Evaluation of crack tip stress and strain fields under nonproportional loading in a viscoelastic material

The crack tip strain and stress fields in a viscoelastic material under nonproportional loading conditions are evaluated. In order to evaluate the strain field, the crack tip displacement field is measured by using the digital image correlation (DIC) technique. This displacement field is then approximated by using the theoretically obtained crack tip displacement field in viscoelastic materials. The result shows that the approximation method can smoothly reconstruct the experimentally obtained displacement field. From the approximated displacement field, the crack tip strain field can be precisely obtained by using the differential form of the theoretical displacement. On the other hand, the crack tip stress field is analyzed by using the stress function. This suggests that the strain and stress fields can be independently evaluated. In addition, different time dependencies between stress and strain fields near the crack tip are observed. Based on this experiment, we can discuss the several criteria for the crack propagation directions in viscoelastic materials.     

Investigation of fatigue crack closure using multiscale image correlation experiments

Two full-field macroscale methods are introduced for estimating fatigue crack opening levels based on digital image correlation (DIC) displacement measurements near the crack tip. Crack opening levels from these two full-field methods are compared to results from a third (microscale) method that directly measures opening of the crack flanks immediately behind the crack tip using two-point DIC displacement gages. Of the two full-field methods, the first one measures effective stress intensity factors through the displacement field (over a wide region behind and ahead of the crack tip). This method reveals crack opening levels comparable to the limiting values (crack opening levels far from the crack tip) from the third method (microscale). The second full-field method involves a compliance offset measurement based on displacements obtained near the crack tip. This method delivers results comparable to crack tip opening levels from the microscale two-point method. The results of these experiments point to a normalized crack tip opening level of 0.35 for R ∼ 0 loading in grade 2 titanium. This opening level was found at low and intermediate ΔK levels. It is shown that the second full-field macroscale method indicates crack opening levels comparable to surface crack tip opening levels (corresponding to unzipping of the entire crack). This indicates that effective stress intensity factors determined from full-field displacements could be used to predict crack opening levels.     

Calculation of K-factor and T-stress for cracks in anisotropic bimaterials

The problem of a crack in a thin layer terminating perpendicular to a layer/substrate interface is analyzed for a general case of elastic anisotropy. The crack is modelled by means of continuous distribution of dislocations, which is assumed to be singular at the crack tip. A system of simultaneous functional equations is obtained that enables to find the singularity exponent λ. The reciprocal theorem (ψ-integral) is used to compute the generalized stress intensity factor (GSIF) through the remote stress and displacement field for a particular specimen geometry and boundary conditions using FEM. The results obtained are compared with the evaluation of GSIF based upon the dislocation arrays technique. Existing semi-analytical solution for singularities in anisotropic trimaterials is applied and its validity for the specimen investigated is checked by FEM. The evaluation of T-stress using the dislocation arrays technique is performed.     

Determination of Stress Intensity Factor for Cracks in Orthotropic Composite Materials using Digital Image Correlation

Abstract: This paper focuses on the application of the digital image correlation (DIC) technique to determine the stress intensity factor (SIF) for cracks in orthotropic composites. DIC is a full‐field technique for measuring the surface displacements of a deforming object and can be applied to any type of material. To determine the SIF from full‐field displacement data, the asymptotic expansion of the crack‐tip displacement field is required. In this paper the expansion of the crack tip displacement field is derived from an existing solution for strain fields. Unidirectional fibre composite panels with an edge crack aligned along the fibre were tested under remote tensile loading and the displacements were recorded using DIC. The SIF was calculated from the experimental data by fitting the theoretical displacement field using the least squares method. The SIF thus determined was in good agreement with theoretical results and therefore demonstrates the applicability of the derived displacement field and DIC technique for studying fracture in composites.     

A new analytical method for stress intensity factors based on insitu measurement of crack deformation under biaxial tension

A new approach for the calculation of stress intensity factors (SIF) for isotropic and orthotropic materials under biaxial tension loading was proposed in this paper. In order to determine SIF from the full-field displacement data, an asymptotic expansion of the crack tip displacement field was performed. The deforming shape and surface residual stress of the crack tip was obtained at the early extended stage of the loading process by using optical microscope and X-ray diffraction measurement. During this stage, a modified Dugdale Model, which takes into account the coupled effect at the crack tip, was proposed for the open displacement of the crack tip. In this paper, the SIFs of two types of silicon steel sheet with isotropic and orthotropic properties were calculated using the modified Dugdale Model based on the biaxial tension experimental data. From the results, it was found that analysis using the modified Dugdale Model is an effective way to evaluate SIF under biaxial stress.     

Identification of damage and cracking behaviours based on energy dissipation mode analysis in a quasi-brittle material using digital image correlation

Characterizing the crack stability to predict the behaviour of ceramics designed for industrial use is a challenging issue. It requires accurate crack tip detection during the controlled crack propagation of notched bending tests. Different indirect methods are available, like for instance the compliance technique. Recently, techniques based on digital image correlation (DIC) have emerged: finite-element DIC (FE-DIC) with a finite element decomposition of the displacement field, integrated-DIC (I-DIC) based on Williams?? series decomposition of the displacement field and regularized-DIC (R-DIC) for mechanical constraints. These full-field techniques enable the quantification of the crack length and the stress intensity factor K ^I . In this paper, these four methods are compared in terms of measurements of crack lengths and stress intensity factors during a notched bending test. The tested material is a damageable quasi-brittle ceramic at room temperature. The non linearity of the stress-strain law of this microcraked ceramic results in a complex behaviour that is not captured by the compliance method during the bending test. Therefore the linear elastic compliance method leads to a different estimation of crack lengths and stress intensity factors compared to DIC methods. On the other hand, the R-DIC approach handles the non linear material constitutive behaviour. It allows a deeper analysis of the mechanical fields, the energy dissipation and the damage mechanisms during the crack propagation.     

Determination of effective stress intensity factors under mixed-mode from digital image correlation fields in presence of contact stresses and plasticity

Digital image correlation (DIC) is more and more popular to monitor fatigue crack growth and to determine the stress intensity factors. However, the posttreatment of the recorded displacement fields becomes tricky when the crack faces are not stress-free and when crack tip plasticity becomes significant. Several posttreatment methods to locate the crack tip and measure the effective stress intensity factors in such cases are compared, using finite element method-computed displacement fields, and then used on real DIC fields. An approach coupling DIC and finite element method is proposed to estimate the contact stresses along the crack.     

Effects of component size, geometry, microstructure and aging on the embrittling behavior of creep crack growth correlated by the Q parameter

The driving force for creep crack growth is dominated by local elastic-plastic stress in the creep damage zone around a crack tip, temperature and microstructure. In previous work, C^∗, C_t, load line displacement rate dδ/dt and Q^∗ parameters have been proposed as formulations of creep crack growth rate (CCGR). Furthermore, using parameters mentioned above, the construction of the algorithm of predictive law for creep crack growth life is necessary for life assessment procedures. The aim of this paper is to identify the effects of component size, geometry, microstructure, aging and weldment on the embrittling behavior of creep crack growth and incorporate these effects in a predictive law, using the Q^∗ parameter. It was found that for specimen size (width and thickness) and of material softening due to aging the values of the activation energy were the same whereas for grain size change and structural brittleness, which affected crack tip multi-axial stress state the values for the activation energy for CCGR differ.     

Effect of overload on crack closure in thick and thin specimens via digital image correlation

The displacement field of compact tension (CT) specimens have been mapped by digital image correlation (DIC) local to growing fatigue cracks to study overload effects for plane stress and plane strain. We have extracted crack opening displacement (ΔCOD) and stress intensity (K) determined by a Muskhelishvili fit to the crack tip displacement field to infer the closure load. In both cases a classical knee was observed upon unloading consistent with closure which disappeared during the accelerated growth following OL, before increasing during retardation. In both cases following OL the crack growth rate is perturbed for a distance similar to the plastic zone.     

Fatigue crack closure: A myth or a misconception?

In this paper, we have extended our previous study on fatigue crack closure to examine the phenomenon of crack opening displacement (COD) and its impact on the crack tip fields in both 2D and 3D specimen geometries using full‐field experimental measurements and integrated finite element modelling. Digital image correlation (DIC) and digital volume correlation (DVC) were used to measure the near‐tip material responses on the surfaces (DIC) and the interior (DVC) of the specimens. Materials with elastic‐plastic and large plastic characteristics were chosen for the study, where plasticity‐induced premature contact between the crack flanks is known to occur. Displacement maps around the cracks were obtained using DIC and DVC at selected load increments and were introduced as boundary conditions into the finite element (FE) models to obtain the “effective” crack driving force in terms of J‐integral, and the results were compared with those “nominal” from the standard FE analysis. Both visual observation and compliance curves were used to determine the “crack opening” levels; whilst the impacts of the crack opening on the crack driving force J and the normal strains ahead of the crack tip were evaluated in 2D and 3D. The results from the study indicate that, crack closure, although clearly identifiable in the compliance curves, does not appear to impact on global crack driving force, such as J‐integral, or strains ahead of the crack tip; hence, it may well be a misconception.     

Mode I and mixed mode fracture of polysilicon for MEMS

An experimental study was carried out to investigate the local and effective fracture behaviour of polycrystalline silicon for microelectromechanical systems (MEMS). The apparent mode I critical stress intensity factor was determined from MEMS‐scale tension specimens containing atomically sharp edge pre‐cracks, while local deformation fields were recorded near the crack tip, with high resolution by the in situ Atomic Force Microscopy (AFM)/Digital Image Correlation (DIC) method previously developed by this group. The effective mode I critical stress intensity factor varied in the range 0.843–1.225 MPa√m. This distribution of values was attributed to local (in grain) cleavage anisotropy and to enhanced grain boundary toughening. The same sources resulted in very different local and macroscopic (apparent) stress intensity factors, which, combined with the small grain size of polysilicon (0.3 μm,) were the reason for subcritical crack growth that was evidenced experimentally by AFM topographic and AFM/DIC displacement measurements. The effect of local in‐grain anisotropy and granular inhomogeneity was stronger under mixed mode loading of edge cracks inclined at angles up to 55° with respect to the applied far‐field load. The K_I–K_II locus was characterized by scatter in the K_Ic values but on average it followed the curves calculated by the maximum tensile stress and the maximum energy release rate criteria calculated assuming isotropy.     

Mode I–III Decomposition of the J‐integral from DIC Displacement Data

This paper presents the implementation of the decomposition method on digital image correlation (DIC) obtained displacement fields to obtain J‐integral results (J) and respective stress intensity factors (SIFs). DIC is increasingly used with the J‐integral approach in experimental mechanics to obtain J estimates from complex fracture processes. In this approach, the decomposition method is applied to DIC displacement fields for the first time. Here, displacement fields are separated before stresses and strains are computed, so that subsequent computation of separate J or SIF components may follow the classical full‐field J‐integral approach. The sensitivity of the decomposition method to experimental errors is investigated using synthetically generated errors imposed on crack tip displacement fields (Williams' series), from which improvements to the procedure are proposed. The method is experimentally tested on PMMA Arcan specimens under mode I, II, and III, and mixed‐mode I–III loading. Test results were compared to fracture toughness values obtained from ASTM tests and literature with close agreement.     

The M-integral for calculating intensity factors of an impermeable crack in a piezoelectric material

In this study, a conservative integral is derived for calculating the intensity factors associated with piezoelectric material for an impermeable crack. This is an extension of the M-integral or interaction energy integral for mode separation in mechanical problems. In addition, the method of displacement extrapolation is extended for this application as a check on results obtained with the conservative integral. Poling is assumed parallel, perpendicular and at an arbitrary angle with respect to the crack plane, as well as parallel to the crack front. In the latter case, a three-dimensional treatment is required for the conservative integral which is beyond the scope of this investigation. The asymptotic fields are obtained; these include stress, electric, displacement and electric flux density fields which are used as auxiliary solutions for the M-integral.Several benchmark problems are examined to demonstrate the accuracy of the methods. Numerical difficulties encountered resulting from multiplication of large and small numbers were solved by normalizing the variables. Since an analytical solution exists, a finite length crack in an infinite body is also considered. Finally, a four point bend specimen subjected to both an applied load and an electric field is presented for a crack parallel, perpendicular and at an angle to the poling direction. It is seen that neglecting the piezoelectric effect in calculating stress intensity factors may lead to errors.     

Analysis of the effects of compressive stresses on fatigue crack propagation rate

In this study, the effects of compressive stresses on the crack tip parameters and its implication on fatigue crack growth have been studied. Elastic–plastic finite element analysis has been used to analyse the change of crack tip parameters with the increase of the applied compressive stress level.The near crack tip opening displacements and the reverse plastic zone size around the crack tip have been obtained. The finite element analysis shows that when unloading from peak tensile applied stress to zero applied stress, the crack tip is still kept open and the crack tip opening displacement gradually decreases further with the applied compressive stress. It has been found that for a tension–compression stress cycle these crack tip parameters are determined mainly by two loading parameters, the maximum stress intensity K_max in the tension part of the stress cycle and the maximum compressive stress σ_maxcom in the compression part of the stress cycle.Based on the two parameters, K_max, and σ_maxcom, a fatigue crack propagation model for negative R ratios only has been developed to include the compressive stress effect on the fatigue crack propagation rate.Experimental fatigue crack propagation data sets were used for the verification of this model, good agreements have been obtained.     

A constraint based parameter for quantifying the crack tip stress fields in welded joints

By means of finite element analyses of plane strain crack tip stress fields from homogeneous and heterogeneous modified boundary layer formulations, as well as homogeneous and mismatched full field solutions, a new constraint parameter β_m has been established for overmatched welded joints, allowing the material mismatching effect on the crack tip stress fields to be quantified. In the case of complete specimens, both geometry and material mismatching affect the crack tip stress fields, and a total constraint parameter β_T can be defined. This approach allows to quantify the stress fields directly from the values of the remote applied load.     

Stress intensity factor analysis at an interfacial corner between anisotropic bimaterials under thermal stress

A numerical method using a path-independent H-integral based on the Betti reciprocal principle was developed to analyze the stress intensity factors of an interfacial corner between anisotropic bimaterials under thermal stress. According to the theory of linear elasticity, asymptotic stress near the tip of a sharp interfacial corner is generally singular as a result of a mismatch of the materials’ elastic constants. The eigenvalues and the eigenfunctions are obtained using the Williams eigenfunction method, which depends on the materials’ properties and the geometry of an interfacial corner. The order of the singularity related to the eigenvalue is real, complex or power-logarithmic. The amplitudes of the singular stress terms can be calculated using the H-integral. The stress and displacement fields around an interfacial corner for the H-integral are obtained using finite element analysis. A proposed definition of the stress intensity factors of an interfacial corner involves a smooth expansion of the stress intensity factors of an interfacial crack between dissimilar materials. The asymptotic solutions of stress and displacement around an interfacial corner are uniquely obtained using these stress intensity factors.     

Procedure for accurate calculation of the J-integral from digital volume correlation displacement data

The application of digital image and volume correlation techniques to obtain displacement fields from images has become ubiquitous in experimental fracture mechanics. In this paper, a procedure to extract the J-integral (J) from three-dimensional displacement fields obtained using digital volume correlation is presented. The procedure has been specially adapted to allow for experimental noise and errors, such as poorly defined crack front displacements, smearing of the displacement field across the crack faces, and knowledge of the imprecise crack front location. The implementation is verified using analytical crack-tip fields perturbed with synthetic image correlation errors to characterise the response of J. The method is then applied to experimental results using a Magnesium alloy WE43 loaded elastically in mixed mode. The steps outlined are intended as a guideline for the application of the volume integral from displacement fields to allow for accurate calculation of J along a crack front embedded within the volume.     

Analytical and numerical study of cohesive zones for a crack in an adhesive layer between identical isotropic materials

A crack in a thin adhesive elastic-perfectly plastic layer between two identical isotropic elastic half-spaces is considered. Uniformly distributed normal stress is applied to the substrates at infinity. First, stress distribution in the cohesive zones and the J-integral values are defined numerically by the finite element method (FEM). Further, a mathematical formulation of the problem is given and its analytical solution is proposed. It is assumed that, at the crack continuations, there exist cohesive zones. The interlayer thickness is neglected since it is much smaller than the crack length. The distribution of the normal stress, which was obtained by means of the FEM, is now approximated by a piecewise-constant function and assumed to be applied at the faces of the cohesive zones. The formulated problem is solved analytically and an equation for determination of the cohesive zone lengths is derived. Also, closed expressions for the crack tip opening displacement and for the J-integral are obtained in an analytical form. These parameters are found with respect to the values of the normal stress applied at infinity. Finally, a universal approximating function, which describes the stress distribution in the cohesive zones, is constructed. This function depends on the ratio between the interlayer thickness and the crack length and on the ratio between the normal stress applied at infinity and the yield limit of the interlayer’s material. Once again, the problem is solved analytically, but this time for the stress distribution prescribed by the universal approximating function. The cohesive zone lengths, the values of the crack tip opening displacement and of the J-integral are calculated. A comparative analysis of the obtained results is carried out. A good agreement of the J-integral values calculated by means of the developed analytical models and by the associated finite element analysis is demonstrated.     

ON DETERMINING STRESS INTENSITY FACTORS FOR MIXED MODE CRACKS FROM THERMOELASTIC DATA

Abstract— An alternative methodology is presented for determining stress intensity factors for cracks subject to mixed-mode displacements. The methodology involves thermoelastic data generated from a SPATE (Stress Pattern Analysis by Thermal Emission) system and has been adapted from one used successfully in photoelasticity. The thermoelastic data is collected throughout the elastic stress field dominated by the crack tip singularity. The stress field is described using a Fourier series within Muskhelishvili's approach. This method allows different applied stress fields to be described which may include transient or non-uniform stress fields. The results obtained using the new methodology are at least as good as those obtained previously for pure mode I cases, and generally better for mixed mode displacement conditions.     

Locating the Crack Tip Using Displacement Field Data: A Comparative Study

Abstract: The evaluation of stress intensity factors from experimentally determined crack‐tip stress or displacement fields almost always requires that the location of the crack tip is identified beforehand. In this work, a study has been performed to compare how different methods to locate the crack‐tip position from the displacement field around a crack tip obtained by digital image correlation influence the estimation of stress intensity factors. The methods used were two constrained Newton type methods: the trust‐region reflective Newton method and quasi‐Newton method; an unconstrained direct search method: the Nelder–Mead Simplex method; a constrained genetic algorithm; and a constrained Pattern Search (PS) method. It is shown that the Newton type methods are less accurate compared with the direct search methods studied. The PS method was found to be the most accurate. Furthermore, the PS method was found to be about twice as fast as the Simplex method and 10 times faster than a Genetic Algorithm for the same computing hardware and the same input data.