Interaction of residual stress with mechanical loading in a ferritic steel

A well-defined residual stress field was introduced into modified single edge notched bend, SEN(B), specimens by the ‘in-plane compression’ procedure in order to investigate the interaction between residual stress and applied mechanical loading. Numerical predictions of the residual stress field arising from the in-plane compression procedure are given along with details of the numerical fracture modelling and experimental fracture test results made on A533B ferritic steel specimens in the lower transition region at −150 °C. Use was made of a recently developed finite element post-processor capable of determining path-independent J-integral values in the presence of residual stress fields. The paper compares the experimental results to predictions made using a probabilistic ‘global approach’ based on the conventional crack-tip parameters K and J and predictions made using a well-known structural integrity assessment code, R6 (Revision 4). It is shown that obtaining more accurate estimates of the crack driving force created by residual stresses leads to better correlation between experiments and predictions, and less conservatism in the assessment code.     

Observations on fatigue crack paths in the corners of cold-formed high-strength steel tubes

Fatigue crack propagation in cold-formed corners of high-strength structural steel plate-type structures has been investigated. Large- and small-scale test specimens having complex residual stress states and subject to multi-axial cyclic local stresses have been investigated using both laboratory tests and numerical simulations. The combinations of alternating bending stress, alternating shear stress and static mean stress producing complex multi-axial stress states have been found to influence the fatigue crack path behaviour. Straight, zig-zag and “S” shaped cracks were observed depending on the material strength, range of cyclic loading, residual stress field and multi-axiality of the local stresses. Numerical simulations of residual stresses and linear elastic fracture mechanics were used to help understand the alternate crack paths. Mode I cracks propagating into a static compressive stress field did not arrest, but, due to the multi-axial stresses, combinations of mixed mode I, II and III crack growth with distinct paths were observed. The crack paths depend on the type and range of cyclic loading, material properties and residual stress conditions of the specimens.     

Determination of Remnant Residual Stresses in Fracture Toughness Specimens Extracted From Large Components

Abstract: Material fracture toughness data are required to undertake fitness‐for‐service assessments of engineering components containing cracks. Calculations of crack driving force in the component are compared with material fracture toughness values to assess the likelihood of subsequent failure. Experimental measurements of fracture toughness are usually made on small specimens extracted from a larger ‘parent’ component following strict experimental guidelines, formulated to ensure measured toughness values in the fracture specimens are appropriate for use in the full‐size component. Implicit in this procedure is the assumption that the extracted fracture specimens contain no residual stresses, with any residual stresses in the full‐size component being accounted for in the crack driving force calculation. This paper considers a recent conjecture within the structural integrity community that the extracted fracture specimens may themselves contain a residual stress field which may influence measurements of fracture toughness. This could potentially lead to a degree of ‘double accounting’, i.e. the effect of residual stresses may be included in both the material toughness and the crack driving force. This, in turn, could lead to unnecessary conservatism in safety assessments. To explore this conjecture, the results of numerical modelling and neutron diffraction measurements of residual stresses in fracture specimens extracted from two different welded parent components are presented. One of the components is significantly larger than the extracted specimens, with the other being marginally larger than the extracted specimens. Results confirm the intuitive expectation that the residual stresses in specimens extracted from much larger components are negligible, whereas if the dimensions of the extracted specimens are comparable with the larger component then significant residual stresses may remain.     

Effect of residual stresses on ductile crack growth resistance

It is well known that residual stresses influence the ductile fracture behaviour. In this paper, a numerical study was performed to assess the effect of residual stresses on ductile crack growth resistance of a typical pipeline steel. A modified boundary layer model was employed for the analysis under plane strain, Mode I loading condition. The residual stress fields were introduced into the finite element model by the eigenstrain method. A sharp crack was embedded in the center of the weld region. The complete Gurson model has been applied to simulate the ductile fracture by microvoid nucleation, growth and coalescence. Results show that tensile residual stresses can significantly reduce the crack growth resistance when the crack growth is small compared with the length scale of the tensile residual stress field. With the crack growth, the effect of residual stresses on the crack growth resistance tends to diminish. The effect of residual stress on ductile crack growth resistance seems independent of the size of geometrically similar welds. When normalized by the weld zone size, the ductile crack growth resistance collapses into one curve, which can be used to assess the structural integrity and evaluate the effect of residual stresses. It has also been found that the effect of residual stresses on crack growth resistance depends on the initial void volume fraction f₀, hardening exponent n and T-stress.     

Quasistatic fracture behaviour and defect assessment of brazed soft martensitic stainless steel joints

Brazed components are widely applied in industry and are often subjected to complex loading conditions. Even if such components often contain brazing defects, no failure assessment procedures for brazed joints are reported in the literature. In this work, the deformation and the quasistatic behaviour of brazed joints of the martensitic stainless steel X3CrNiMo13-4 were investigated. This includes the determination of stress–strain-curves as well as of the fracture toughness. In addition, the mechanical behaviour of components such as specimens with T-joint geometry under tensile loading were characterized. In order to consider the effect of brazing defects on the structural integrity, typical defects with different sizes and geometries were introduced in the brazing zone. The experimentally determined material parameters were used for additional numerical deformation analyses by means of finite elements (FE). Both the experimental and the numerical results were in good agreement with predictions according to the R6 method and provided a basis for the engineering defect assessment of brazed components based on failure assessment diagrams.     

Residual stress and constraint effects on cleavage fracture in the transition temperature regime

Defects in structural components are often associated with welds that may contain significant levels of residual stress. Whilst the primary load acting on the component may induce low constraint conditions at the crack tip, the presence of residual stresses, e.g. due to welding, can modify this constraint level and consequently influence the observed fracture toughness behaviour. This paper presents the results of a combined experimental and numerical programme aimed at exploring this issue. Cleavage fracture toughness data for high and low constraint specimens are presented with and without residual stresses. The results indicate that under certain conditions, the constraint-induced increase in cleavage fracture toughness may be eroded by the presence of a residual stress in the vicinity of the crack. The results are quantified with respect to two-parameter fracture mechanics in which the  T  and  Q  parameters are appropriately defined. Preliminary guidance is provided for the assessment of defects when residual stresses may influence crack-tip constraint.     

The effect of a residual stress field on fracture initiation in RPV steel

Whether flaws in structures containing residual (secondary) stresses will extend under particular operational (primary) loads depends on the extent to which the residual stress field affects: (a) the nature and distribution of initiators; (b) the combined (primary + secondary) stresses and strains experienced by potential initiators. This paper compares fractographic data from specimens loaded by only a primary stress with data from specimens also containing a tensile residual stress field. Three‐dimensional elastic–plastic finite element calculations are used to characterize the stress–strain conditions at the initiation sites at the onset of brittle fracture. The introduction of a residual stress changes the dominant stage in fracture nucleation from microcrack extension to particle cracking. This offsets some of the decrease in fracture toughness expected when the residual stress field increases specimen constraint.     

Variables affecting the fatigue resistance of PVD-coated components

The effect of intrinsic properties of CrN coatings on fatigue behaviour was studied in this paper. The coating layer microhardness and the residual stresses characterising the surface film were measured and the obtained results were introduced in a numerical modelling predicting fatigue life procedure of coated components. The effect of a CrN monolayer film deposited on bulk samples, produced in 2205 duplex stainless steel, H11 tool steel or 6082 aluminium alloy was investigated. The fatigue limit of coated and uncoated samples was experimentally determined while the development of FEM models, confirmed by means of experimental tests, represents a powerful tool to predict fatigue life of coated components. The effects on the fatigue strength of coating and bulk material defects like droplets and non-metallic inclusions were considered along with the residual stress gradient characterising the coating and evaluated by means of X-ray measurements. The influence of the substrate material plastic deformation on the integrity of the coating was evaluated too.     

Fatigue life prediction for stainless steel welded plate CCT geometry based on Lawrence''s local-stress approach

In the present study, the effect of welding process and procedure on fatigue crack initiation from notches and fatigue crack propagation in AISI 304L stainless steel welds was experimentally investigated. Full penetration, double-vee butt welds have been fabricated and CCT type specimens were used. Lawrence's local-stress approach (a two-stage model) is used to predict the fatigue life. The notch-root stress method was applied to calculate the fatigue crack initiation life, while the fatigue crack propagation life was estimated using fracture mechanics concepts. The fatigue notch factor is calculated using Lawrence's approach. Constant amplitude fatigue tests with stress ratio, R=0 were carried out using 100 kN servo-hydraulic DARTEC universal testing machine with a frequency of 30 Hz. The predicted lives were compared with the experimental values. A good agreement has been reached. It is found that the weld procedure has a stronger effect on lives to initiation than on propagation lives.     

Using local out-of-plane compression (LOPC) to study the effects of residual stress on apparent fracture toughness

To study and understand the effects of residual stresses on fracture behaviour, it is necessary to introduce well characterised and reproducible residual stresses into laboratory fracture specimens. One technique capable of providing such residual stresses is local compression, where the local compression is applied to the sides of a test specimen. In this paper, the technique is used to create a residual stress field in compact tension, C(T), specimens. The specimens are used subsequently to study the effects of residual stress on fracture. Finite element studies show that significant changes to the distribution of the residual stresses occur when the position of the compression tools is changed relative to the crack tip. It is also revealed that both a single and double pair of compression tools can generate both tensile and compressive residual stresses in the vicinity of the crack tip depending upon the location of the tools relative to the crack tip. The impact of local compression is illustrated by experimental results from room temperature fracture tests performed on two aluminium alloys, Al2650 and Al2024. Tensile residual stresses, created by the application of a single pair of compression tools, reduced the initiation fracture toughness of Al2650 by about one half. The ductile tearing resistance of Al2024 decreases when a double pair of tools introduces tensile residual stresses. Conversely, the tearing resistance increases when compressive residual stresses are created through local compression.     

Behaviour of sub-clad and through-clad cracks under consideration of the residual stress field

Aim of the present study is an assessment of the behaviour of cracks in the ferritic base metal of components supplied with an austenitic welded cladding under special consideration of the residual stress field caused by the welding and heat treatment processes. For this purpose, an experimental and numerical investigation has been performed. The experimental study consisted of two component tests at low temperature using large-scale specimens with sub-clad and surface cracks. Subsequently, the experiments were analyzed numerically where the residual stress field was determined in an advanced numerical simulation of the welding and heat treatment processes. Based on the results, a fracture mechanics assessment of the ferritic and austenitic material zones on crack initiation and arrest was performed. The experimental and numerical results reveal that fracture was initiated in the ferritic range whereas the austenitic cladding remained intact even in the case of a limited crack extension in the base metal underneath the cladding.     

Evaluation of Equibiaxial Compressive Stress Introduced into Austenitic Stainless Steel Using an Eddy Current Method

Equibiaxial compressive residual stress is introduced into steel after peening in order to improve both its resistance to stress corrosion cracking and its fatigue strength. Thus, a nondestructive and relatively quick method to evaluate the equibiaxial compressive residual stress in a surface layer modified by peening is required in order to evaluate the peening intensity needed to enhance the integrity of structural components. The purpose of the work reported here is to establish an eddy current method to evaluate equibiaxial compressive stress which can be applied to the residual stress introduced into various non-ferromagnetic materials after peening. To this end, hydraulic jacks were used to elastically deform specimens of the austenitic stainless steel, Japanese Industrial Standard (JIS) SUS316L, thereby introducing an equibiaxial compressive stress. In the case of SUS316L steel, stress-induced martensitic transformation is rare. The electromagnetic properties of these specimens were then measured. In addition, the eddy current signals from peened specimens were compared with these. The results demonstrate that it is possible to establish a method for evaluating the equibiaxial stress utilizing eddy current signals.     

Adhesion of lacquer to phosphated steel — A shear test evaluation

Measurement of the adhesion toughness of a fast cure thermosetting powder coating used for corrosion protection of cold-rolled steel has been attempted in a shear test under uniform plane stress loading conditions at the interface. A specially designed test specimen preparation procedure (by direct crosslinking) and geometry (symmetrical) was developed to enable proper mechanical behaviour under shear initiation of fracture and uniform plane stress loading in the significant section of the specimen — the interface. The shear test was designed to measure the nominal and the net ultimate shear stress values (USS)_n and (USS)_net' as well as the critical stress intensity factor (SIF) of interfaces. From experimentally measured critical load at which the adhesion failed, the ultimate shear stress values (USS_net N mm^–2) were calculated and used as a quantitative information of the bond toughness along the interfaces. The experimental results with a range of specimens revealed that the test can, indeed, discern subtle variations influencing adhesion such as type of cold-rolled steel, an iron phosphate pretreatment before coating or variation in stoving temperatures. Fractographic analysis of shear failed specimens on mating surfaces revealed generation of a microcrack network in most of the fracture pattern tested, indicating fracture mechanism transitions characteristic of pure shear for both iron phosphated free cold-rolled steel-lacquer (SL) as well as for iron phosphated cold-rolled steel-lacquer (SPL) specimens. The fractographs, however, indicate fracture propagation more difficult for SPL specimens and comparatively smooth fracture surface for SL specimens, obviously affected by variations in their respective interface structure and morphology. This behaviour correlates well with measurements of (USS)_net in test.     

Analysis of the unstable fracture behaviour of a high strength low alloy steel weldment

Local brittle zones (LBZ) cause the unstable fracture behaviour of weld metals. This threatens the safe service of welded structures and makes structural assessment procedures difficult. Therefore, the unstable fracture behaviour of an overmatched high strength low alloyed steel weldment was experimentally investigated. It showed that any interaction between two adjacent weld metal matrix and soft weld metal inclusions produces LBZ, causing local unstable fracture behaviour. The formation of a low hardness region is attributed to the multipass welding reheating process between Ac₁ and the self-tempering temperature. The presence of partly solid metallic inclusions with a high content of alloying elements and pro-eutectoid ferrite microstructure were found to be additional causes for the local unstable fracture behaviour of the weld metal. Local strength mis-match induced the yielding and strain hardening in the soft weld metal inclusions, contributing significantly to unstable fracture behaviour. Thus, a significantly different scatter of experimental results can be obtained. In the cases of specimens with through-the-thickness crack, not only is the scatter significantly lower, but the toughness itself.     

THE FRACTURE BEHAVIOUR OF AN AXIAL CRACK IN A PRESSURISED PIPE

Abstract— The multiple specimen technique was developed to measure the crack growth fracture resistance of a through axial crack in a pressurised pipe and the results compared with data measured from test specimens. The comparison indicates that there is no significant difference between pipe and specimen behaviour. The results are also compared with elastic-plastic three-dimensional finite element analyses of the pipe and the R6 failure assessment curve. Reasonably good agreement was found between the experimental results and finite element analyses. The experimental results all lie outside the material specific failure assessment curve of the R6 structural integrity assessment procedure.     

Influence of residual stresses on fracture behaviour: An experimental study

The grinding process is known to induce high magnitudes of tensile residual stresses beneath a surface which are responsible for development of cracks over the ground surface. In this paper, measurements of mouth opening displacement (MOD) values have been used to determine the influence of residual stresses on MOD values of ground specimens. The results show the influence of residual stresses on fracture behaviour of ground mild steel plates.     

Comparison of dynamic initiation toughness measured by strain gauges and the shadow optical method

The deformation and fracture behaviour in dynamically loaded Charpy specimens of BS11 rail steel were studied by two different measuring techniques. The transient records obtained from straingauges were compared with results obtained simultaneously by the shadowoptical method. Good agreement was obtained when measuring and comparing the stress intensity factor K in the initial stages of deformation behaviour prior to crack initiation. During fast fracture, the shadow optical method indicated the influence of dynamic effects on crack propagation.     

Apparent fracture toughness of low-carbon steel CSN 411353 as related to stress corrosion cracks

The occurrence of cracks in structural components indicates a certain threat to their reliable operation, because these cracks can grow during operation and reach critical sizes, leading to fracture. The fracture resistance of a structural component is given by the fracture toughness of the material, determined on standardized specimens with a precycled fatigue crack, and the constraint. The fracture toughness itself depends also on the environment. There is enough evidence that in the conditions of the environment assisted cracking the fracture toughness can be significantly reduced by hydrogen mechanism. Our research results have confirmed this and have demonstrated a considerable reduction in the stress corrosion fracture toughness as compared to that related to fatigue cracks. This should be taken into account when assessing the integrity of structural components with stress corrosion cracks. This paper presents experimental results concerned with the stress corrosion fracture toughness of specimens from a DN150 gas line pipe made of low-C steel CSN 411353.     

The influence of partial surface shot peening on fatigue crack growth behaviour of a high‐strength ferritic steel

The effects of partial surface shot peening on the fatigue crack growth behaviour of a ferritic steel have been experimentally investigated in this paper. Dog‐bone specimens fabricated from Optim700QL were tested under tension‐tension fatigue loads. Three distinct extents of partial shot peening, with respect to the crack tip and specimen symmetry line, were tested. The fatigue crack growth results from these experiments have been compared with those obtained from the same specimen geometry but with no peening. The results show that the residual stress fields formed ahead of the initial notch tip due to the partial peening process play a significant role in the fatigue crack growth behaviour of the material and effectively result in accelerated crack propagation at the midwidth of the specimens. It has been shown in this study that partial peening can lead to a fatigue crack growth rate around twice as fast as that of the unpeened specimen.     

Stress–strain curves of metallic materials and post‐necking strain hardening characterization: A review

For metallic materials, standard uniaxial tensile tests with round bar specimens or flat specimens only provide accurate equivalent stress–strain curve before diffuse necking. However, for numerical modelling of problems where very large strains occur, such as plastic forming and ductile damage and fracture, understanding the post‐necking strain hardening behaviour is necessary. Also, welding is a highly complex metallurgical process, and therefore, weldments are susceptible to material discontinuities, flaws, and residual stresses. It becomes even more important to characterize the equivalent stress–strain curve in large strains of each material zone in weldments properly for structural integrity assessment. The aim of this paper is to provide a state‐of‐the‐art review on quasi‐static standard tensile test for stress–strain curves measurement of metallic materials. Meanwhile, methods available in literature for characterization of the equivalent stress–strain curve in the post‐necking regime are introduced. Novel methods with axisymmetric notched round bar specimens for accurately capturing the equivalent stress–strain curve of each material zone in weldment are presented as well. Advantages and limitations of these methods are briefly discussed.