Mismatch effect in creep properties on creep crack growth behavior in welded joints

The finite element method based on ductility exhaustion model was used to systematically investigate the mismatch effect in creep properties on creep crack growth (CCG) behavior in welded joints. The crack-tip damage, stress states, CCG paths, CCG rate and rupture life were calculated for different configurations of creep properties between weldment constituents under the same load level, and the creep life assessment and design for welded joints were discussed. The results show that when the zone containing the crack is softer than at least one of the other two surrounding materials or both, the creep crack propagates straight along the initial crack plane. Otherwise, it will form a second crack in the soft material near interface. These simulation results were confirmed by the experimental observations in the literature, and the mechanism was analyzed. The harder surrounding materials can lead to higher CCG rate and shorter rupture life due to the higher constraint given from them. The early initiation and propagation of the second cracks increase CCG rate and reduce rupture life, and the incubation time of the second cracks in soft materials near interfaces should be accurately determined in the creep life assessment and design for the welded joints. A proper mismatch design with harder material containing crack and softer surrounding material can improve CCG properties of welded joints (decreasing CCG rate and prolong rupture life).     

Fatigue and creep crack growth behaviour of Inconel MA 6000

Crack growth in MA 6000 under cyclic loading was studied at 24, 760, and 1000°C and under static loading at 1000°C in two matenal onentatwns. Correlatwns of fattgue crack growth rate with parameters ?K and ?J were examined. Also comparisons were made of experimental and predicted growth rates.

The rate of growth was influenced by temperature and onentatwn m addttwn to the loading mode. Fatigue crack growth rate generally increased with temperature. However in the L-T orientation at 1000°C secondary cracks developed perpendtcular to the primary crack and significantly altered its behaviour. Creep crack growth at 1000°C was strongly orientation dependent, mainly due to secondary crackmg m the L-T oriented specimen in the direction perpendicular to the main crack.

Fracture surfaces were examined by scanning electron microscopy. Also, comparisons were made between crack growth behaviour of MA 6000, MA 754 and MA 956.     

Experimental investigation of specimen size effect on creep crack growth behavior in P92 steel welded joint

In order to clarify the effect of constraint induced by specimen size on creep crack growth behavior of P92 steel welded joint, creep crack tests were carried out on the compact tension specimens with thick thickness and thin thickness, the crack tip of which were located at different distinct zones of welded joint. Tested results revealed that even in thin thickness specimens, fine grained heat affected zone specimens exhibited a fast creep crack growth rate compared with other micro-zones specimens due to a low creep crack resistance and a high multistress state. The fractographies of these specimens exhibited an accelerated number of spherical particles that were caused by the coalescence of creep voids. Furthermore, the correlation of C^* with creep crack growth rate was dependent on specimen thickness. As the specimen thickness increased from 10 to 30 mm, the creep crack growth rate increased. This was due to the increase in constraint level ahead of crack tip during creep crack propagation.     

Numerical prediction of creep crack growth in different geometries using simplified multiaxial void growth model

Abstract

This paper considers the prediction of creep crack growth (CCG) in different fracture mechanics geometries using finite element (FE) analysis based on a material independent simplified multiaxial failure strain model at the crack tip. The comparison is first made by modelling C(T) specimen tests under plane stress and plane strain conditions using creep properties of a C–Mn steel at 360°C. In addition, in order to examine CCG due to different geometries, a single edge notch specimen (SENT), centre cracked tension specimen (CCT) and three-point bending (3PB) specimen have been modelled and analysed. In all cases, it is found, depending on the geometry, that for this steel at low creep temperatures the applied load develops a high reference stress/yield stress (σ_ref/σ_y) ratio, which helps reduce constraint at the crack tip. The predictions are analysed under plane stress/plane strain loading conditions identifying the effects of geometry on cracking rates and the implications for predicting long term test or component failure times exceeding where the applied σ_ref/σ_y<<1.     

Characterization of incubation time on creep crack growth for weldments of P92

Most structures are mainly fabricated by welding which are likely to be regions of crack initiation and propagation. In such weldment, it is known that the multi-axial stress fields appear due to the plastic constraint induced by the differences in material micro-structure between the weld metal, heat affected zone (HAZ) and base metal. In the present study, the experiments of creep crack growth tests and the structural mechanical analyses of weldment were conducted to understand the effects of stress multi-axiality of weldment on the characteristics of creep crack growth, creep deformation and creep ductility. Additionally, to characterize the time of creep crack initiation up to the start of a brittle type creep crack growth, the distribution of stress multi-axiality (TF) through the base metal, fine-grain HAZ, coarse-grain HAZ to weld metal were investigated.     

Crack opening displacements of Vickers indentation cracks

Vickers indentation cracks are an appropriate tool to determine the crack-tip toughness K_I0 and, possibly, the bridging relation of ceramics with an R-curve behaviour from the total crack opening displacements. Two contributions to the total crack opening displacement field are addressed. First, the residual stresses occurring in the uncracked body are considered and then, the contact stresses generated by preventing crack face penetration are computed. The COD solution resulting from the superposition of residual and contact displacements is given and an analytical expression is provided. Near-tip displacements are represented by the first terms of series expansions. As an example of application, an evaluation of the actual stress intensity factor is presented for a window glass 1 h after Vickers indentation.     

Round robin on creep fatigue crack growth testing for verification of ASTM standard 2760-10

Abstract

This paper presents early results from an ongoing round robin study to verify the newly developed ASTM standard E-2760-10 on creep fatigue crack growth testing. This round robin is an international effort with 18 participants from 11 countries from Asia, North America and Europe. All participants are testing compact type, C(T) specimens according to the procedure described in the standard. The test material is P91 taken from a section of retired steam pipe that was heat treated to rejuvenate the microstructure. All background materials data such as tensile, creep deformation and creep fatigue crack formation data are already available on the test material. Creep fatigue crack growth testing was conducted as part of a pilot program at 625°C using C(T) specimens under constant load amplitude conditions at two load levels. The tests are conducted at hold times of 0, 60 and 600 s. Creep fatigue crack growth rates are analysed using the two methods included as part of the test standard. The data from the various participants will be assessed to determine the expected levels of precision and bias in creep fatigue crack growth data obtained using the ASTM standard. Modifications to the current version of the standard will be proposed and balloted as needed from the round robin results.     

Experimental investigation of crack growth direction in multiple cracks

In this paper, the interaction between multiple cracks in crack growth direction is studied in an aluminium alloy under static and fatigue loading. Self similar as well as non‐self‐similar crack growth has been observed which depends on the relative crack positions defined by crack offset distance and crack tip distance. On the basis of experimental observations, the criterion for crack coalescence and crack growth direction are expressed in terms of the crack positions defined by crack offset and crack tip distances. The criterion presented in this study can be used to determine the limiting value of crack tip and crack offset distance and to determine the mode in which cracks coalesce during their growth process. Experimental results and crack interaction criterion presented under various crack positions and size conditions could be used to derive a new evaluation method of crack growth in multiple crack geometry.     

Effects of short cracks produced at blunted pre-crack tip on stress and strain distributions

The present work investigates problems: (1) How are the plastic strain and the stress (triaxiality) re-distributed after a short crack initiated, extended and blunted at the pre-crack tip? (2) How do the above changes put a crucial effect on the triggering of the cleavage fracture? Based on the previous observations of configuration changes and fracture surfaces of pre-crack tips, Finite element method (FEM) simulations of a short crack initiated, extended and blunted at a pre-crack tip and calculations of distributions of stress, strain and triaxiality are carried out for 3PB pre-cracked HSLA steel specimens tested at -130^°C. The results reveal that: as long as the fatigue pre-crack is only blunted, in its vicinity a region where the accumulated strain is sufficient to nucleate a crack, and a region where the stress (triaxiality) is sufficient to propagate a crack nucleus are separated by a distance. The nucleated crack cannot be propagated and the cleavage fracture cannot be triggered. While a short crack produced at the fully blunted fatigue pre-crack, the strain retains, the stress (triaxiality) is rebuilt. An initiated and significantly extended and then blunted short crack makes a tip configuration, which on one hand is much sharper than that of the fully blunted original pre-crack tip, on other hand is wide enough to spread its effects into the high stress covered region. This sharpened crack tip configuration re-builds a ‘sharper’ distribution of stress (triaxiality) and makes two regions metioned above closer. Finally the two regions overlap each other and a cleavage crack can be initiated and propagated at a distance ahead of the blunted fatigue pre-crack.     

Effect of stress dependent creep ductility on creep crack growth behaviour of steels for wide range of C*

Abstract

In this work, the effect of stress dependent creep ductility on the creep crack growth (CCG) behaviour of steels has been investigated by finite element simulations based on ductility exhaustion damage model. The relationship between the transition region of creep ductility and the transition behaviour of CCG rate on da/dt-C* curves has been examined and the CCG life assessments of components and CCG resistance of materials for a wide range of C* were discussed. The results show that with increasing the transition region size of creep ductility, the transition C* region size on da/dt-C* curves increases. With moving transition region position of creep ductility to high stress region (increasing transition stress levels), the transition C* region on the da/dt-C* curves also moves to high C* region. Decreasing transition stress levels and transition region sizes of creep ductility and increasing the lower shelf and upper shelf creep ductility values can improve the CCG resistance of materials. If the extrapolation CCG rate data from the high C* region or from the transition C* region are used in life assessments of the components at low C* region, the non-conservative or excessive conservative results may be produced. Therefore, the CCG rate data should be obtained for a wide range of C* by long term laboratory tests or numerical predictions using the stress dependent creep ductility and model.     

Fatigue strength assessment of initial semi-elliptical cracks located at a hole

In the present paper, the residual strength of a pin-loaded lug and a finite plate, both with a semi-elliptical crack emanating from a hole, is examined. A new analytical methodology, based on Fracture Mechanics concepts, is proposed to analyse the crack propagation process in terms of life estimation and crack front evolution. Firstly, the stress field and the stress intensity factor are computed by applying both analytical and numerical approaches. Then, the two-parameter driving force model proposed by Kujawski is implemented for the fatigue life estimation and the crack front evolution. The validity of model here employed is assessed through the comparison between crack growth calculations and experimental data available in the literature, such comparison shows a quite good correlation for the crack and geometrical configurations here examined.     

Issues relating to numerical modelling of creep crack growth

In this paper creep crack growth behaviour of P92 welds at 923 K are presented. Creep crack growth behaviour for P92 welds are discussed with C^* parameter. Creep crack growth behaviour of P92 welds has been compared with that of P91 welds with C^* parameter. NSW and NSW-MOD model were compared with the experimental creep crack growth data. Plane strain NSW model significantly overestimates the crack growth rate, and plane stress NSW model underestimates it. Whilst, NSW-MOD model for plane stress and plane strain conditions gives lower and upper bound of the experimental data, respectively.FE analysis of creep crack growth has been conducted. Constrain effect for welded joints has been examined with C^* line integrals of C(T) specimens. As a result, constant C^* value using the material data of welded joint gives 10 times lower than that of only HAZ property. Whilst, the predicted CCG rates for welded joint are 10 times higher than those for only HAZ properties. Compared with predicted CCG rate from FE analysis and the experimental CCG rate, it can be suggested that creep crack growth tests for lower load level or for large specimen should be conducted, otherwise the experimental data should give unconservative estimation for components operated in long years.     

Singular and non-singular approaches for predicting fatigue crack growth behavior

In this work, three classes of mechanisms that can cause load sequence effects on fatigue crack growth are discussed: mechanisms acting before, at or after the crack tip. After reviewing the crack closure idea, which is based on what happens behind the crack tip, quantitative models are proposed to predict the effects at the crack tip due to crack bifurcation. To predict the behavior ahead of the crack tip, a damage accumulation model is proposed. In this model, fatigue cracking is assumed caused by the sequential failure of volume elements or tiny εN specimens in front of the crack tip, calculated by damage accumulation concepts. The crack is treated as a sharp notch with a small, but not zero radius, avoiding the physically unrealistic singularity at its tip. The crack stress concentration factor and a strain concentration rule are used to calculate the notch root strain and to shift the origin of a modified HRR field, resulting in a non-singular model of the strain distribution ahead of the crack tip. In this way, the damage caused by each load cycle, including the effects of residual stresses, can be calculated at each element ahead of the crack tip using the correct hysteresis loops caused by the loading. The proposed approach is experimentally validated and extended to predict fatigue crack growth under variable amplitude loading, assuming that the width of the volume element broken at each cycle is equal to the region ahead of the crack tip that suffers damage beyond its critical value. The reasonable predictions of the measured fatigue crack growth behavior in steel specimens under service loads corroborate this simple and clear way to correlate da/dN and εN properties.     

Fatigue growth of short cracks in Ti-17: Experiments and simulations

The fatigue behaviour of through thickness short cracks was investigated in Ti-17. Experiments were performed on a symmetric four-point bend set-up. An initial through thickness crack was produced by cyclic compressive load on a sharp notch. The notch and part of the crack were removed leaving an approximately 50 μm short crack. The short crack was subjected to fatigue loading in tension. The experiments were conducted in load control with constant force amplitude and mean values. Fatigue growth of the short cracks was monitored with direct current potential drop measurements. Fatigue growth continued at constant R-ratio into the long crack regime. It was found that linear elastic fracture mechanics (LEFM) was applicable if closure-free long crack growth data from constant K_Imax test were used. Then, the standard Paris’ relation provided an upper bound for the growth rates of both short and long crack.The short crack experiments were numerically reproduced in two ways by finite element computations. The first analysis type comprised all three phases of the experimental procedure: precracking, notch removal and fatigue growth. The second analysis type only reproduced the growth of short cracks during fatigue loading in tension. In both cases the material model was elastic-plastic with combined isotropic and kinematic hardening. The agreement between crack tip opening displacement range, cyclic J-integral and cyclic plastic zone at the crack tip with ΔK_I verified that LEFM could be extended to the present short cracks in Ti-17. Also, the crack size limits described in the literature for LEFM with regards to plastic zone size hold for the present short cracks and cyclic softening material.     

Fatigue and creep crack growth of Alloy 800 and Alloy 617 at high temperatures

A common evaluation is given for creep crack growth and fatigue crack growth experiments which have been performed at the companies ABB, Siemens-KWU and KFA. The materials under investigation were X10NiCrAlTi32 20 (Alloy 800) and NiCr22Col2Mo (Alloy 617). Several production lots and semi-finished materials as well as welded materials have been tested. Testing techniques differed at the different labs. In order to eliminate the influence of individual testing techniques, material from some production lots was investigated at different labs. The given data cover fatigue crack growth (the materials were tested between room temperature and 1050°C; the influence of temperature, R?ratio, and frequency was investigated) and creep crack growth (Alloy 800 was tested between 550°C and 900°C, Inconel 617 between 800°C and 1000°C; the evaluation was done on the basis of the fracture mechanics parameters K₁ and C*).     

Modeling of facesheet crack growth in titanium-graphite hybrid laminates. Part II: Experimental results

Titanium-graphite hybrid composite laminates exhibit a coupled damage growth mode of facesheet cracking and delamination. Part I of this work modeled the growth of the coupled damage mode. Fatigue experiments were conducted on single edge notch tension specimens to measure the crack growth rate. This paper compares the model predictions with experimental data. The three-dimensional finite element model successfully captured the damage growth behavior for two of the lay-ups ([Ti/0/90/0₂]_s and [Ti/90/0/90₂]_s) in the experimental program. However, in a third lay-up, [Ti/0/90/±30]_s, the underlying damage modes were found to be sufficiently different than the other two lay-ups and the model did not capture the steady-state growth behavior. The effects of temperature and specimen size were also investigated for TiGr laminates. Except for the effects of the load ratio, elevated temperatures did not affect the crack growth rate significantly. For wider specimens, the steady-state fatigue crack growth behavior was similar to the narrow specimens, indicating that the steady-state facesheet crack growth behavior is independent of specimen size.     

Deterministic and probabilistic creep–fatigue–oxidation crack growth modeling

Fatigue, creep, oxidation or their combinations have long been recognized as the principal mechanisms in many high-temperature failures in power plant components, turbine engines, and exhaust systems in vehicles. Depending on the specific materials and loading conditions and temperature, the role of each damage mechanism may change significantly, ranging from independent development to competing and combined creep–fatigue, fatigue–oxidation, and creep–fatigue–oxidation. In this paper a new linear superposition theory is proposed to model the cycle-dependent and time-dependent creep–fatigue–oxidation crack growth phenomena. The model can be reduced to creep–fatigue and fatigue–oxidation crack growth models previously developed by the authors as well as, under some assumptions, the current widely used linear superposition theory. The limits of the current superposition theory and the advantages of the new theory are clearly demonstrated with several worked examples. A general probabilistic analysis procedure is also proposed by introducing the uncertainties of parameters in fatigue, creep, and oxidation crack growth laws with the help of the Monte Carlo simulation.     

A simulation on growth of multiple small cracks under stress corrosion

In order to keep high reliability of components in a nuclear power plant, it is important to understand the damaging process due to multiple small cracks. The growth shows random behavior because of the microstructural inhomogeneity and the interaction between cracks. The former includes the effects of crack kinking and anisotropic deformation in each crystal of polycrystalline. In this study, a Monte Carlo simulation method is developed in order to analyze the random behavior, taking into account the their influences on the stress intensity factor. The damaging process of mill-annealed alloy 600 in the primary water stress corrosion cracking (PWSCC) is numerically simulated by the proposed method. The crack size distribution obtained agrees well with the experimental observation, and the maximum crack size is statistically estimated on the basis of the Gumbel statistics.     

Influence of fiber and grain bridging on crack profiles in SiC fiber-reinforced alumina-matrix composites

Initial crack extension and crack propagation in sintered SiC fiber reinforced alumina matrix composites were observed in situ in the scanning electron microscope (SEM). In these composites, coupled toughening mechanisms associated with both grain and fiber bridging are operative in the crack wake. Their contribution to toughness were obtained from crack profiles measured in the crack wake at various applied loads and crack lengths. The crack profiles of the fiber reinforced samples reveal much smaller crack opening displacements compared to the monolithic samples. The fibers act as ligaments which bridge and thereby exert closure stresses on the crack surfaces. The profiles revealed pronounced reduction in the crack opening displacement (COD) around the fiber positions. Accordingly, grain bridging in the vicinity of the fibers was still operative up to an applied stress intensity factor of 5.7 MPa m^1/2 which is 30% above the maximum toughness that could be obtained with the monolithic samples for the same crack length.     

Ratchetting strain as a damage parameter in controlling crack growth at elevated temperature

Progressive increase in tensile strains near a crack tip has been observed from finite element studies of stationary and growing cracks (Zhao, 2004, 2008) [1] and [2] under cyclic loading conditions. In this work, the significance of such a phenomenon was further explored. In particular, stress-controlled experiments were carried out to evaluate the uniaxial ratchetting response of a nickel-based superalloy, and the material parameters were re-calibrated using both strain-controlled and stress-controlled experimental data. An additional kinematic hardening term was introduced in the viscoplastic constitutive model and the models were utilised via a user-defined subroutine to study near crack tip ratchetting behaviour of a single edge notch tension (SENT) model geometry at elevated temperature. Loading modes near the crack tip were examined, together with the influence of particular constitutive models on the mechanistic response of the crack tip. The crack tip deformation was found to be predominantly strain-controlled, where the mean ratchetting strain seems to be more relevant to crack growth than the strain range. The former was used as a measure of crack tip damage to correlate crack growth rates at selected loading conditions.