Fracture toughness of glasses as measured by the SCF and SEPB methods

The fracture toughness, K_Ic, of six glasses was measured by the surface crack in flexure (SCF) and single-edged precracked beam (SEPB) methods. Results depended upon the loading rate as well as the test environment. Environmentally-assisted slow crack growth affects the results for tests done in air. Dry nitrogen testing is preferred. Crack healing may be a severe complicating factor with precracked flexure bar type specimens if the specimens are unloaded between the precracking and final fracture test. Success in K_Ic testing depends to a large degree on upon the ability to make good precracks.     

Fracture Toughness of Ceramic Precracked Bend Bars

Fracture toughness was measured for four ceramic materials using precracked bend bar specimens. The effect of the precracking parameters, used for the bridge indentation method on fracture toughness values, was determined. Excellent agreement was obtained between fracture toughness values measured by this method and values obtained by other techniques.     

Crack Stability and Its Effect on Fracture Toughness of Hot-Pressed Silicon Nitride Beam Specimens

The effect of stable crack extension on fracture toughness test results was determined using single-edge precracked beam specimens. Crack growth stability was examined theoretically for bars loaded in three-point bending under displacement control. The calculations took into account the stiffness of both the specimen and the loading system. The results indicated that the stiffness of the testing system played a major role in crack growth stability. Accordingly, a test system and specimen dimensions were selected which would result in unstable or stable crack extension during the fracture toughness test, depending on the exact test conditions. Hot-pressed silicon nitride bend bars (NC132) were prepared with precracks of different lengths, resulting in specimens with different stiffnesses. The specimens with the shorter precracks and thus higher stiffness broke without stable crack extension, while those with longer cracks, and lower stiffness, broke after some stable crack extension. The fracture toughness values from the unstable tests were 10% higher than those from the stable tests. This difference, albeit small, is systematic and is not considered to be due to material or specimen-to-specimen variation. It is concluded that instability due to the stiffness of test system and specimen must be minimized to ensure some stable crack extension in a fracture toughness test of brittle materials in order to avoid inflated fracture toughness values.     

Tensile Fracture Toughness Measurements in Ceramics

A novel procedure is outlined whereby fracture toughness values for ceramics can be measured under uniaxial tension (mode I) in specimens containing a fatigue crack. Circumferentially notched rods of rapolycrystalline aluminum oxide were precracked in cyclic compression to introduce a fatigue crack at room temperature, following the technique proposed by Suresh and co-workers.^7,10,11 Subsequently, the precracked rods were fractured in pure tension. Highly reproducible values of fracture toughness were obtained using this method.     

Fracture Behavior of the Space Shuttle Thermal Protection System

Stable crack-growth and fracture-toughness experiments were conducted using precracked specimens machined from LI-900 reusable surface insulation (RSI) tiles of the space shuttle thermal protection system (TPS) at room temperature. Similar fracture experiments were conducted on fracture specimens with preexisting cracks at the interface of the tile and the strain isolation pad (SIP). Stable crack growth was not observed in the LI-900 tile fracture specimens which had a fracture toughness of 12.0 kPaμm. The intermittent subcritical crack growth at the tile-pad interface of the fracture specimens was attributed to successive local pull-outs due to tensile overload in the LI-900 tile and cannot be characterized by linear elastic fracture mechanics. No subcritical interfacial crack growth was observed in the fracture specimens with densified LI-900 tiles where brittle fracture initiated at an interior point away from the densification.     

Fracture Toughness of Polycrystalline Ceramics in Combined Mode I and Mode II Loading

Fracture of Polycrystalline alumina and zirconia ceramics in combined mode I and mode II loading was studied using precracked disk specimens in diametral compression. Fracture toughness was assessed in different stress states (including pure mode I, combined mode I and mode II, and pure mode II) by aligning the center crack at specific angles relative to the loading diameter. The resulting mixed-mode fracture-toughness envelope showed significant deviation to higher fracture toughness in mode II relative to the predictions of the linear elastic fracture mechanics theory. Critical comparison with corresponding results on soda–lime glass and fracture-surface observations showed that crack-surface resistances arising from grain interlocking and abrasion were the main sources of the increased fracture resistance in mode II loading of the polycrystalline ceramics. Quantitative fractography confirmed an increased percentage of transgranular fracture of the grains in mode II loading.     

On the Vickers Indentation Fracture Toughness Test

The Vickers indentation fracture toughness test, or VIF, is addressed by considering its origins and the numerous equations that have been applied along with the technique to estimate the fracture resistance, or the K _{I c} of ceramics. Initiation and propagation of cracks during the VIF test are described and contrasted with the pre-cracking and crack growth for internationally standardized fracture toughness tests. It is concluded that the VIF test technique is fundamentally different than standard fracture toughness tests. The VIF test has a complex three-dimensional crack system with substantial deformation residual stresses and damage around the cracks. The VIF test relates to an ill-defined crack arrest condition as opposed to the rapid crack propagation of the standardized fracture toughness tests.
Previously published fracture toughness results employing the VIF technique are reviewed. These reveal serious discrepancies in reported VIF fracture toughness values. Finally, recent fracture resistance measurements by the VIF technique for the Standard Reference Material SRM 2100 are presented. These are compared with standardized test results for the same material. It is concluded that the VIF technique is not reliable as a fracture toughness test for ceramics or for other brittle materials. What the VIF actually measures in terms of fracture resistance cannot be readily defined. It is recommended that the VIF technique no longer be acceptable for the fracture toughness testing of ceramic materials.     

Dislocation Activity, Stable Crack Motion, and the Warm-Prestressing Effect in Magnesium Oxide

Four-point bend tests were performed on precracked single-crystal MgO specimens at different temperatures and strain rates. A large amount of stable crack growth before fracture occurred; etching revealed dislocations in the crack advance region. We believe that dislocation sources near the crack tip emit loops, producing shielding and antishielding dislocations; the latter promote crack advance by a repeated microcleavage mechanism. "Warm-prestressing" experiments, which improve the room-temperature fracture toughness by dislocation shielding, were performed. There was a prestress below which no "warmprestressing effect" (WPSE) was exhibited and the magnitude of the WPSE increased with increasing prestressing temperature.     

Crack mouth opening displacement controlled fracture tests of brittle ceramics

Controlled fracture tests are required for the accurate determination of the toughness parameters of materials in order to assure the full conversion of the supplied energy into crack surface energy. From the three parameters involved in the test, load, displacement of the load point and crack mouth opening displacement (CMOD), this latter is the only one that continuously increases as fracture proceeds. Therefore, the CMOD has been proposed as control variable for the stable fracture tests. In this work, a new equipment to perform stable fracture tests of single edge V-notch beams (SEVNB) of ceramics in three points bending controlled by the CMOD is presented. The developed equipment allows performing stable fracture tests of extremely brittle materials. The equipment is presented together with results obtained for fine grained aluminium–magnesium aluminate and alumina ceramics.     

In Situ Toughened Silicon Carbide with Al-B-C Additions

" In situ toughened" silicon carbides, containing Al, B, and C additives, were prepared by hot pressing. Densification, phase transformations, and microstructural development were described. The microstructures, secondary phases, and grain boundaries were characterized using a range of analytical techniques including TEM, SEM, AES, and XRD. The modulus of rupture was determined from fourpoint bend tests, while the fracture toughness was derived either from bend tests of beam-shaped samples with a controlled surface flaw, or from standard disk-shaped compact-tension specimens precracked in cyclic fatigue. The R -curve behavior of an in situ toughened SiC was also examined. A steady-state toughness over 9 MPa·m^1/2 was recorded for the silicon carbide prepared with minimal additives under optimum processing conditions. This increase in fracture toughness, more than a factor of three compared to that of a commercial SiC, was achieved while maintaining a bend strength of 650 MPa. The mechanical properties were found to be related to a microstructure in which platelike grain development had been promoted and where crack bridging by intact grains was a principal source of toughening.     

Mixed-Mode Fracture of Ceramics in Asymmetric Four-Point Bending: Effect of Crack-Face Grain Interlocking/Bridging

The mixed-mode fracture of a large-grain-size alumina ceramic and a soda-lime glass is investigated. These ceramics are tested using straight-through precracked or notched specimens. The straight-through precrack is introduced by the single-edge-precracked beam method. Precracked or notched specimens are subjected to combined mode I/II or pure mode II fracture, under asymmetric four-point bending, and pure mode I fracture, under symmetric four-point bending. A pure mode II fracture is never achieved in the precracked polycrystalline alumina by the crack-face friction inevitably induced by grain interlocking/bridging. The crack-face friction in sliding mode reduces the local mode II stress intensity factor in the crack-tip region and produces a sizable amount of mode I deformation. Accounting for the contribution of the crack-face friction to the crack-tip local stress intensity factors, K _I and K _II, in mixed-mode fracture tests, the experimental results of the K _I/ K _{I c} versus K _II/ K _{I c} envelope and the initial angle of noncoplanar crack extension are in good agreement with the theoretical predictions of the maximum hoop-stress theory.     

Fatigue crack initiation and damage characterization in Brazilian test specimens for adhesive joints

The present study is focused on the fatigue failure initiation at bimaterial corners by means of a configuration based on the Brazilian disc specimens. These specimens were previously used for the generalized fracture toughness determination and prediction of failure in adhesive joints, carried out under static compressive loading. Under static loading, local yielding effects might affect the asymptotic two-dimensional linear elastic stress representation under consideration. Fatigue loading avoids this fact due to the lower load levels used. The present tests were performed using load control; video microscopy and still cameras were used for monitoring initiation and crack growth. The fatigue tests were halted periodically and images of the corner were taken where fatigue damage was anticipated. Damage initiation and subsequent crack growth were observed in some specimens, especially in those which presented brittle failure under static and fatigue tests. These analyses allowed the characterization of damage initiation for a typical bimaterial corner that can be found in composite to aluminium adhesive lap joints.     

Fracture Toughness Evaluation of Small Thin Ceramic Specimens

A test method to evaluate the fracture toughness, K_IC, of thin, small, precracked ceramic specimens is described. The method is applicable for thin plates, wafers, self-supported layers, etc., especially when a large amount of material is not available for testing. The method consists of bonding a small, thin single-edge notched beam on one side of a metallic beam. A stress-free precrack with a square root singularity is achieved when the assembly is deformed in three-point bending.
The fracture toughness of a thin, alumina single-edge precracked beam was evaluated experimentally using this method, and compared with that obtained for similar specimens having a 0.3-mm-wide machined notch. Comparison with previously reported fracture toughness values suggests that even a very sharp machined notch overestimates the evaluated fracture toughness.     

Fracture Toughness of a Toughened Silicon Nitride by ASTM C 1421

The fracture toughness of a sintered reaction-bonded silicon nitride was measured by the single-edge precracked beam and surface crack in flexure methods, which are two of the three complementary test methods in ASTM C 1421. Results were compared with chevron-notched beam results that were available from another source. Precracks ranged from tiny artificial flaws introduced by Knoop indentation to millimeter-long precracks in single-edge precracked beams. The fracture toughness values from the three methods were in good agreement at 5.6 MPa·m^1/2.     

Local Fracture Toughness of Si3N4 Ceramics Measured using Single‐Edge Notched Microcantilever Beam Specimens

Local fracture toughness gives us useful and important information to understand and improve mechanical properties of bulk ceramics. In this study, the local fracture toughness of silicon nitride (Si₃N₄) ceramics was directly measured using single‐edge notched microcantilever beam specimens prepared by the focused ion beam technique. The measured fracture toughness of grain boundary of the Si₃N₄ ceramics is higher than the fracture toughness of SiAlON glass, which exists in the grain boundaries of Si₃N₄ ceramics. It is also shown that the fracture toughness of grain boundary depends on the rare earth oxide added as a sintering aid, which is expected in terms of the difference in the grain‐boundary structure. The fracture toughness of a single β‐Si₃N₄ grains is higher than the grain‐boundary fracture toughness. It was also higher than the value estimated from ab initio calculations and surface energy, which means that any dissipative energy should be included in the fracture toughness of a grain in spite of the brittle fracture in Si₃N₄. The fracture toughness of polycrystals of Si₃N₄ ceramics measured using single‐edge notched microcantilever beam specimens is intermediate between those of grains and grain boundaries, and it agrees with the estimated initial value of the Rcurve, K_I0, in Si₃N₄ ceramics.     

V-Notch Technique for Single-Edge Notched Beam and Chevron Notch Methods

The technique of a V-shaped notch with very sharp root radius was used with the single-edge notched beam and chevron notch methods to evaluate fracture toughness of ceramics. These methods are improved techniques using a V-shaped diamond wheel. The single-edge precracked beam and chevron notch techniques were also used to compare with these methods. The material used is a gas-pressured Si₃N₄. The fracture toughness measured by these techniques showed quite small scatters and coincided with one another quite well, except for the usual chevron notch method.     

Measurement of the Fracture Toughness of Ceramic Materials Using a Miniaturized Disk-Bend Test

The fracture toughness of several ceramic materials has been measured using a miniaturized disk-bend test apparatus and methodology based on small disk-shaped samples 3 mm in diameter. The method involves the Vickers indentation of specimens ranging in thickness from 300 to 700 μm, and testing them in a ring-on-ring bending mode. New experiments on a glass-ceramic (GC) and Si₃N₄ have been performed to demonstrate the validity of the technique, supplementing the original work on ZnS. The fracture resistances of these materials increase with increasing crack length ( R -curve behavior). The data are analyzed using a specific model for the relationship between fracture resistance and crack length; this model enables the R -curve behavior to be treated analytically, and the fracture resistance at "infinite" crack length to be evaluated using a straightforward graphical procedure. The resulting values of the fracture toughness for ZnS, GC, and Si₃N₄ are 0.74 ± 0.02, 2.18 ± 0.09, and 4.97 ± 0.07 MPa-m^1/2, respectively, which are all in very good agreement with values obtained from conventional fracture toughness tests on large specimens. The results verify the utility of the miniaturized diskbend method for measuring the fracture toughness of brittle materials.     

Sandwiched-Beam Procedure for Precracking Brittle Materials

A technique for precracking brittle materials is presented. This procedure, which is called the sandwiched-beam (SB) technique, allows the production of sharp through-thickness cracks with predetermined length in specimens with a rectangular section. A bar, in which an initial notch is produced by using a conventional saw, is inserted between two supporting beams and the sandwich assembly is loaded in three-point bending. Conditions can be defined that allow the stable propagation of a sharp flaw from the notch as the applied load is increased. Then, the cracked bar can be used to determine the fracture toughness. The SB technique is applied to different brittle materials, including soda-lime-silica glass, alumina, Si₃N₄, a SiC _w -Si₃N₄ composite, graphite, a Ti-Al intermetallic, and Carrara marble.     

A Fracture Toughness Test Using the Ball‐on‐Three‐Balls Test

A method for fracture toughness measurement of ceramics using small disks and plates is presented. Similar to the surface‐crack‐in‐flexure (SCF) method a semielliptical surface crack is introduced centrally into one plane side of the specimen which is fractured in a ball‐on‐three‐balls test. Finite element simulations are used to evaluate the stress intensity factor (SIF) for this loading geometry for a range of crack sizes and crack geometries. Empirical formulae for the geometric function are provided for evaluation of the test. The effect of position uncertainties is investigated using FEM and experiments. Other sources which may contribute to the measurement error are identified and quantified, resulting in recommendations for the practical realization of the test. A determination of the fracture toughness within ±10% measurement uncertainty is possible with specimens larger than 8 mm in diameter and thicker than 0.5 mm. With larger specimens an uncertainty comparable to other fracture toughness tests can be achieved. For precise measurements it is important to position the crack within ±120 μm of the stress maximum, to know Poisson's ratio exactly and to test cracks that have the maximum SIF at their deepest point. A method how this can be achieved is presented.