Simulation of crack growth in ductile materials

During crack growth of real materials, the total energy released can be partitioned into elastic and dissipative terms. By analyzing material models with mechanisms for dissipating energy and tracking all energy terms during crack growth, it is proposed that computer simulations of fracture can model crack growth by a total energy balance condition. One approach for developing fracture simulations is illustrated by analysis of elastic-plastic fracture. General equations were derived to predict crack growth and crack stability in terms of global energy release rate and irreversible energy effects. To distinguish plastic fracture from non-linear elastic fracture, it was necessary to imply an extra irreversible energy term. A key component of fracture simulations is to model this extra work. A model used here was to assume that the extra irreversible energy is proportional to the plastic work in a plastic-flow analysis. This idea was used to develop a virtual material based on Dugdale yield zones at the crack tips. A Dugdale virtual material was subjected to computer fracture experiments that showed it has many fracture properties in common with real ductile materials. A Dugdale material can serve as a model material for new simulations with the goal of studying the role of structure in the fracture properties of composites. One sample calculation showed that the toughness of a Dugdale material in an adhesive joint mimics the effect of joint thickness on the toughness of real adhesives. It is expected, however, that better virtual materials will be required before fracture simulations will be a viable approach to studying composite fracture. The approach of this paper is extensible to more advanced plasticity models and therefore to the development of better virtual materials.     

Fatigue crack propagation damaging micromechanisms in ductile cast irons

Ductile iron discovery in 1948 gave a new lease on life to the cast iron family. In fact, these cast irons are characterized both by a high castability and by high toughness values, combining cast irons and steel good properties. Ductile cast irons are also characterized by high fatigue crack propagation resistance, although this property is still not widely investigated.In the present work, three different ferritic–pearlitic ductile cast irons, characterized by different ferrite/pearlite volume fractions, and an austempered ductile cast iron were considered. Their fatigue crack propagation resistance was investigated in air by means of fatigue crack propagation tests according to ASTM E647 standard, considering three different stress ratios (R = K_min/K_max = 0.1; 0.5; 0.75). Crack paths were investigated by means of a crack path profile analysis performed with an optical microscope. Crack surfaces were extensively analysed by means of a scanning electron microscope both considering a traditional procedure and performing a quantitative analysis of 3D reconstructed surfaces, mainly focusing graphite nodules debonding.     

Effect of thickness on ductile fatigue crack propagation in polycarbonate

Resistance to slow fatigue crack propagation in polycarbonate is investigated with respect to specimen thickness. In the thickness range considered (0.33–3.22 mm), microscopic analysis reveals that a zone of yielded material constitutes the resistance to crack propagation. As the sheet thickness is increased, the amount of yielded material per unit crack surface is reduced. Consequently, faster crack growth rates are observed with increasing specimen thickness. Crack layer theory is applied to analyse crack propagation kinetics and stability. Accordingly, a specific enthalpy of damage (yielding) is found constant for the thickness range considered and is equal to 60 J g^–1 . It is further noticed that as the thickness increases, resistance to crack initiation increases.     

Prediction of the energy dissipation rate in ductile crack propagation

In this paper, energy dissipation rate D vs. Δa curves in ductile fracture are predicted using a ‘conversion’ between loads, load‐point displacements and crack lengths predicted by NLEFM and those found in real ELPL propagation. The NLEFM/ELPL link was recently discovered for the DCB testpiece, and we believe it applies to other cracked geometries. The predictions for D agree with experimental results. The model permits a crack tip toughness R(Δa) which rises from J_c and saturates out when (if) steady state propagation is reached after a transient stage in which all tunnelling, crack tip necking and shear lip formation is established. J_R is always greater than the crack tip R(Δa) and continues to rise even after R(Δa) levels off. The analysis is capable of predicting the usual D vs. Δa curves in the literature which have high initial values and fall monotonically to a plateau at large Δa. It also predicts that D curves for CCT testpieces should be higher than those for SENB/CT, as found in practice. The possibility that D curves at some intermediate Δa may dip to a minimum below the levelled‐off value at large Δa is predicted and confirmed by experiment. Recently reported D curves that have smaller initial D than the D‐values after extensive propagation can also be predicted. The testpiece geometry and crack tip R(Δa) conditions required to produce these different‐shaped D vs. Δa curves are established and confirmed by comparison with experiment. The energy dissipation rate D vs. Δa is not a transferable property as it depends on geometry. The material characteristic R(Δa) may be the ‘transferable property’ for scaling problems in ELPL fracture. How it can be deduced from D vs. Δa curves (and by implication, J_R vs. Δa curves) is established.     

Simulation of ductile crack propagation and determination of CTOAs in pipeline steels using cohesive zone modelling

This paper presents recent results of numerical studies on stable crack extension of high toughness steels typical of those in modern gas pipelines using cohesive zone modelling (CZM). The main focus of the work is on the determination of crack‐tip opening angles (CTOAs) of these steels from CZM. Two sets of materials are modelled. The first material set models a typical structural steel, with variable toughness described by four traction–separation (TS) laws. The second set models an X70 pipe steel, with three different TS laws. For each TS law, there are three defining parameters: the maximum cohesive strength, the final separation and the work of separation. The specimens analysed include a crack in an infinite plate (small‐scale yielding, SSY) and a standard drop‐weight tear test (DWTT). Fracture propagation characteristics and values of CTOA are obtained from these two types of specimens. It is shown that cohesive zone models can be successfully used to simulate ductile crack propagation and to numerically measure CTOAs. The ductile crack propagation characteristics and CTOAs obtained from SSY and DWTT specimens are compared for each set of steels. In addition, the CTOA results from numerical CZM of DWTT specimens of X70 steel are compared with those from laboratory tests.     

Modeling of hydrogen-assisted ductile crack propagation in metals and alloys

This paper presents a finite element study of the hydrogen effect on ductile crack propagation in metals and alloys by linking effects at the microstructural level (i.e., void growth and coalescence) to effects at the macro-level (i.e., bulk material deformation around a macroscopic crack). The purpose is to devise a mechanics methodology to simulate the conditions under which hydrogen enhanced plasticity induces fracture that macroscopically appears to be brittle. The hydrogen effect on enhanced dislocation mobility is described by a phenomenological constitutive relation in which the local flow stress is taken as a decreasing function of the hydrogen concentration which is determined in equilibrium with local stress and plastic strain. Crack propagation is modeled by cohesive elements whose traction separation law is determined through void cell calculations that address the hydrogen effect on void growth and coalescence. Numerical results for the A533B pressure vessel steel indicate that hydrogen, by accelerating void growth and coalescence, promotes crack propagation by linking simultaneously a finite number of voids with the crack tip. This “multiple-void” fracture mechanism knocks down the initiation fracture toughness of the material and diminishes the tearing resistance to crack propagation.     

Brittle and ductile crack propagation using automatic finite element crack box technique

In this paper, a numerical automatic crack box technique (CBT) is developed to perform fine fracture mechanics calculations in various structures without complete re-meshing. This technique aims to simulate the fatigue crack growth under mixed mode loading in 2D medium and shell structures calculated with the ABAQUS code, for elastic and for elastic-plastic materials. Using this method, series of numerical calculations by FEM of the mixed mode crack growth are carried out and compared with experimental tests such as a special cracked specimen subjected to different mixed mode loads. The crack growth paths are determined by using different elastic and elastic-plastic crack extension criteria. It is shown that the proposed technique is an efficient tool to simulate the crack extension angle in elastic and elastic-plastic materials. Nevertheless further experiments are needed to confirm conclusions deduced from elastic-plastic calculations.Using this technique, several phenomena influencing the crack extension are analyzed: the overload during fatigue, the fracture toughness of the material in relation with its critical J integral and its behaviour law.     

A damage model for ductile crack initiation and propagation

Damage-induced ductile crack initiation and propagation is modeled using a constitutive law with asymmetrical contraction of the yield surface and tip remeshing combined with a nonlocal strain technique. In practice, this means that the void fraction depends on a nonlocal strain. Finite strain plasticity is used with smoothing of the complementarity condition. The prototype constitutive laws take into account pressure sensitivity and the Lode angle effect in the fracture strain. Two plane idealizations are tested: plane stress and plane strain. Thickness variation in the former is included by imposing a null out-of-plane normal stress component. In plane strain, pressure unknowns and bubble enrichment are adopted to avoid locking and ensure stability of the equilibrium equations. This approach allows the representation of some 3D effects, such as necking. The nonlocal approach is applied to the strains so that the void fraction value evolves up to one and this is verified numerically. Three verification examples are proposed and one validation example is shown, illustrating the excellent results of the proposed method. One of the verification examples includes both crack propagation in the continuum and rigid particle decohesion based on the same model.     

Dynamic crack initiation in 3PB ductile steel specimens

Conclusions The design of the experimental set-up has exposed several advantages but also one drawback: the U-shaped hammer with fixed impact heads gives uncertain boundary conditions at the impact points and thus an uncertain stress-strain state at the crack tip. The set-up will therefore be redesigned in order to avoid this uncertainty.The advantage with the U-shaped hammer is that the crack growth area of the specimen will only get a minor translation and therefore close up photography is possible. The high speed photos have shown to be an excellent way to evaluate the experiments. The CMOD can be measured with an accuracy within about 0.1 mm. Necking (which follows after crack growth in the interior of the specimen) and visible crack growth can be fairly well determined from the photos.The evaluation of the experiments is made from a combination of measurements and calculations. Excessive nonlinear dynamic FEM calculations is a necessary part of the investigation.The results indicate that the J-integral for onset of crack growth is about the same for the two lower impact velocities 15 m/sec and 30 m/sec and it is decreased when the impact velocity is increased to 45 m/sec.Published in Fiziko-Khimicheskaya Mekhanika Materialov, Vol. 28, No. 1, pp. 69–73, January–February, 1992.     

Bifurcation and propagation of a mixed-mode crack in a ductile material

The bifurcation and the propagation of a 2-D mixed-mode crack in a ductile material under static and cyclic loading were investigated in this work. A general methodology to study the crack bifurcation and the crack propagation was established. First, for a mixed-mode crack under static loading, a procedure was developed in order to evaluate the fracture type, the beginning of the crack growth, the crack growth angle and the crack growth path. This procedure was established on the basis of a set of criteria developed in the recent studies carried out by the authors [Li J, Zhang XB, Recho N. J-M^p based criteria for bifurcation assessment of a crack in elastic-plastic materials under mixed mode I-II loading. Engng Fract Mech 2004;71:329-43; Recho N, Ma S, Zhang XB, Pirodi A, Dalle Donne C. Criteria for mixed-mode fracture prediction in ductile material. In: 15th European conference on fracture, Stockholm, Sweden, August 2004]. A new criterion, by combining experimentation and numerical calculation, was developed in this work in order to predict the beginning of the crack growth. Second, in the case of cyclic loading, the crack growth path and crack grow rate are studied. A series of mixed-mode experiments on aluminium and steel specimens were carried out to analyse the effect of the mixed mode on the crack growth angle and the crack growth rate. On the basis of these experimental results, a fatigue crack growth model was proposed. The effect of the mixed mode on the crack growth rate is considered in this model. The numerical results of this model are in good agreement with the experimental results.     

Analysis and design of dual-phase steel microstructure for enhanced ductile fracture resistance

The goal of this paper is to predict how the properties of the constituent phases and microstructure of dual phase steels (consisting of ferrite and martensite) influence their fracture resistance. We focus on two commercial low-carbon dual-phase (DP) steels with different ferrite/martensite phase volume fractions and properties. These steels exhibit similar flow behavior and tensile strength but different ductility. Our experimental observations show that the mechanism of ductile fracture in these two DP steels involves nucleation, growth and coalescence of micron scale voids. We thus employ microstructure-based finite element simulations to analyze the ductile fracture of these dual-phase steels. In the microstructure-based simulations, the individual phases of the DP steels are discretely modeled using elastic-viscoplastic constitutive relations for progressively cavitating solids. The flow behavior of the individual phases in both the steels are determined by homogenizing the microscale calibrated crystal plasticity constitutive relations from a previous study (Chen et al. in Acta Mater 65:133–149, 2014) while the damage parameters are determined by void cell model calculations. We then determine microstructural effects on ductile fracture of these steels by analyzing a series of representative volume elements with varying volume fractions, flow and damage behaviors of the constituent phases. Our simulations predict qualitative features of the ductile fracture process in good agreement with experimental observations for both DP steels. A ‘virtual’ DP microstructure, constructed by varying the microstructural parameters in the commercial steels, is predicted to have strength and ductile fracture resistance that is superior to the two commercial DP steels. Our simulations provide guidelines for improving the ductile fracture resistance of DP steels.     

On the mechanism of fatigue crack propagation in ductile metallic materials

An overview of our research performed during the last 15 years is presented to improve the understanding of fatigue crack propagation mechanisms. The focus is devoted to ductile metals and the material separation process at low and intermedial crack propagation rates. The effect of environment, short cracks, small‐scale yielding as well as large‐scale yielding are considered. It will be shown that the dominant intrinsic propagation mechanism in ductile metallic materials is the formation of new surface due to blunting and the re‐sharpening during unloading. This process is affected by the environment, however, not by the length of the crack and it is independent of large‐ or small‐scale yielding.     

Dynamic crack propagation in large steel specimens

Dynamic fracture experiments on crack initiation and crack growth in single edge bend specimens are performed. The impact velocity is in the range of 14 to 50 m/s and the specimen size is 320×75 mm with a thickness varying from 18 to 40 mm. The experiments are recorded by high speed photography.Two different steel qualities are investigated and their constitutive characterisation are obtained from uni-axial tension tests and shear tests with strain rates in the range 10⁻⁴ to 10³ s⁻¹ and tension tests at temperatures between −196 and 600°C.One of the materials exhibits a transition from a ductile dimple fracture to a brittle cleavage fracture as the loading velocity increases and as the specimen thickness increases. Scanning electron microscope fractographs show that the density of plastic bridges within cleavage ligaments decreases with increasing impact velocity and with increasing specimen thickness. It is also noted that the local crack propagation direction deflects from the global one in cleavage fracture areas with a high density of plastic bridges.The other material fails in a ductile mode in all the investigated cases.     

Simulation of hot-rolled dual-phase weathering steel 09CuPCrNi

The continuous cooling transformation diagram of deformed austenite for steel 09CuPCrNi was constructed by means of a combined method of dilatometry and metallography. The diagram exhibits an elongated polygonal ferrite C-curve with a delayed pearlite start and a metastable austenite gap between the polygonal ferrite and pearlite regions and between the ferrite and bainite regions. For this experimental steel, it is possible to obtain a dual-phase microstructure directly by hot rolling and appropriate cooling. Based on the diagram, the technical process of a hot-rolled dual-phase treatment was established and simulated using a thermal simulation testing machine. Dual-phase microstructures were obtained that show some bainite phase and are characterized by an irregular distribution of island-shaped martensite in a matrix of equiaxed ferrite grains. The morphology of the martensite phase is essentially of the lath type, with small areas of micro-twins appearing.     

Damage driven crack initiation and propagation in ductile metals using XFEM

Originally Continuum Damage Mechanics and Fracture Mechanics evolved separately. However, when it comes to ductile fracture, an unified approach is quite beneficial for an accurate modelling of this phenomenon. Ductile materials may undergo moderate to large plastic deformations and internal degradation phenomena which are well described by continuum theories. Nevertheless in the final stages of failure, a discontinuous methodology is essential to represent surface decohesion and macro-crack propagation. In this work, XFEM is combined with the Lemaitre ductile damage model in a way that crack initiation and propagation are governed by the evolution of damage. The model was built under a finite strain assumption and a non-local integral formulation is applied to avoid pathological mesh dependence. The efficiency of the proposed methodology is evaluated through various numerical examples.     

Boundary element analysis of fatigue crack propagation micromechanisms in austempered ductile iron

The Dual Boundary Element Method (DBEM) is used in this work to model the micro mechanics of fatigue crack propagation in austempered ductile iron (ADI). Emphasis is put in devising accurate procedures for the evaluation of the interaction effects between very close crack–microcrack arrays. Fracture parameters are computed via the so-called one-point displacement formula using special crack-tip elements. Crack propagation is modelled using an incremental crack extension analysis; with crack extensions calculated using a propagation law that accounts for the near-threshold regime. Obtained results are in agreement with experimental observations, providing evidence to fracture mechanics models proposed in the literature.     

Simulation of ductile crack growth in thin panels using the crack tip opening angle

The aim of this work is the assessment of the efficiency of the crack tip opening angle (CTOA) with respect to the transferability from one geometry to another, in particular the transferability obtained from Kahn tear tests to M(T) panels. The load-displacement behaviour recorded during a Kahn tear test was reproduced by means of finite element analysis using a variable CTOA as a function of crack length. The CTOA extracted from Kahn tests has then been used to simulate the R-curve of M(T) panels with different widths. Experiments and simulations were run first on a 6013-T6 aluminium alloy and then also on butt, friction stir welded butt joints of the same material.