不同拘束条件下P92钢高温蠕变裂纹扩展速率的有限元模拟

基于蠕变损伤力学,仿真了蠕变裂纹扩展过程。用ABAQUS软件模拟研究了试样几何形状和宽度不同的两种面内拘束条件对P92钢在650℃时蠕变裂纹扩展(CCG)速率的影响,并进行了试验验证。仿真结果表明:试样几何形状和宽度对CCG速率的影响与载荷水平(C*)有关;在低载荷水平区内,C(T)试样的拘束水平大于SEN(T)试样,并且对应的CCG速率较大;在中载荷水平区,随着试样宽度的增大,裂纹尖端拘束和CCG速率增大;在高载荷水平区,CCG速率基本不受面内拘束(试样几何形状、宽度)条件的影响;在条件相同的情况下,试样宽度拘束水平大于试样几何形状。试验结果表明,试验与有限元分析(FEA)的蠕变裂纹扩展结果相符合。     

铝合金6082T6中的疲劳不扩展裂纹

铝合金6082T6作为一种常用的航空材料具有很好的力学性能,使用这种材料对疲劳不扩展裂纹进行了研究。试样形状为单边缺口拉伸试样,并在裂纹尖端使用数控机床钻直径为1mm的止裂孔。通过分析可得：疲劳不扩展裂纹可以通过对试样几何尺寸的合理设置得到。在设计中可以在疲劳构件容易萌生裂纹的部位预留出不扩展裂纹的容许长度,从而更大限度的提高构件的寿命可靠性,并且可以抵抗一定程度的外界不确定载荷的冲击影响,减少在裂纹维修或检查间隔期间的裂纹扩展风险。     

预制裂纹角度对橡胶拉伸断裂影响的有限元分析

初始裂纹的形态影响着裂纹尖端的应力场和扩展方向,进而决定着橡胶材料的使用寿命。目前人们关于预制裂纹试样拉伸断裂的研究主要集中在直裂纹,很少涉及预制裂纹角度的改变对橡胶拉伸断裂的影响。文中应用ANSYS有限元分析软件计算拉伸状态下含不同裂纹角度橡胶试样裂纹尖端的等效应力值和撕裂能的大小,判断裂纹是否扩展及扩展方向,并对橡胶试样进行拉伸验证试验测试。结果表明,在拉伸断裂过程中,裂纹尖端的应力值和撕裂能随着初始预制裂纹角度的增大而增大,裂纹尖端形状均由初始的尖点变成圆弧状;含不同裂纹角度橡胶试样的拉伸断裂形貌与裂纹预测扩展方向基本一致,验证了有限元分析的正确性。     

孔洞形状对砂岩强度及破坏特征的影响

岩石内部富含形态各异的缺陷,对其力学特性有影响显著。通过对含单一预制孔洞砂岩试样进行单轴压缩试验,分析了孔洞几何形状对砂岩试样强度特征及破坏模式的影响规律,并利用RFPA2D数值模拟软件,对试样强度变化特征的力学机制进行探讨。研究表明:含孔洞砂岩试样的承载能力和弹性模量较完整岩样发生显著劣化,其中含正方形孔洞岩样的承载能力最弱,而含菱形孔洞岩样承载能力最强;试样最终失稳破坏主要由拉应力引起,且最大拉应力随孔洞几何形状不同而各异,其最终破坏模式主要有剪切破坏、张拉破坏和拉剪混合破坏3种;孔洞缺陷的结构效应对砂岩试样峰值强度和裂纹扩展特征也有影响。     

SiC/BN层状陶瓷耐损伤性能

采用压痕法在SiC/BN层状陶瓷试样的表面引入不同尺寸的表面裂纹,利用三点弯曲测量含裂纹试样的极限断裂应力,研究了不同尺寸的表面裂纹对层状陶瓷断裂强度的影响;根据压痕载荷-强度实验结果,测定层状陶瓷的阻力曲线,并与单相SiC陶瓷对比。结果表明,层状陶瓷的压痕强度对压痕裂纹深度的变化不敏感,阻力曲线呈上升型;而单相SiC陶瓷的压痕强度随压痕裂纹深度的增加急剧下降,阻力曲线呈平稳型,说明层状陶瓷具有优异的耐损伤性能和升值R-曲线行为。分析认为,裂纹在弱界面处发生偏折是层状陶瓷具有优良耐损伤性能和升值R-曲线行为的主要原因。这为陶瓷材料在含有一定的制备和加工缺陷以及承受冲击、磨损等接触损伤的条件下保持高强度提供了可能。     

钢桥面板纵肋与横隔板焊接细节表面缺陷及疲劳效应研究

初始焊接缺陷是影响结构件疲劳性能的关键因素之一。在断裂力学评估框架下引入特征化初始焊接缺陷,结合相互作用积分法与复合断裂准则解决由表面缺陷所导致的复合型疲劳裂纹扩展问题,在此基础上编写裂纹扩展模拟程序,建立表面焊接缺陷效应评价方法,通过分析揭示了不同形态和尺度的初始焊接缺陷对于钢桥面板纵肋与横隔板构造细节裂纹扩展关键性度量指标和疲劳寿命预测的影响。结果表明:所建立的方法可有效用于评估焊趾部位表面焊接缺陷对于疲劳性能的效应;面状缺陷对于裂纹扩展度量指标和疲劳寿命预测结果的影响更为显著,其初始缺陷深度和形态均是影响疲劳性能的关键因素,体积型缺陷对于疲劳寿命的影响主要由深度方向的缺陷尺寸决定;焊接缺陷的形态和几何参数取值应根据工程实际和规范建议值共同确定,直接简化为面状缺陷会低估结构件的疲劳寿命;考虑焊接缺陷不确定性的可靠度评估方法尚需进一步研究。     

CRO试样的疲劳裂纹扩展行为试验方法研究

考虑到如紧凑拉伸和三点弯曲等标准试样的大尺寸要求以及高试验成本等突出问题,该文发展了含外侧径向裂纹C形环小试样（C-ring with an outer radial crack,CRO）的疲劳裂纹扩展行为试验方法。利用有限元分析建立了CRO小试样的高精度应力强度因子算式以及基于柔度法理论的裂纹长度预测公式。采用5083-H112铝合金分别完成了CRO试样和标准CT试样的疲劳裂纹扩展速率试验,获得了相应的Paris方程中的幂指数。通过对比发现,CRO和CT试样的疲劳裂纹扩展规律基本一致,验证了新方法的有效性。基于上述方法对C250钢两种厚度CRO试样的疲劳裂纹扩展行为进行了应用研究。     

拘束度测量在焊接工程中的应用

钢材用于焊接结构时必须具有一定的抵抗形成焊接裂纹的能力,简称须具有良好的抗裂性。结构拘束程度是影响抗裂性的重要因素。拘束度作为与结构形状及尺寸有关的力学判据,正在成为参与预测和评定钢材工艺焊接性的主要判据。 本文探索了拘束度测量在焊接工程中的应用。通过对钢材工艺焊接性评定,对实际结构拘束度测量以及确定焊接工艺等方面的试验研究,确认,拘束度测量对预测钢材工艺焊接性及按结构拘束选择钢材和确定施工工艺等方面有着实用价值。它将成为钢材焊接性研究及评定的重要组成部分。     

金属疲劳裂纹初期扩展的特征及其影响因素

本文回顾了各种金属及合金在门坎区附近的疲劳裂纹扩展的机制和特徵。 根据一系列试样和结构的微观断口金相分析的结果表明,在近门坎区产生的占主导的断口形态是小平面或河流花样。对于不同金属与合金小平面的方位与晶体点阵结构的相互关系,用滑移型和层错能进行描述,在非轴向载荷下,曾提出一个更为普遍的疲劳裂纹扩展特性。 在本文中,对于板状及缺口试样的疲劳极限和门坎值的相互关系以及短裂纹的疲劳裂纹扩展机制也一起进行了评述,短裂纹的裂纹扩展行为可以一般地表达为: △K_(th)=f(a)△σ_(th)(πa)~(1/2)式中,f(a)为裂纹长度与试样几何形状的函数。 本文对应力比、显微组织、环境对在门坎区附近疲劳裂纹扩展行为的影响也进行了回顾,曾提出产生裂纹闭合效应的“氧化物诱发”及“粗糙度诱发”的概念,可以用来解释结构材料中上述因素对在近门坎区疲劳裂纹扩展行为的影响。     

温度波动及晶粒尺寸不均匀性对超塑性拉伸过程的影响

本文分析了由于温度的波动及初始晶粒尺寸差异对超塑性拉伸过程的影响。结果表明,它们对产生试样的不均匀变形都有重要的作用。并且能够将初始晶粒尺寸不均匀性和试样初始几何不均匀性在形式上统一起来。     

Effects of side‐groove depth on creep crack‐tip constraint and creep crack growth rate in C(T) specimens

The effects of side‐groove depth on creep crack‐tip constraint and creep crack growth (CCG) rate in C(T) specimens have been quantitatively studied. The results indicate that with increasing side‐groove depth, the constraint level and CCG rate increase and constraint distribution along crack front (specimen thickness) becomes more uniform. The constraint and CCG rate of thinner specimen are more sensitive to side‐groove depth. Two new creep constraint parameters (namely R^* and A_c) both can quantify constraint levels of the specimens with and without side‐grooves, and the quantitative correlations of CCG rate with constraint have been established. The mechanism of the side‐groove depth effect on the CCG rate has also been analyzed.     

In-plane and out-of-plane constraint effects on creep crack growth rate in Cr–Mo–V steel for wide range of C*

Abstract

In this work, the stress dependent creep ductility and strain rate model have been implemented in a ductility exhaustion based damage model and the creep crack growth (CCG) rates of a Cr–Mo–V steel in compact tension (C(T)) and middle tension (M(T)) specimens with different thicknesses and crack depths have been simulated over a wide range of C*. The effects of in-plane and out-of-plane constraints on CCG rates are examined. The results show that the in-plane and out-of-plane constraint effects on CCG rate are more pronounced for the high constraint specimen geometry (C(T)), while such effects are less significant for low constraint specimen geometry (M(T)). The constraint effects on CCG rates mainly occur in low and transition C* regions and the CCG rate increases with increasing in-plane and out-of-plane constraints. There exists interaction between in-plane and out-of-plane constraint in terms of their effects on CCG rate. The higher in-plane constraint strengthens the out-of-plane constraint effect on CCG rate and higher out-of-plane constraint also strengthens the in-plane constraint effect on CCG rate. The constraint effects on creep crack growth behaviour for a wide range of C* mainly arise from the interaction of crack-tip stress states and stress dependent creep ductility of the steel in different C* levels.     

Numerical investigation of creep crack growth in cross‐weld CT specimens. Part II: influence of specimen size

A numerical investigation of the influence of specimen size on creep crack growth in cross‐weld CT specimens with material properties of 2.25Cr1Mo at 550 °C is performed. A three‐dimensional large strain and large displacement finite element study is carried out, where the material properties and specimen size are varied under constant load for a total of eight different configurations. The load level is chosen such that the stress intensity factor becomes 20 MPa √m regardless of specimen size. The creep crack growth rate is calculated using a creep ductility‐based damage model, in which the creep strain rate ahead of the crack tip perpendicular to the crack plane is integrated taking the degree of constraint into account. Although the constraint ahead of the crack tip is higher for the larger specimens, the results show that the creep crack growth (CCG) rate is higher for the smaller specimens than for the larger ones. This is due to much higher creep strain rates ahead of the crack tip for the smaller specimens. If, on the other hand, the CCG rate is evaluated under a constant C * condition, the creep crack growth rate is found to be higher for the larger specimens, except when the crack is located in a HAZ embedded in a material with a lower minimum creep strain rate; then, the creep crack growth rate is predicted to be higher for the smaller specimen. In view of these results, it is obvious that the size effect needs to be considered in assessments of defected welded components using results from CCG testing of cross‐weld CT specimens.     

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.     

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).     

Numerical investigation of creep crack growth in cross-weld CT specimens. Part I: influence of mismatch in creep deformation properties and notch tip location

Creep crack growth (CCG) in cross-weld CT specimens is investigated using two-dimensional finite element simulations. A creep ductility-based damage model describes the accumulation of creep damage ahead of the crack tip where a constraint parameter and the creep strain rate perpendicular to the crack plane are used as characterizing parameters.
The numerical results reveal that, not only the material properties of the region in which the crack is propagating, but also the deformation properties of the surrounding material influence the CCG behaviour. For the specimen configurations investigated, the location of the starter notch in the HAZ of the cross-weld CT specimen has, however, a minor influence on the CCG rate and the value of C *. This applies as long as the crack is propagating within a sufficiently narrow region that has material properties which can be regarded as homogeneous.     

A unification of small- and large-crack growth laws

A generalized model enhancement is proposed to link small- and large-crack growth laws. The enhancement is based on crack growth rate laws with crack tip plastic zone size formulations. Transition functions are used to transform small-crack plastic zone sizes and crack growth law exponents to those predicted by linear-elastic fracture mechanics. In doing so, influences on crack growth, e.g. constraint, crack aspect ratio and specimen geometry are accounted for. The applicability of the enhancement is directed toward instances where small cracks start from geometric features and grow through stress gradients to eventually become large cracks under nominal LEFM conditions. The enhancement is applied to the Wang model, and crack growth rate and fatigue lifetime predictions are made. The enhancement is shown to provide a good correlation to experimental results for Ti–6Al–4V under various maximum stresses at a stress ratio of R = 0.4.     

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.     

The influence of cross-sectional thickness on fatigue crack growth

For thin structures, fatigue crack growth rates may vary with the structure's thickness for a given stress intensity factor range. This effect is mainly due to the change in the nature of the plastic deformation when the plastic zone size becomes comparable with, or greater than, the cross-sectional thickness. Variations in the constraint affect both the crack tip plastic blunting behaviour as well as the fatigue crack closure level. Approximate expressions are constructed for the constraint factor based on asymptotic values and numerical results, which are shown to correlate well with finite element results. It is demonstrated that the present results not only permit predictions of the specimen thickness effects on fatigue crack propagation under spectrum loading, but also eliminate the need to determine the constraint factor by curve-fitting crack growth data.     

PREDICTING THE EFFECTS OF CRACK TIP CONSTRAINT ON MATERIAL RESISTANCE CURVES USING DUCTILE DAMAGE THEORY

Abstract— In recent years much interest has been focused on the geometry dependence of the resistance to stable ductile crack growth of engineering materials, and in particular, in explaining this in terms of "constraint" effects. This paper describes the results of work using the Rousselier ductile damage model in finite element studies to simulate the growth and coalescence of voids, and hence the mechanics of ductile crack growth, to predict the effect of constraint on resistance to fracture. Using the modified boundary layer solution, where constraint is controlled by the application of remote displacements, it was possible to simulate resistance curves for different constraint conditions. This has produced a "net" of resistance curves, within which the curve for any specimen geometry can be found from a knowledge of the crack tip constraint for that specimen. This has been tested by comparing the results with those obtained from two specimens for which the constraint conditions are known. Good agreement has been achieved.
The results show that, although constraint has very little effect on conditions at the crack tip at initiation of crack growth, beyond that constraint plays an important part in defining the resistance curve. For low constraint geometries there is a very large loss in crack tip constraint which results in a large increase in the slope of the resistance curve. On the other hand, high constraint geometries exhibit very little dependence on crack tip constraint.