Crack propagation rate as a function of crack tip characteristics

The dependence of crack growth rate on various crack tip parameters was studied. Experiments were performed on thin sheets of 6063-T6 Al-alloy having a central notch, to find crack tip opening displacement, total strain range, plastic strain range, crack opening stress and crack growth rate. Crack tip opening displacement and crack opening stress were measured, using a surface measurement technique, with small crack opening displacement gauges. The theoretical predictions of crack tip opening displacement compare fairly well with the experimental values. It is found that crack propagation rate vs total strain range-plastic strain range gives a straight-line fit on a log-log graph and, for positive stress ratios, the fatigue crack growth rates are found to be independent of R.

Experimental results show that the crack opening stress is not affected by the position of the gauge when it is mounted behind and near the crack tip.

The effect of mechanical properties and loading on crack growth were also studied. The specimens were fatigue cracked to a predetermined length and some specimens were annealed and again loaded cyclically. The application of cyclic loads to annealed specimens caused significant increase in crack propagation rates in comparison with the specimens having no heat-treatment. The load-displacement record was found to stabilize in about 10 cycles; the crack then extended slowly as a fatigue crack. Crack propagation rates for different values of R for annealed and work-hardened material were plotted against a crack tip parameter, ΔK*, based on notional crack lengths. Since the results of da/dN vs ΔK* for both states of material (as-received and annealed) seem to lie on the same straight line on a log-log graph, the study provides a hope that the results for a material tested in any state (annealed or work-hardened) for positive values of R (0·0≤R≤0·3) will lie on this line, thus eliminating fatigue tests on the same material under different work-hardening conditions for different values of R. Models for da/dN have been developed using various crack tip parameters.     

Creep crack growth in welded components — a numerical study and comparison with the R5 procedures

In the present study, creep crack growth (CCG) in a circumferentially welded low alloyed pipe is numerically investigated for a number of different combinations of weldment constituent material properties. 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 characterising parameters. It is assumed that a fully circumferential creep crack, located in the heat affected zone with a depth of one quarter of the pipe thickness, is growing at a constant rate from the outer surface towards the inside. The numerical results reveal that not only the properties of the zone containing the crack, but also the deformation properties of the surrounding material influence the CCG behaviour. This influence can be noted on the characterising parameters used for the CCG rate predictions as well as on the CCG rate itself. The mismatch influence on corresponding C^* values is, however, marginal. This indicates that determination of the CCG rate in weldments, based on the C^* value only, may result in uncertain estimates.The numerically investigated cases are also assessed by use of the R5 procedures for the sake of comparison. Considering the stress re-distribution, due to the mismatch effect, the CCG rate is determined for the different weldment configurations. The comparison shows that the assumption of plane strain or plane stress conditions in the R5 analysis is essential for the agreement of the results between R5 and the two-parameter approach. Assuming plane stress conditions at the crack tip results in a relatively good agreement for the axial stress dominated cases investigated. However, for the hoop stress dominated cases, the R5 procedures predict higher CCG rates by an order of magnitude.     

Experimental determination of the stress intensity factor for a part-through thickness crack

Based on the relationship between the stress intensity factor and the plastic zone size at the crack tip, an experimental method for the evaluation of the stress intensity factor for a part-through thickness crack is proposed. Approximating the geometrical shape of the crack to a semi-elliptical surface crack, an empirical K-expression for the surface crack in a plate under bend loading configuration is derived and verified experimentally where the new K-expression contains both crack depth and length as a crack tip singularity parameter. The experimental work makes use of newly developed etching techniques to reveal the plastic zone size in deformed A533B pressure vessel steel.     

Lifetime estimates of cracked high temperature components

Cracked high temperature components subjected to creep-fatigue loading can fail by crack growth, net-section rupture or some combination of both processes. Models for describing this behaviour are presented. The influence of build up of damage in a process zone at the crack tip, material deterioration in the uncracked ligament and the importance of tertiary creep on the mode of failure are each considered. It is shown how the models can be employed to predict crack growth and for making residual life assessments in high temperature equipment. Finally a simple cumulative damage law is outlined for describing creep-fatigue interaction.     

Using the results of creep crack incubation tests on CrMoV steel for predicting long time creep rupture properties

The results of a series of creep crack incubation (CCI) tests have been used to examine the effectiveness of the LICON methodology for predicting long duration uniaxial rupture strength of a CrMoV steel at 550° C. The study has revealed that effective long time predictions can be made, but only with the availability of additional information including: an awareness of the short and long time rupture mechanisms and the associated multi-axial rupture criteria obeyed by the material, the results of uniaxial and multi-axial creep tests, and a knowledge of the steady state creep stress conditions existing in the testpieces (structures) forming part of the evaluation.     

Creep crack growth data and prediction for a P91 weld at 650 °C

Creep crack growth tests have been carried out on compact tension (CT) specimens machined from a P91 weldment. Four of these specimens were cut from the parent material side of the weld and another seven specimens were cut across the weld. For the cross-weld specimens, starter cracks were positioned into (or close to) the Type IV region. The creep tests were carried out under constant loads, at 650 °C. The results obtained showed that, the creep crack growth rates for parent material specimens are about ten times lower than those for the cross-weld specimens and that the scatter in the data is relatively high. In this respect, the accuracy of the crack tip location, in the cross-weld CT specimens, plays an important role. Finite Element (FE) analyses were carried out, on notched bar and CT models, using damage mechanics material behaviour models. These analyses were used to estimate the triaxial stress factor, α, for the parent material (PM), the weld metal (WM) and the heat affected zone (HAZ). FE analyses were then used to predict the creep crack growth in the CT specimens. Results from the FE analyses for both the PM and the cross-weld CT specimens were in good agreement with the corresponding experimental results. The effect of the potential drop versus crack length calibration on the calculated C* values was also investigated.     

The characterization of creep crack growth rate and its life of TiAl inter-metallic compound with full lamellar microstructure

TiAl inter-metallic compound is considered to be an effective material for high temperature structural materials. Since, this material is considered to be a creep brittle like material, it is necessary to construct the prediction law for the life of creep crack growth. The introduction of a fatigue pre-crack was found to be difficult due to material structure. Therefore, the validity of using a sharp-notched specimen (machined or EDM) instead of a fatigue pre-cracked specimen to perform creep crack growth rate test (CCGR test) has been proposed. In this paper, creep crack growth tests were conducted for this material using CT specimens with a sharp notch. On the basis of a thermally activated process, CCGR of TiAl inter-metallic compound with full lamellar microstructure was characterized in terms of temperature and stress component and Q¹ parameter for this material is derived. Furthermore, the algorithm of predicting the life of creep crack growth based on the Q¹ parameter was derived. This equation was found to well predict the life of creep crack growth.     

Creep crack growth in service-exposed weld metal of 2.25Cr1Mo

Creep crack growth (CCG) has been studied for ex-service weld metal of 2.25Cr1Mo (P22). The testing was conducted at a temperature of 550°C and prior to testing, the material had been exposed to high temperature service for 110 000 h at 530°C. The results show a marked effect of the service exposure on the CCG properties of the material when compared to similar testing performed on a new material. The CCG rate was higher by a factor 3.1 in the service-exposed material, which should be compared to the model value of 3.2 based on the relations between the elongation values. The consumed deformation capacity was also estimated with the omega model for tertiary creep. In this case, an enhanced growth rate of 2.4 was obtained. Within a distance of about 10 mm in front of the propagating cracks, the number of creep cavities was significantly higher than in the surrounding material. The variation of the density of cavities as a function of distance from the crack tip was successfully modelled.     

Removal of the influence of stress triaxiality on crack tip opening displacement fracture toughness by continuum damage mechanics approach

Experimental data for AS 1405-180, AS 1204-350, HY 80 and C-Mn steels shows that the crack tip opening displacement (CTOD) elastic-plastic fracture toughness at initiation δ_c decreases with increasing crack tip stress trifaxiality. This trend is confirmed by the continuum damage analysis in this paper. The dependence of the CTOD parameter at initiation on the local constraint, i.e. the stress triaxiality, provides the motivation to seek parameters that could rank the toughness of steels. Since the local effective plastic strain can be related to the CTOD, a relationship is described between the initiation CTOD toughness and the crack tip constraint, i.e. the stress triaxiality, on the basis of a new local damage theory for ductile fracture. Furthermore, a new constraint corrected toughness parameter δ_dc (and corresponding criterion) for ductile fracture is proposed, in which both crack tip deformation and crack tip constraint intensity are taken into account. Several series of experimental data have shown that the parameter δ_dc is nearly a constant or independent of the local constraint. It is found that the toughness variation with constraint changes can effectively be removed by use of the constraint correction procedure proposed in this paper.     

Unstable crack growth in a component subject to constant applied loads. II: Effect of crack size and component width

When a crack grows slowly, by, for example, a stress corrosion mechanism, in a component that is subject to constant applied loads, it is possible that there will be a transition from slow growth to unstable non-environmentally-assisted (plastic) growth. Part I of this investigation¹ examined the plane strain deformation of a non-work-hardening solid containing two symmetrically situated deep cracks, and with tension of the small remaining ligament. The main conclusion was that the transition from stress corrosion crack growth to plastic crack growth, accompanied by instability, should not occur under constant load conditions until the general yield state is almost attained, even though a material's resistance to plastic crack growth might be only moderate.The present paper extends the earlier study by analysing the more general model of a solid of finite width containing two symmetrically situated cracks of equal depth. Irrespective of the crack size and solid width, it is shown that unstable plastic crack growth should not occur until the general yield state is almost attained, even if the plastic crack growth resistance is only moderate. The scope of the conclusion reached in Part I is therefore broadened, and the results therefore provide further support for the view that the occurrence of unstable plastic fracture under load control conditions approximately correlates with the attainment of a critical net-section stress across the remaining ligament. The results consequently provide additional underpinning for the currently used empirical net-section stress approach for predicting failure under load control conditions.     

Difficulties in interpreting data from creep crack growth tests on type 316H weldments

Abstract

Experimental creep crack growth data are generally obtained by following standard methods such as ASTM E1457-07 and subsequently characterised using the C* parameter. These data are then used in assessment procedures, such as R5, together with reference stress estimates of C* in the component, to predict creep crack growth behaviour. Some modifications to the ASTM E1457 creep crack growth testing and analysis methods have already been proposed following a previous analysis of data from long term creep crack growth tests on type 316H parent material. This paper reports the results of creep crack growth tests on type 316H heat affected zone material at 550°C using compact tension (CT) specimens manufactured from non-stress relieved thick section butt welds. It is shown that interpretation of the data from these weldment tests is complicated by both the discontinuous nature of the cracking process and the presence of significant residual stresses in the CT specimens. Further modifications to creep crack growth testing and analysis methods are proposed to address difficulties arising from the discontinuous nature of the cracking process, and further work is identified to investigate the influence of the residual stresses present in the specimens on the observed crack growth behaviour.     

Creep fatigue crack development in dissimilar metal welded joints between steels and nickel based alloy

Abstract

Creep and strain controlled cyclic/hold creep fatigue tests have been performed at temperatures in the range of 550–575°C on specimens extracted from dissimilar metal welded (DMW) joints between two classes of steel and a nickel based alloy. The details and results of the tests are described. While crack development in the cyclic/hold creep fatigue test specimens tends to be creep dominated, the microstructural paths followed in the steels in the vicinity of their heat affected zones are not identical to those observed in creep rupture testpieces taken from the same DMW joint. In pure creep tests, cracking may occur adjacent to the fusion line and/or in the fine grain heat affected zone (FGHAZ), with rupture location being dependent on temperature stress and microstructural condition. In contrast, creep dominated creep fatigue cracking typically occurs in the intercritical heat affected zone/FGHAZ or the overtempered parent material on the steel side of such weldments, depending on the composition of the joint.     

Modelling crack growth for creep and fatigue loading

Estimates of creep crack growth in engineering components under steady load conditions are usually based on the application of fracture mechanics concepts. In particular the creep parameter C* has become widely used together with creep crack growth data obtained from laboratory tests. There are now a number of practical methods to utilise experimental data. For high temperature components, which are subjected to cyclic (fatigue) as well as creep loading, the estimation of the fracture mechanics parameters becomes much more difficult, and consequently the extent to which the growth of pre-existing cracks grow by creep and fatigue is difficult to quantify. In this paper the response of Type 316L stainless steel is examined. This material progressively strain hardens under reversed cyclic loading, and the creep behaviour also changes. Using uniaxial fatigue and creep results, fracture parameter maps are developed to establish the appropriate regimes for creep-fatigue crack growth. Using the maps a model is developed which can predict the combined effect of fatigue and creep on crack growth. The implications of the model are discussed in relation to the limitations of obtaining results from laboratory tests at short times, and the assessment of practical engineering components.     

Effect of plastic prestrain on the crack tip constraint of pipeline steels

Before and during operation, pipelines may suffer from plastic pre-deformation due to accidental loading, cold bending and ground movement. Plastic prestrain not only modifies steel's yield and flow properties but also influences its fracture performance. This paper focuses on the effect of prestrain history on crack driving force and crack tip constraint. A single-edge notched tension specimen has been selected for the study and the crack is assumed to exist before a prestrain history was applied. The results show that prestrain history has a strong effect on the crack tip stress field. A new parameter has been proposed to characterize the prestrain-induced crack tip constraint. For the same crack tip opening displacement level, prestrain history will elevate the crack tip stress field. The prestrain-induced constraint decreases with the increase of loading.     

Stability of a crack in a cantilever beam undergoing large plastic deformation after impact

A simple model is employed to determine the dynamic response of a rigid-perfectly plastic cantilever beam with an attached tip mass and a crack, taking into account the weakening effect of the crack. The crack is assumed to be located at the base of the beam, and an initial velocity is imparted to the tip mass. The subsequent stability of the crack is considered by calculating the tearing modulus based on the J-integral associated with the deflecting beam. For the example of circumferential cracks in thin-walled piping, whose idealized geometry models some stress corrosion cracks found in service, radial propagation and instability are found to be more likely than circumferential. Once a crack penetrates the wall, however, stability in the circumferential direction is found to depend in a complex way upon loading and crack geometry.     

Inhibition of a curvilinear bridged crack by induced thermoelastic stress field

Temperature changes near the end of a curvilinear crack in the presence of end areas with cohesive forces of the material are considered. It is assumed that these areas adjoin to the crack tip and their sizes are comparable with the crack size. The goal of local changes of temperature is to delay or inhibit the growth of a curvilinear crack. A boundary value problem on equilibrium of a bridged curvilinear crack under the action of external tensile loads, induced thermoelastic temperature field, and tractions in the bonds preventing its disclosure is reduced to the system of nonlinear singular differential equations with a Cauchy-type kernel. Normal and tangential tractions in the bonds are found from the solution of this system. The stress intensity factors are calculated. The condition of limit equilibrium of a curvilinear crack with an end area is formed based on two-parameter fracture criterion.     

Atomistic simulation of hydrogen-induced plastic zone compression during cyclic loading

To investigate the effect of hydrogen atoms on the size of the plastic deformation zone, molecular dynamics (MD) simulations were performed on a single crack model. The model uses pre-charged hydrogen to quantify the compression effect of hydrogen atoms on the plastic zone during cyclic loading. The results show that stress release at the crack tip occurs mainly in the form of plastic deformation, and the degree of compression in the plastic zone increases with increasing hydrogen concentration. A compression factor, which considers hydrogen concentration, is found with the help of the simulation results. A modified fatigue crack growth rate (FCGR) model, combined with the compression factor, was then used to predict the hydrogen-assisted fatigue crack growth rate. The proposed model shows excellent agreement with the experimental data for X100 steel, and it provides a new framework to describe hydrogen-assisted cracking.     

Creep test of type 304 stainless steel tube containing a notch subjected to internal pressure

This paper summarises the results of experimental creep tests of type 304 stainless steel tube subjected to internal pressure at 650°C. The equipment used was especially developed for these tests.

The tubes without notches were tested at pressures of 9·32 and 7·36 MPa. Test results indicate that the rupture time of the tubes without notches is in good agreement with that of uniaxial specimens when the maximum stress is taken as the rupture criterion. The tubes containing axial and circumferential surface notches were tested at a pressure of 7·36 MPa. Test results indicate that the ductile fracture theory is applicable to the life prediction in the case of axial notches.

An electric potential method was very useful for monitoring the creep crack growth from the notch root. The relationship between the creep crack growth rate and the fracture mechanics parameter, σ_net or K₁, was investigated.     

长期运行后汽轮机转子裂纹扩展行为的研究

对运行16年的30Cr1Mo1V亚临界汽轮机高中压转子进行解剖试验,采用直流电位法对材料在538℃下的蠕变裂纹、蠕变-疲劳裂纹萌生与扩展行为进行了研究,分析了不同初始应力强度因子对蠕变裂纹扩展孕育时间和蠕变裂纹扩展速率的影响,并对高温段和低温段的相关性能进行了比较,研究了不同保持时间对蠕变-疲劳裂纹扩展行为的影响,同时还分析了不同条件下裂纹扩展行为的时间或循环相关性．结果表明：疲劳缩短了蠕变-疲劳裂纹的扩展孕育期,加速了裂纹的扩展;载荷保持时间较短情况下,蠕变-疲劳裂纹扩展行为与循环相关;栽荷保持时间较长情况下,裂纹扩展行为与时间相关．     

Effects of crack depth and specimen size on ductile crack growth of SENT and SENB specimens for fracture mechanics evaluation of pipeline steels

A strong geometry dependence of ductile crack growth resistance emerges under large scale yielding. The geometry dependence is associated with different levels of crack tip constraint conditions. However, in a recent attempt to identify appropriate fracture mechanics specimens for pipeline steels, an “independent” relationship between the crack growth resistance curves and crack depths for SENT specimens has been observed experimentally. In this paper, we use the complete Gurson model to study the effects of crack depth and specimen size on ductile crack growth behavior. Crack growth resistance curves for plane strain, mode I crack growth under large scale yielding conditions have been computed. SENB and SENT specimens with three different specimen sizes, each specimen size with three different crack depths, have been selected. It has been found that crack tip constraint (Q-parameter) has a weak dependence on the crack depth for specimens in the low constraint regime.