phases. Detailed fractography analysis was conducted to understand the crack growth behaviour observed during the fatigue tests. Significant differences in crack initiation and propagation behaviour were observed when a phase difference was applied. Primarily, crack retardation and splitting were observed because of the constantly varying mode mixity caused by phase difference. The crack growth behaviour and fatigue lives under out‐of‐phase loading were compared with those under in‐phase loading to understand the effect of mixed‐mode fracture.     

Determination of the fracture properties of metallic materials using pre‐cracked small punch tests

In this paper, the use of pre‐cracked small punch test (p‐SPT) miniature specimens to obtain the fracture parameters of a material is presented. The geometry of the specimens used was square of 10 × 10 mm with a thickness of 0.5 mm. An initial crack‐like notch was created in the SPT specimens by means of a laser micro‐cutting technique. In order to obtain the fracture parameters from p‐SPT specimens three different approaches have been considered here. The first approach is based on the crack tip opening displacement concept, the second is based on the measure of the fracture energy using the area under the load–displacement curve for different crack sizes, and the third approach is based on the direct numerical simulation of the p‐SPT specimen and the numerical calculation of the J‐integral. In order to study the crack initiation in these p‐SPT specimens, several interrupted tests and the subsequent scanning electron microscope analysis have been carried out. The results indicate that p‐SPT specimens can be used as an alternative method for determining the fracture properties of a material in those cases where there is not enough material to undertake conventional fracture tests. For these p‐SPT specimens, the multi‐specimen method for the determination of the fracture energy is the most promising approach. The results indicate that this small specimen size allows the value of the material toughness, under low constraint conditions to be obtained.     

State‐of‐the‐art review on extended stress intensity factor concepts

The stress intensity factor concept for describing the stress field at pointed crack or slit tips is well known from fracture mechanics. It has been substantially extended since Williams' basic contribution (1952) on stress fields at angular corners. One extension refers to pointed V‐notches with stress intensities depending on the notch opening angle. The loading‐mode‐related simple notch stress intensity factors K₁, K₂ and K₃ are introduced. Another extension refers to rounded notches with crack shape or V‐notch shape in two variants: parabolic, elliptic or hyperbolic notches (‘blunt notches’) on the one hand and root hole notches (‘keyholes’ when considering crack shapes) on the other hand. Here, the loading‐mode‐related generalised notch stress intensity factors K_1ρ, K_2ρ and K_3ρ are defined. The concepts of elastic stress intensity factor, notch stress intensity factor and generalised notch stress intensity factor are extended into the range of elastic–plastic (work‐hardening) or perfectly plastic notch tip or notch root behaviour. Here, the plastic notch stress intensity factors K_1p, K_2p and K_3p are of relevance. The elastic notch stress intensity factors are used to describe the fatigue strength of fillet‐welded attachment joints. The fracture toughness of brittle materials may also be evaluated on this basis. The plastic notch stress intensity factors characterise the stress and strain field at pointed V‐notch tips. A new version of the Neuber rule accounting for the influence of the notch opening angle is presented.     

Fracture investigation of U‐notch made of tungsten–copper functionally graded materials by means of strain energy density

The averaged strain energy density over a well‐defined control volume was employed to assess the fracture of U‐notched specimens made of tungsten–copper functionally graded materials under prevalent mode II loading. The boundary of control volume was evaluated by using a numerical method. Power law function was employed to describe the mechanical properties (elasticity modulus, Poisson's ratio, fracture toughness and ultimate tensile stress) through the specimen width. The effect of notch tip radius and notch depth on notch stress intensity factors and mode mixity parameter χ were assessed. In addition, a comparison based on fracture load between functionally graded and homogeneous W–Cu was made. Furthermore, in this research, it was shown that the mean value of the strain energy density over the control volume can be accurately determined using coarse meshes for functionally graded materials.     

Mesoscopic mechanisms in fatigue crack initiation in an aluminium alloy

The mechanistic aspects of process of initiation of a mode‐I fatigue crack in an aluminium alloy (AA 2219‐T87) are studied in detail, both computationally as well as experimentally. Simulations are carried out under plane strain conditions with fatigue process zone modelled as stress‐state–dependent cohesive elements along the expected mode‐I failure path. An irreversible damage parameter that accounts for the progressive microstructural damage due to fatigue is employed to degrade cohesive properties. The simulations predict the location of initiation of the fatigue crack to be subsurface where the triaxiality and the opening tensile stresses are higher in comparison with that at the notch surface. Examination of the fracture surface profile of fracture test specimens near notch tip reveals a few types of regions and existence of a mesoscopic length scale that is the distance of the location of highest roughness from the notch root. A discussion is developed on the physical significance of the experimentally observed length scale.     

Multiaxial fatigue of V‐notched steel specimens: a non‐conventional application of the local energy method

The paper deals with the multi‐axial fatigue strength of notched specimens made of 39NiCrMo3 hardened and tempered steel. Circumferentially V‐notched specimens were subjected to combined tension and torsion loading, both in‐phase and out‐of‐phase, under two nominal load ratios, R=?1 and R= 0, also taking into account the influence of the biaxiality ratio, λ=τ_a/σ_a. The notch geometry of all axi‐symmetric specimens was a notch tip radius of 0.1 mm, a notch depth of 4 mm, an included V‐notch angle of 90° and a net section diameter of 12 mm. The results from multi‐axial tests are discussed together with those obtained under pure tension and pure torsion loading on plain and notched specimens. Furthermore the fracture surfaces are examined and the size of non‐propagating cracks measured from some run‐out specimens at 5 million cycles. Finally, all results are presented in terms of the local strain energy density averaged in a given control volume close to the V‐notch tip. The control volume is found to be dependent on the loading mode.     

Unified triaxiality at the crack tip subjected to plane strain condition under mixed‐mode (I + II) fracture

The new model of stress triaxiality, subjected to plane strain condition under mixed‐mode (I + II) loading, at the yield loci of the crack tip, has been formulated using unified strength theory. It evaluates critical values of triaxiality for various convex and non‐convex failure criteria, unlike the existing model. It shows the effects of Poisson's ratio and intermediate principal stress for materials whose strength in tension and compression is either equal or unequal. Further, on this basis, the crack initiation angles are predicted for various crack inclinations and compared with those obtained from other fracture criteria. The plastic zone shapes supplement the results. Critical yield stress factor, a significant parameter at the crack tip got lowered as the difference among the three principal stresses reduced to a minimum. The crack initiation angles obtained from the model showed good agreement with those obtained from G‐, S‐, and T‐criterion.     

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.     

Failure assessment of notched polycrystalline graphite under tensile-shear loading

The fracture load and the fracture initiation angle were experimentally measured for a V-notched specimen made of polycrystalline graphite under combined tensile-shear loading. The experimental results were obtained for several specimens with different notch angles and various notch tip radii. The experimental observations showed that for a constant notch tip radius, the fracture load in pure tensile loading conditions decreases as the notch angle increases. Moreover, for a constant notch angle, as the notch tip radius increases the fracture load in graphite specimens enhances in the entire domain between pure tensile and pure shear loading conditions. A recently developed failure criterion was then used to estimate the experimental values of the notch fracture resistance and the fracture initiation angle for the tested graphite specimens. The experimental results could be estimated very well by using the results of the proposed criterion.     

State‐of‐the‐art review on the local strain energy density concept and its relation to the J‐integral and peak stress method

The local average strain energy density (SED) approach has been proposed and elaborated by Lazzarin for strength assessments in respect of brittle fracture and high‐cycle fatigue. Pointed and rounded (blunt) V‐notches subjected to tensile loading (mode 1) are primarily considered. The method is systematically extended to multiaxial conditions (mode 3, mixed modes 1 and 2). The application to brittle fracture is documented for PMMA flat bar specimens with pointed or rounded V‐notches inclusive of U‐notches. Results for other brittle materials (ceramics, PVC, duraluminum and graphite) are also recorded. The application to high‐cycle fatigue comprises fillet‐welded joints, weld‐like shaped and V‐notched base material specimens as well as round bar specimens with a V‐notch. The relation of the local SED concept to comparable other concepts is investigated, among them the Kitagawa, Taylor and Atzori–Lazzarin diagrams, the Neuber concept of fictitious notch rounding applied to welded joints and also the J‐integral approach. Alternative details of the local SED concept such as a semicircular control volume, microrounded notches and slit‐parallel loading are also mentioned. Coarse FE meshes at pointed or rounded notch tips are proven to be acceptable for accurate local SED evaluations. The peak stress method proposed by Meneghetti, which is based on a notch stress intensity factor consideration combined with a globally even coarse FE mesh and is used for the assessment of the fatigue strength of welded joints, is also presented.     

Mode I Fracture Toughness of CNT‐Reinforced PMMA

The influence of carbon nanotube (CNT) concentration on the fracture toughness of poly(methyl methacrylate) (PMMA) was examined on single‐edge V‐notched‐beam (SEVNB) specimens. Six groups of SEVNB specimens containing 0.5, 1, 2, 4, 8.5 wt% of CNTs and neat PMMA as a reference were tested. First, a notch was introduced into the specimens by a specially made disk whose edge is V‐shaped with a 30^° angle and a 30 μm tip width. As suggested by an American Society for Testing and Materials Standard for polymers, induction of a natural crack was attempted, without success. Therefore, fracture toughness values were determined with the ‘sharp’ machined notch by means of a calibration formula. These were compared to values obtained using a stress concentration factor and found to differ by less than 3%. The latter calculation takes into account the geometry of the notch. Results showed a decrease in the fracture toughness values with an increase in the CNT concentration. For specimens in which a natural crack was attempted, referred to as a razor‐cut notch, a significant increase in the apparent fracture toughness was observed, as a result of the induced damage.