Toughness and fatigue of encapsulation-processed silicon carbide-polymer matrix particulate composites

A new process for composite fabrication was developed which improves distribution of the particulate reinforcing phase by polymer encapsulation of the particulate prior to consolidation. The effect of such processing on the fatigue-crack propagation and fracture toughness behaviour of particulate thermoplastic composites was investigated. Composites of several particulate size ranges were fabricated into disc-shaped, compact tension specimens and tested under cyclic and monotonie loading conditions. For comparison, a composite was also fabricated using a standard casting technique. The observed fatigue-crack growth rates spanned three orders of magnitude (10^–11 to 10^–9 m per cycle) over an applied stress intensity range, K, of 0.3 to 1.1 MPa m^1/2. The measured fracture toughness values ranged from 0.69 to 2.95 MPa m^1/2. Comparison of the two processing techniques indicated that encapsulation processing increased the fracture toughness of the composite by approximately 33%; however, the fatigue-crack growth behaviour was unaffected. In addition, a trend of increasing crack growth resistance (toughness) with increasing reinforcement particle size was observed. These results are discussed in the light of crack shielding and bridging models for composite toughening.     

A NOTE ON MODELLING SHORT FATIGUE CRACK BEHAVIOUR

Based upon experimental short fatigue crack growth data and adopting the Brown–Hobson model, new crack growth equations have been derived in an attempt to describe more precisely short fatigue crack growth behaviour that separates the physically small crack regime from the long crack regime. An empirical model for physically small crack growth was developed by employing elastic–plastic fracture mechanics parameters.
By considering the proposed approach to short fatigue crack modelling, a new second 'microstructural' threshold condition has been established using only short fatigue crack growth data. In the case of fatigue in an aggressive environment it is suggested that three transition (threshold) conditions can be identified representing: (i) a stress-assisted pitting/pit-to-crack transition; (ii) a microstructurally short shear crack/physically small tensile crack transition; and (iii) a physically small crack/long crack transition.
A comparison of this approach with that of existing models has been made, and predictions of total fatigue lifetime using the model have been presented. A reasonable agreement has been observed between predicted and experimental crack growth rates.     

Fracture toughness of microsphere Al2O3–Al particulate metal matrix composites

The fracture toughness and behaviour of COMRAL-85^TM, a 6061 aluminium–magnesium–silicon alloy reinforced with 20 vol% Al₂O₃-based polycrystalline ceramic microspheres, and manufactured by a liquid metallurgy route, have been investigated. Fracture toughness tests were performed using short rod and short bar (chevron-notch) specimens machined from extruded 19 mm diameter rod, heat treated to the T6 condition. The fracture toughness in the R–L orientation was found to be lower than in the C–R or L–R orientations owing to the presence of particle-free bands in the extrusion direction. Short rod tests were also conducted for the R–L orientation on six powder metallurgy composites with particle volume fractions ranging between 5% and 30%. It was found that the fracture toughness decreased progressively with particle volume fraction, but at a decreasing rate. A detailed examination of the fracture behaviour was made for both the liquid metallurgy and powder metallurgy processed composites.     

Failures analysis of particle reinforced metal matrix composites by microstructure based models

This paper discusses the methodology of microstructure based elastic–plastic finite element analysis of particle reinforced metal matrix composites. This model is used to predict the failure of two dimensional microstructure models under tensile loading conditions. A literature survey indicates that the major failure mechanism of particle reinforced metal matrix composites such as particle fracture, interfaces decohesion and matrix yielding is mainly dominated by the distribution of particles in the matrix. Hence, analyses were carried out on the microstructure of random and clustered particles to determine its effect on strength and failure mechanisms. The finite element analysis models were generated in ANSYS, using scanning electron microscope images. The percentage of major failures and stress–strain responses were predicted numerically for each microstructure. It is evident from the analysis that the clustering nature of particles in the matrix dominates the failure modes of particle reinforced metal matrix composites.     

High cycle fatigue behaviour of microsphere Al2O3–Al particulate metal matrix composites

The high-cycle stress-life (S–N) curve and fatigue crack growth threshold (ΔK_th) behaviour of COMRAL-85^TM, a 6061 aluminium–magnesium–silicon alloy reinforced with 20 vol.% Al₂O₃-based polycrystalline ceramic microspheres, and manufactured by a liquid metallurgy route, have been investigated for a stress ratio of R = −1 (fully reversed loading). Fatigue testing was conducted on both smooth round bar (S–N) specimens and notched round bar (fatigue threshold) specimens. Unreinforced Al 6061-T6 also processed by a liquid metallurgy route and six powder metallurgy processed composites with particle volume fractions ranging between 5% and 30% were also studied. S–N data revealed that the powder metallurgy processed composites generally gave longer fatigue lives than the matrix alloy, whereas COMRAL-85^TM exhibited a reduced fatigue life. The fatigue threshold results were very similar for all the composites, being lower than for Al 6061-T6. Fatigue failure mechanisms were determined from examination of the fracture surfaces and the crack profiles.     

Influence of grain boundaries on short crack growth behaviour of IGSCC

Understanding short crack behaviour is essential for predicting the lifetime of light water reactor components. However, crack growth rates of short cracks are unsteady due to microstructural obstacles such as grain boundaries. On the other hand, the statistical behaviour of short cracks can be deduced from crack size distributions. Some papers have pointed out that the crack size distributions obtained by stress corrosion cracking tests showed a kink in the distribution line. This kink suggests that the short crack growth rate is slow compared with that of long cracks. And it can be thought that the slow growth rate is caused by the microstructural obstacles. This study investigated the influence of grain boundaries on the short crack growth behaviour of intergranular stress corrosion cracking. A crack growth simulation model, which considered the mechanical effects of the crack kink and bifurcation by grain boundaries, was developed. The crack depth distribution obtained by the simulation also exhibited a kink in the distribution line as seen in the experimental results. This suggests that grain boundaries play an important role in short crack growth behaviour.     

Cyclic fatigue crack growth behaviour in β-(Si–Al–O–N) at ambient and elevated temperatures

Four-point bending fatigue tests on a hot-pressed sintered Sm–-(Si–Al–O–N) ceramic were conducted at room temperature, 900 °C and 1000 °C in air under different load ratios and cyclic frequencies. The growth of indentation cracks was measured during the fatigue tests. The results indicate that the cyclic fatigue crack growth threshold is lower and crack growth rates are higher, for given values of K_max, at 1000 °C than those at room temperature. The cyclic fatigue crack growth behaviour at 900 °C is similar to that at room temperature. It was found that the crack growth retardation due to cyclic fatigue loading is much more pronounced at higher frequencies. An increase in cyclic frequency from 1 to 10 Hz cause a reduction of up to two orders of magnitude in crack propagation rates. High-temperature cyclic fatigue crack growth rates increased and threshold stress intensity factor ranges decreased with increasing load ratio. Possible mechanisms for cyclic crack growth are discussed.     

Finite element analysis of observed high strengthening in composites with regularly segregated microstructures

Abstract

A distinct dual phase composite has been developed, comprising spherical reinforcement clusters and an unreinforced matrix, according to numerical simulation of crack initiation and propagation in discontinuously reinforced MMCs. The present work is aimed at interpretation of the high strengthening ratios which were actually measured in such dual phase composites. Elastic-plastic finite element modelling is utilised to analyse the strengthening ratio in a two-dimensional idealised microstructure with periodic clustering. As the degree of clustering increases, the strengthening ratio is predicted to increase. In composites with a networking cluster, much more strengthening is exhibited together with relatively uniform strain distribution. The primary mechanism leading to additional strengthening due to clustering derives from an optimum ratio in deformation resistance between a matrix and a reinforcing phase. In the proposed dual phase composites, each cluster can behave as a single reinforcement which can deform plastically and there is no distinct interface between the cluster and the softer phase.     

Crack propagation behavior under creep conditions

The creep crack propagation behavior of a Cr–Mo–V rotor steel has been investigated at 538°C using time-dependent fracture mechanics concepts. The creep crack propagation lives and the creep deflection rates of double-edge-notched (DEN) specimens were estimated using previous data from compact-type specimens. The predicted crack growth lives and deflection rates compared favorably with the experimental data. When plotted as a function of the C _t parameter, the experimentally determined creep crack propagation rates of DEN specimens were found to be in agreement with those of compact and center-crack-tension specimens. These results provide further experimental verification for the validity of the C _t parameter for characterizing creep crack growth behavior. Some discrepancies between the predicted and the observed behavior are attributed to primary creep deformation behavior which was not considered in estimating the value of C _t .     

INFLUENCE OF PARTICLE SIZE AND VOLUME FRACTION ON DAMAGE AND FRACTURE IN Al–Al3 Ti COMPOSITES AND MICROMECHANICAL MODELLING USING THE GTN MODEL

Six different Al–Al₃ Ti composites were prepared via the powder metallurgy route. The size and volume fraction of Al₃ Ti particles was varied for a systematic investigation of fracture behaviour. The dominant failure mechanism in the composites is particle fracture and void growth starting from the broken particles. In comparison with the pure Al–matrix, an incorporation of Al₃ Ti particles reduces the crack initiation toughness and reduces the slope of the crack growth resistance curve. The inter-particle distance was found to be the main microstructural parameter controlling the slope of the crack growth resistance curve. The modified Gurson–Tvergaard–Needleman model (GTN model) was applied to one of the composites. The behaviour of tensile specimens could be successfully modelled, whereas the experimentally observed crack propagation in precracked single edge bend specimens [SE(B)] could not be simulated with the GTN model.     

Crack initiation and growth path under multiaxial fatigue loading in structural steels

In real engineering components and structures many accidental failures occur due to unexpected or additional loadings, such as additional bending or torsion. There are many factors influencing the fatigue crack paths, such as the material type (microstructure), structural geometry and loading path. It is widely believed that fatigue crack nucleation and early crack growth are caused by cyclic plasticity. This paper studies the effects of multiaxial loading paths on the cyclic deformation behaviour, crack initiation and crack path. Three types of structural steels are studied: Ck45, medium carbon steel, 42CrMo4, low alloy steel and the AISI 303 stainless steel. Four biaxial loading paths were applied in the tests to observe the effects of multiaxial loading paths on the additional hardening, fatigue crack initiation and crack propagation orientation. Fractographic analyses of the plane orientations of crack initiation and propagation were carried out by optical microscope and SEM approaches. It is shown that these materials have different crack orientations under the same loading path, due to their different cyclic plasticity behaviour and different sensitivity to non-proportional loading. Theoretical predictions of the damage plane were conducted using the critical plane approaches, either based on stress analysis or strain analysis (Findley, Smith–Watson–Topper, Fatemi–Socie, Wang–Brown–Miller, etc). Comparisons of the predicted crack orientation based on the critical plane approaches with the experimental observations for the wide range of loading paths and the three structural materials are shown and discussed. Results show the applicability of the critical plane approaches to predict the fatigue life and crack initial orientation in structural steels.     

Crack growth resistance (R-curve) behaviour and thermo-physical properties of Al2O3 particle-reinforced AlN/Al matrix composites

Crack growth resistance behaviour and thermo-physical properties of Al₂O₃ particle-reinforced AlN/Al matrix composites have been studied as a function of AlN volume fraction as well as Al₂O₃ particle size. The fracture toughness of the composites decreased with increase in vol% AlN and decrease in Al₂O₃ particle size. All the composites exhibited R-curve behaviour which has been attributed to crack bridging by the intact metal ligaments behind the crack tip. The Young’s modulus of the composites increased with the vol% of AlN whereas the thermal diffusivity and coefficient of thermal expansion followed a reverse trend. The composites exhibited hysteresis in thermal expansion as a function of temperature and the hysteresis decreased with decrease in metal content of the composite.     

Prediction of creep–fatigue crack growth rates in inert and active environments in an aluminium alloy

This paper reports on a study on creep–fatigue crack growth resistance of a precipitation hardened 2650 T6 aluminium alloy selected for fuselage panels of a future civil supersonic aircraft. The objective is to develop a methodology to predict crack growth under very low frequency loading at elevated temperatures. With this aim, creep crack growth rates (CCGRs), fatigue crack growth rates (FCGRs), creep–fatigue crack growth rates (CFCGRs) have been measured at 130 °C and 175 °C in laboratory air and in vacuum at R = 0.5 under different load frequencies and waveshape signals. It is shown that, for a given temperature, CFCGRs are unaffected by frequency below a critical value of the load period T_c. Above this value CFCGRs are directly proportional to the load period. This time-dependent crack growth regime is assisted by a significant creep damage as indicated by the large amount of intergranular decohesions induced by cavitation on fracture surfaces. CFCGRs are calculated under the assumption that fatigue damage and creep damage can be linearly summed. In vacuum the predictions are in good agreement with experimental data at both temperatures. In air however a discrepancy is observed for low frequency loading, suggesting the occurrence of a creep–fatigue–environment interaction. As a consequence the time-dependent crack growth behaviour affected by this interaction is different from creep crack growth behaviour, although the reasons for this are still unclear. A methodology is then proposed to predict CFCGRs in air. This methodology, if assessed by very low frequency experimental results, could be extended to different structural components made of aluminium alloys operating at elevated temperatures, provided that the mechanisms are unchanged.     

Short-fiber/particle hybrid reinforcement: Effects on fracture toughness and fatigue crack growth of metal matrix composites

We have studied the effects of short-fiber/particle hybrid reinforcement on fracture toughness and fatigue crack growth in metal matrix composites. Reinforcement hybridization was achieved by a hybrid preform process, and composites were fabricated by the squeeze casting method. Al6061 matrix alloy and four composites having different short-fiber/particle ratio were tested. The fracture toughness (K_IC) and the fatigue threshold (ΔK_th) increased with increasing particle contents, whereas the Paris’ exponent (m) was insensitive to the short-fiber:particle ratio. These results emerged as a shift of the crack growth curve which implies on enhanced crack resistance over the entire stress intensity factor range. The positive aspect of particulate reinforcement is advocated by comparison of microstructural variables, and by observation of the crack path and surfaces. The characteristics of hybrid composites in damage tolerance are emphasized.     

In situ SEM studies on the effects of particulate reinforcement on fatigue crack growth mechanism of aluminium-based metal-matrix composite

The effects of particulate reinforcement on the fatigue behaviour and fatigue mechanisms of two 6061 aluminium-based metal-matrix composites (MMCs) in three different heattreatment conditions were studied in situ with a scanning electron microscope and compared to the unreinforced alloy in the as-received condition. It was observed that the fatigue properties of the MMCs were influenced by the ceramic particles in two ways: firstly the particles increased the fatigue stress intensity threshold mainly by crack-deflection and crack-closure mechanisms, and secondly, the particles raised the fatigue crack growth rates in the Paris region by providing an easy crack path. The effect of ageing was small on the fatigue stress intensity threshold of MMCs, but for the peak-aged MMCs the fatigue crack growth rates in the Paris region were faster. The mechanism of fatigue crack growth was largely associated with the matrix/particle interface and the linkage with subcracks initiated ahead of the main crack at high applied stress intensity factors.     

Some considerations of asymmetric cracking in an applied-moment double cantilever beam

In situ observations of crack propagation in applied-moment double cantilever beam specimens have been used to obtain the R-curve behaviour of Si₃N₄/50% BN–50% Al₂O₃ laminated composites, in which the BN–Al₂O₃ layers function as weak interphases. The crack plane and the crack direction were, respectively, normal and parallel to the plane of the laminated layers. During crack propagation, both delamination and crack deviation from the centreline of the specimen occurred. A deviated crack resulted in an uneven moment of inertia in the two beams of the specimen. For a non-laminated material, a deviated crack would become unstable, such that the crack would propagate towards the beam with the smaller moment of inertia. It was found in the present study that delamination in a laminated composite can stabilize the propagation of a deviated crack. The stabilization of a deviated crack with delamination was due to a decrease in the inequality in the moment of inertia of the two beams compared to that without delamination.     

FINITE ELEMENT ANALYSIS OF DELAMINATION CRACKS IN BENDING OF CROSS-PLY LAMINATES

SUMMARY

A study of delamination crack growth due to bending in cross-ply laminates is presented. For the understanding of interlaminar fracture behaviour of laminated composites the modelling of delamination crack growth induced by bending and shear cracks in three point bending specimens is carried out. A plane strain two-dimensional (2-D) finite element analysis is used to determine the strain energy release rates during delamination of the laminated beam. Contact elements were used to prevent the material interpenetration on the crack surfaces. The solution of the contact problem taking into account friction along crack surfaces is obtained. Energy release rates G_I and G_II for Mode I and Mode II fracture are calculated by virtual crack closure integral (VCCI) methods. Comparison of total energy release rates, obtained by local energy methods, with an analytical solution based on the beam theory and a global energy method have been carried out. Good agreement of the results obtained by various methods have been observed. Comparison of the results obtained by the solution of the contact problem and without contact elements have been performed. Significant differences between the values of energy release rates obtained with and without using contact elements have been observed. The influence of the coefficient of friction on the energy release rates is insignificant.     

Load history effects in ductile cast iron for wind turbine components

Fracture-mechanics experiments were carried out on samples of ductile cast iron to investigate the fracture behaviour under cyclic and random loading. Under cyclic loading, the crack growth rate was described well by the ESACRACK model. Fatigue crack growth behaviour depends on the graphite particle size. Increasing particle size leads to higher threshold-values ΔK_th, lower da/dN values and higher transition to static fracture K_fc. The investigation of load history effects with low–high and high–low transitions shows that crack growth acceleration is independent of the transition type. The computation of the a–N curves based on different load history models yields non-conservative results.     

FATIGUE CRACK GROWTH BEHAVIOUR IN MOLTEN-METAL PROCESSED Sic PARTICLE-REINFORCED ALUMINIUM ALLOYS

Fatigue crack initiation and subsequent short crack growth behaviour of 2014-5wt%SiC aluminium alloy composites has been examined in 4-point bend loading using smooth bar specimens. The growth rates of long fatigue cracks have also been measured at different stress ratios using pre-cracked specimens. The distributions of Sic particles and of coarse constituent particles in the matrix (which arise as a result of the molten-metal processing and relatively slow cooling rate) have been investigated. Preferential crack initiation sites were found to be Sic-matrix interfaces, Sic particles associated with constituent particles and the coarse constituent particles themselves. For microstructurally short cracks the dispersed SiC particles also act as temporary crack arresters. In the long crack growth tests, higher fatigue crack growth rates were obtained than for monolithic alloys. This effect is attributed to the contribution of void formation, due to the decohesion of Sic particles, to the fatigue crack growth process in the composite. Above crack depths of about 200 μm “short” crack growth rates were in good agreement with the long crack data, showing a Paris exponent, m= 4 in both cases. For the long crack and short crack growth tests little effect of specimen orientation and grain size was observed on fatigue crack growth rates, but, specimen orientation affected the toughness. No effect of stress ratio in the range R=0.2-0.5 was seen for long crack data in the Paris region.