Further developments in <Emphasis Type="Italic">J</Emphasis> evaluation procedure for growing cracks based on LLD and CMOD data

Laboratory testing of fracture specimens to measure resistance curves (J − Δa) have focused primarily on the unloading compliance method using a single specimen. Current estimation procedures (which form the basis of ASTM E1820 standard) employ load line displacement (LLD) records to measure fracture toughness resistance data incorporating a crack growth correction for J. An alternative method which potentially simplifies the test procedure involves the use of crack mouth opening displacement (CMOD) to determine both crack growth and J. However, while the J-correction for crack growth effects adopted by ASTM standard holds true for resistance curves measured using load line displacement (LLD) data, it becomes unsuitable for J-resistance measurements based upon the specimen response defined in terms of load-crack mouth opening displacement (CMOD). Consequently, direct application of the evaluation procedure for J derived from LLD records in laboratory measurements of resistance curves using CMOD data becomes questionable. This study provides further developments of the evaluation procedure for J in cracked bodies that experience ductile crack growth based upon the eta-method and CMOD data. The introduction of a constant relationship between the plastic components of LLD (Δ _p ) and CMOD (V _p ) drives the development of a convenient crack growth correction for J with increased loading when using laboratory measurements of P-CMOD data. The methodology broadens the applicability of current standards adopting the unloading compliance technique in laboratory measurements of fracture toughness resistance data (J resistance curves). The developed J evaluation formulation for growing cracks based on CMOD data provides a viable and simpler test technique to measure crack growth resistance data for ductile materials.     

Parametrizing ductile tearing resistance by four parameters

The energy dissipation rate, R, is considered as a measure of resistance to crack extension in elasto-plastic fracture mechanics. It can be re-evaluated from J_R test records of bend and tensile specimens. Three types of R(Δa)-curves are identified. If crack initiation occurs close to or at maximum load, the energy dissipation rate is decreasing with crack extension and approaches a stationary value. This type of R(Δa)-curves can be described by an exponential function with three parameters, namely the initial value, the final stationary value, and a transition length. The cumulative J_R-curves for different specimen geometries can be derived by integration. The three parameters of the R(Δa)-fit together with an integration constant, the initiation value, J_i, characterize ductile fracture resistance both quantitatively and physically interpretable. Constraint effects on R-curves can be quantified in terms of these parameters. A procedure for transferring J_R-curves from one geometry to another is proposed.     

Prediction of the energy dissipation rate in ductile crack propagation

In this paper, energy dissipation rate D vs. Δa curves in ductile fracture are predicted using a ‘conversion’ between loads, load‐point displacements and crack lengths predicted by NLEFM and those found in real ELPL propagation. The NLEFM/ELPL link was recently discovered for the DCB testpiece, and we believe it applies to other cracked geometries. The predictions for D agree with experimental results. The model permits a crack tip toughness R(Δa) which rises from J_c and saturates out when (if) steady state propagation is reached after a transient stage in which all tunnelling, crack tip necking and shear lip formation is established. J_R is always greater than the crack tip R(Δa) and continues to rise even after R(Δa) levels off. The analysis is capable of predicting the usual D vs. Δa curves in the literature which have high initial values and fall monotonically to a plateau at large Δa. It also predicts that D curves for CCT testpieces should be higher than those for SENB/CT, as found in practice. The possibility that D curves at some intermediate Δa may dip to a minimum below the levelled‐off value at large Δa is predicted and confirmed by experiment. Recently reported D curves that have smaller initial D than the D‐values after extensive propagation can also be predicted. The testpiece geometry and crack tip R(Δa) conditions required to produce these different‐shaped D vs. Δa curves are established and confirmed by comparison with experiment. The energy dissipation rate D vs. Δa is not a transferable property as it depends on geometry. The material characteristic R(Δa) may be the ‘transferable property’ for scaling problems in ELPL fracture. How it can be deduced from D vs. Δa curves (and by implication, J_R vs. Δa curves) is established.     

Specimen Size Requirements for Two-parameter Fracture Toughness Testing

Using a single parameter fracture mechanics theory, a minimum specimen size requirement of min(a, b, B) >200J/σ₀ in tension and min(a, b, B) >25J/σ₀ in bending, where B is the thickness, b the remaining ligament and a is the crack length of the specimen, were derived [Shih and German (1981), International Journal of fracture 17, 27–43] which have provided the basis for modern fracture toughness testing procedures. Two-parameter fracture toughness testing including the constraint, on the other hand, is desirable since it offers a solution to the transferability issue. A size requirement for a valid two-parameter fracture toughness testing based on the J-A₂ three-term solution was determined as min(a, b, B) > 11J/σ₀ [Chao and Zhu (1998), International Journal of fracture 89, 285–307] in which the limiting case is bend specimens under large scale yielding (LSY). Recent work by Chao et al. (2004, International Journal of fracture, 27, 283–302) has shown that the J-A₂ dominance at a crack tip can be significantly enhanced for bending specimens under LSY if a modified J-A₂ solution is adopted. This current paper further studies the size of the J-A₂ dominant zone using the modified J-A₂ solution for deep bend specimens with hardening from low to high and loading from SSY to LSY using finite element analysis. Based on the results, a rather relaxed specimen size requirement min(a, b, B) >6J/σ₀ is developed and recommended for a valid two-parameter fracture toughness testing using the J-A₂ fracture criterion. Validity of the size requirement is demonstrated by using the experimental J-R curves from non-standard bending specimens for A285 steel.     

J-resistance curve and ductile tearing of a mild steel

The onset of ductile tearing at room temperature of mild steel BS 15 was studied using side grooved compact tension specimens. The approach to this problem was divided conveniently into two basic parts: first, identification and evaluation of the toughness at initiation of crack extension, and second, assessment and characterization of the subsequent crack growth behaviour. The critical value of the J integral for crack initiation, J_c was obtained using two different techniques: the multispecimen method and a single specimen compliance test. It was found that the latter could be used with much larger unloading than originally proposed. This has the advantage of greater accuracy in the determination of the compliance, and consequently in the evaluation of crack extension. In the second part of the work, resistance curves were obtained applying two different approaches. The resistance curves obtained following the more exact method were used for the determination of the tearing modulus T of the material, and the values thus derived, compared with a selection of other steels.     

Short-rod elastic-plastic fracture toughness test using miniature specimens

The standard ASTM-E399 plane-strain fracture toughness (K _IC) test requires (1) the test specimen dimensions to be greater than a minimum size and, (2) fatigue precracking of the specimen. These criteria render many materials impractical to test. The short-rod elastic-plastic plane-strain fracture toughness test proposed by Barker offers a method of testing not requiring fatigue precracking and furthermore, it appears that test specimens smaller than that stipulated by ASTM can be used to obtain validK _IC values. In this study, the use of a modified miniature short-rod fracture toughness test specimen was investigated. Our miniature short-rod specimen is approximately 7 mm long and 4 mm diameter. These mini specimens are well suited for the purpose of testing biomaterials. The value of the minimum stress intensity factor coefficient (Y _m ^* ) for the mini short-rod specimens was determined experimentally using specimens machined from extruded acrylic rod stock. An elastic-plastic fracture toughness analysis using the mini specimens gave values ofK _IC for extruded acrylic (nominally PMMA) equal to 0.67 ± 0.06 MPa m^1/2. The problem of testing non-flat crack growth resistance curve materials (such as PMMA) using the short-rod fracture toughness test method is discussed. A modification to the test procedure involving the use of aY ^* value corresponding to a short crack length is suggested as a method of overcoming this difficulty.Nomenclature a crack length - a ₀ initial crack length - a ₁ length of the chevron notch on the mini short-rod specimen - a _m critical crack length — crack length atY _m ^* - C specimen compliance - C dimensionless specimen compliance = CED - D mini short-rod specimen diameter - E Young's modulus - K ₁ stress intensity factor - K _1C plane-strain fracture toughness - K _max fracture toughness calculated usingP _max - P load applied to the test specimen during a short-rod fracture toughness test - P _c load applied to the test specimen atY _m ^* - P _max maximum load applied to the specimen during a short-rod fracture toughness test - p plasticity factor - W mini short-rod specimen width - Y ^* stress intensity factor coefficient - Y _m ^* minimum of the stress intensity factor coefficient - dimensionless crack length =a/W - ₀ dimensionless initial crack length = ₀/W - ₁ dimensionless chevron notch length =a ₁/W - _m dimensionless critical crack length =a _m/W     

Single and multi-specimenR-curve methods forJ IC determination of toughened nylons

For characterization of the fracture resistance of materials used in the upper shelf toughness regime,J-R curves are widely considered the most promising candidates. However, there still remain problems concerning both the generation and measurement ofJ-R curves as material characterizing parameters and their application in ductile fracture analyses for failure prediction in polymeric materials. This paper reports the results of investigations conducted on two rubbertoughened nylons at room temperature. Two different methods ofJ-R curve determination are covered, namely multi-specimen and single specimen test methods. The resultingJ-R curves have also been evaluated to obtain values of the initiation toughness,J _IC, following the extrapolation and interpolation schemes prescribed by ASTM E813-81 and ASTM E813-87 test procedures, respectively. The results show that the multiple specimen unloading method and the single specimen partial unloading compliance method can be used to generate comparable crack growth resistanceJ-R curves of the toughened nylons. The value ofJ _IC for the crystalline rubber-toughened nylon was approximately twice the value obtained for the amorphous rubber-toughened nylon. The former material also exhibited a greater resistance to ductile crack growth.     

FATIGUE CRACK GROWTH UNDER MIXED MODES I AND II

Fatigue crack growth behaviour under mixed modes I and II was studied by applying in-phase alternating tensile and torsional loading to a thin-walled hollow cylindrical specimen with an initial crack. In the linear region of a log-log plot where da/dN=A(ΔK)^m, da/dN at first decreases with increasing ΔK₁₁₀ component and then approaches a minimum close to the value of ΔK₁₁₀/ΔK₁₀～ 0.58; here ΔK₁₁₀/ΔK₁₀ is the ratio of the initial ΔK_II to the initial ΔK₁., When ΔK₁₁₀/ΔK₁₀ increases further, da/dN increases. Under shear mode, da/dN becomes higher than that under mode I. The ΔK₁, and ΔK₁₁ components during fatigue crack growth under mixed mode loading increase and decrease, respectively, with an increase in da/dN In the low crack growth rate region the fatigue crack growth rates accelerate with an increase of the initial ΔK₁₁ component, ΔK₁₁₀. Fatigue life increases with increase of ΔK₁₁₀/ΔK₁₀ under the test condition of equivalent stress range being kept constant and the pre-crack length being the same.     

Evaluation of the ISO <Emphasis Type="Italic">J</Emphasis> initiation procedure using the EURO fracture toughness data set

The multiple specimen J _0.2/BL initiation fracture toughness test procedure from the ISO standard, ISO 12135:2002, is evaluated using the EURO fracture toughness data set. This standard is also compared with the ASTM standard, ASTM E 1820, multiple specimen J _Ic procedure. The EURO round robin data set was generated to evaluate the transition fracture toughness methods for steels. However, many of the tests resulted in ductile fracture behavior giving final J versus ductile crack extension points. This is the information that is measured in a multiple specimen J initiation fracture toughness test. The data set has more than 300 individual points of J versus crack extension with four different specimen sizes. It may be the largest data set of that type produced for one material. Therefore, its use to determine J initiation values can provide an important evaluation of the standard procedures. The results showed that a J _0.2/BL value could be determined from the ISO standard for three of the four specimen sizes, the smallest size did not meet the specimen size requirement on J. The construction line slopes in this method are very steep compared with the ASTM construction line slopes. This resulted in low J initiation values, about a factor of two lower than the one from the ASTM method. Of the various criteria imposed to determine a valid J _0.2/BL value, the one limiting the maximum J value was the most questionable. It had an effect of eliminating small specimen data that was identical to acceptable large specimen data.     

The failure of fibre composites and adhesively bonded fibre composites under high rates of test

The dynamic effects which are commonly encountered during high-rate DCB tests with fibre composite and adhesively bonded fibre composite arms have been studied in detail. This paper, Part II of the series, follows Part I, which described the experimental aspects of the high-rate testing. Part III will report the results from mode II and mixed-mode I/II tests on the fibre-composite materials.Nomenclature a crack length - a ₀ initial crack length - a crack speed - ä crack acceleration - c longitudinal wave speed - h thickness of single arm of test specimen - p crack length perturbation (i.e. the measured value of the crack length minus the value predic ted by steady-state theory) - p crack velocity perturbation - crack acceleration perturbation - t time - t ₀ time taken for crack to initiate during the mode I test - u ₀ load-line vertical displacement of single arm of test specimen (/2 in Part I) - u(x) vertical displacement of specimen at distance x from the load-line - u(x) vertical displacement rate of specimen at distance x from the load-line - x distance along the test specimen from the load-line - A constant relating the steady state crack length to root time - B width of specimen - C compliance of the specimen (u ₀/P) - E ₁₁ axial modulus of the fibre-composite beam - G mode I energy release rate - G _Ic mode I critical energy release rate or fracture toughness - G ₁ half the value of G _Ic during steady-state propagation (i.e. calculated for half the beam as shown in Fig. 1) - G ₂ half the value of G _Ic at crack initiation - P end load applied to specimen - U _ext external work done - U _s strain energy - U _k kinetic energy - V velocity of a single arm of test specimen (i.e. half the measured test velocity) - dynamic term, governed by the ratio of the energy to initiate versus that to propagate a crack - _I mode I crack shear deflection and root rotation correction term - crack length correction term, evaluated by the negative intercept on the a versus t ^1/2 plot - dynamic term controlling the form of the computed perturbations - Poisson's ratio for the fibre-composite beams density of the fibre-composite beams - time, normalized by the initiation time, t ₀ and thus equivalent to (t/t ₀) - values of at which crack arrest occurs. n = 1,2,3... - ratio of distance along beam to crack length (x/a)     

J II fracture testing of a plastically deforming material

A compact model II fracture specimen was previously analyzed and employed to determine the mode II fracture toughness K _IIc , of perspex. In employing this specimen for a more ductile material such as aluminium, it was observed that the load vs. crack sliding displacement record becomes nonlinear for small loads. Thus, concepts of linear elastic fracture mechanics cannot be employed. To this end, the specimen was calibrated for J-integral testing, so that J _IIc mesurements can be performed.In this study, mode I and II tests are carried out on an aircraft aluminium alloy, AI 7075-T7351. First, standard K _Ic tests are performed leading to a value of 27.9 15-1 which would be equivalent to a J _Ic of 10.7 kN/m. Then standard J _Ic tests are carried out on this material with specimen thicknesses, of 5, 7.5 and 9.9 mm, leading to an average J _Ic value of 10.5 kN/m. Methods for J _II testing are proposed; a series of specimens of six thicknesses between 5 and 16 mm are employed for testing. An average J _IIc value was found to be 40.2 kN/m which yields a K _IIc value of 54.1 15-2. Thus, K _IIc is seen to be approximately twice that of K _Ic for this material.     

A numerical investigation on the geometry dependence of the crack growth resistance in CT specimens

The influence of the specimen thickness B and the ligament length b on the J _R -curves is numerically investigated for CT specimens. The thickness effect is taken into account with 2-D analyses by dividing a plain sided specimen into a plane stress part and a plane strain part. The fracture process is controlled by experimentally determined critical values of the crack tip opening displacement for crack growth initiation (CTOD_i) and the crack tip opening angle for stable crack growth (CTOA_C). It is shown that for the global behaviour of a plain sided specimen, the B/b ratio is essential. The difference between the geometry dependence of the initiation value of the J-integral and the geometry dependence of the slope of the J _R -curves is also shown.     

Fatigue crack propagation in a ductile superalloy at room temperature and extensive cyclic plastic flow

Fatigue crack propagation experiments under both force and displacement control have been performed on the wrought superalloy Haynes 230 at room temperature, using a single edge notched specimen. The force controlled tests are nominally elastic, and the displacement controlled tests have nominally large plastic hysteresis at the beginning of the tests, but saturates towards linear elastic conditions as the crack grows. As some tests are in the large scale yielding regime, a non-linear fracture mechanics approach is used to correlate crack growth rates versus the fracture parameter $\mathrm{\Delta }$J. It is shown that crack closure must be accounted for, to correctly model the crack growth seen in all the tests in a unified manner. For the force controlled small scale yielding tests the Newman crack closure model was used. The Newman equation is however not valid for large nominal cyclic plasticity, instead the crack closure in the displacement controlled tests is extracted from the test data. A good agreement between all tests is shown, when closure is accounted for and effective values of $\mathrm{\Delta }$J are used.     

On the fitting and extrapolation of J-resistance data derived through the linear normalization technique

In this paper, an assessment is made regarding the effects of J–R curve fitting and extrapolation methods in two J‐integral criteria – namely crack initiation, J_i, and tearing instability, J₅₀– which were obtained through the linear normalization technique. Power‐law, logarithmic and linear fits were concurrently applied to J–Δa data derived from sub‐sized compact tensile specimens machined from a nuclear grade steel and tested at 300 °C. Research results show that the logarithmic J–R fit is the most conservative approach within a broad range of elastic–plastic fracture resistance, compared to the conventional power‐law fit. On the other hand, the linear fitting method provided the most non‐conservative J‐predictions. The values of J_i and J₅₀ have been successfully correlated with the net energy absorbed during Charpy impact testing of the materials.     

Calculation of J-integrals using experimental and numerical data: Influences of ratio (a/W) and the 3D structure

Contrary to J-integral values calculated from the 2D numerical model, calculated J-integrals [1] from 3D specimen in the numerical and experimental cases are not very close with J-integral used in the literature and two distinct points are present. The first one is according to (a/W) and can be reduced, when this ratio is inferior to 0.2. The second is a structure problem and can be explain by local three-dimensional effects surrounding the crack tip. Two applications using polymer materials for large and minor deformations are experimented. A grid method is used to experimentally determine the in-plane displacement fields around a crack tip in a Single-Edge-Notch (SEN) tensile polyurethane and PMMA specimens. This indirect method composed of experimental in-plane displacement fields and of two theoretical formulations, allows the experimental J-integral to be determined and the results obtained by the numerical simulations to be confirmed.     

The load separation and η pl

Load separation is the theoretical basis for the single specimen J form and the incremental calculation of J-R and J _M -R curves. It is based on the assumption that the load can be represented as a multiplication of two separate functions; a crack geometry function and a material deformation function. Until recently, the main experimental basis for such an assumption was the approximate agreement between the experimental results of the single specimen J form and the energy rate interpretation of J in blunt notched bending geometries. The load separation assumption has been also implied in the growing crack records in order to develop the R-curve analysis. Both the crack geometry and material deformation functions were assumed to maintain their forms as the crack grows. Recently, an experimental study investigated the load separation in the test records of stationary crack specimens of different geometry, material, and constraint. The study showed that the load can be represented by a separable form for the entire plastic region except for a limited region at the early region of plastic behavior. Also, it was found that the load separation is not limited to a certain geometry, material, or constraint but it is a dominant property in the ductile fracture behavior of stationary crack specimens. The study also showed that the crack geometry function is a power law function. Hence _pl is a constant equal to the power law exponent of the geometry function.The objective of this study is to investigate the extension of load separation to growing crack records. Sets of test records from three different materials are used in this study. For each material three or four precracked specimen test records and one blunt notched record are analyzed for the compact specimen geometry. The study will discuss the main condition to have a separable behavior in a growing crack test record. It will also construct the geometry and deformation functions for the materials studied, these functions are compared with those obtained from stationary crack records.     

Estimation of high‐temperature fracture parameters for small punch specimen with a surface crack

An outline of a newly proposed methodology for evaluating creep crack growth (CCG) parameters using cracked small‐punch (SP) specimens is explained. Three‐dimensional finite element analyses were performed to calculate the stress intensity factor along the crack front for a surface crack formed at the centre of a SP specimen. Effects of crack ratio, (a/t); crack aspect ratio, (a/c); and thickness of the specimen, (t), on the fracture parameters were studied. It was observed that the minimum variation of K‐value along the crack front can be achieved when a/c was 0.50 except the location very near the intersection of the crack and free surface. This condition is similar to the case of constant K‐values along the crack front of the conventional compact tension specimen. Thus, it can be argued that the SP specimen with a surface crack is a suitable specimen geometry for CCG testing. The proposed CCG test method was found to be practically applicable for the crack geometry of 0.10 to 0.30 of a/t with constant aspect ratio of 0.50. An estimation of the K and C_t‐parameter under the small scale creep condition was derived. Future work for further development of the suggested CCG testing is discussed.     

Constraint-modified J−R curves and its application to ductile crack growth

The concept of J-controlled crack growth is extended to J–A ₂ controlled crack growth using J as the loading level and A ₂ as the constraint parameter. It is shown that during crack extension, the parameter A ₂ is an appropriate constraint parameter due to its independence of applied loads under fully plastic conditions or large-scale yielding. A wide range of constraint level is considered using five different types of specimen geometry and loading configuration; namely, compact tension (CT), three-point bend (TPB), single edge-notched tension (SENT), double edge-notched tension (DENT) and centre-cracked panel (CCP). The upper shelf initiation toughness J _IC, tearing resistance T _R and J–R curves tested by Joyce and Link (1995) for A533B steels using the first four specimens are analysed. Through finite element analysis at the applied load of J _IC, the values of A ₂ for all specimens are determined. The framework and construction of constraint-modified J–R curves using A ₂ as the constraint parameter are developed and demonstrated. A procedure of transferring the J–R curves determined from standard ASTM procedure to non-standard specimens or practical cracked structures is outlined. Based on the test data, the constraint-modified J–R curves are presented for the test material of A533B steel. Comparison shows the experimental J–R curves can be reproduced or predicted accurately by the constraint-modified J–R curves for all specimens tested. Finally, the variation of J–R curves with the size of test specimens is produced. The results show that larger specimens tend to have lower crack growth resistance curves.     

Fracture toughness of Si3N4 measured with short bar chevron-notched specimens

The short bar chevron-notched specimen was used to measure the plane strain fracture toughness of hot-pressed Si₃N₄. Specimen proportions and chevron-notch angle were varied, thereby varying the amount of crack extension to maximum load (upon which K_ic was based). The measured toughness (4.68 ± 0.19 MN m^3/2) was independent of these variations, inferring that the material has a flat crack growth resistance curve.Nomenclature a crack length - a _A crack length at arrest of unstable crack advance - a ₁ length of chevron notch at specimen surface (distance from line of load application to point of chevron emergence at specimen surface) - a ₀ initial crack length (distance from line of load application to tip of chevron) - a _R crack length at ending of stable crack extension (conversely, crack length at onset of abrupt, unstable crack advance) - B specimen thickness - H specimen half-height - K _1A stress intensity factor at arrest of unstable crack advance - K _IR stress intensity factor at end of stable crack extension (crack growth resistance) - K _IC plane strain fracture toughness - P _max maximum applied load in fracture toughness test - W specimen width - Y ^* dimensionless stress intensity factor coefficient for chevron-notched specimen - Y ^* _m minimum value ofY ^* as a function of - a/W - ₀ a ₀/W - ₁ a ₁/W     

A crack propagation criterion based on ΔCTOD measured with 2D‐digital image correlation technique

The fatigue cracks growth rate of a forged HSLA steel (AISI 4130) was investigated using thin single edge notch tensile specimen to simulate the crack development on a diesel train crankshafts. The effect of load ratio, R, was investigated at room temperature. Fatigue fracture surfaces were examined by scanning electron microscopy. An approach based on the crack tip opening displacement range (ΔCTOD) was proposed as fatigue crack propagation criterion. ΔCTOD measurements were carried out using 2D‐digital image correlation techniques. J‐integral values were estimated using ΔCTOD. Under test conditions investigated, it was found that the use of ΔCTOD as a fatigue crack growth driving force parameter is relevant and could describe the crack propagation behaviour, under different load ratio R.