A photoelastic determination of Ki stress intensity factors

The quantitative relation between the exact solution of the stress field at the vicinity of a crack tip derived fron Westergaard's formulation and the well-known Irwin singular solution was established and results obtained were correlated with photoelastic data for the study of the reigon near the crack tip. The maximum shear stress distribution expressed by the isochromatic pattern for the exact and the singular solution were calculated respectively for uniaxial and biaxial tension. The region where accurate measurements in the isochromatic pattern are possible to evaluate the stress intensity factor to any desired decree of accuracy was established and the extrapolation law for the analysis of the region near the crack tip from data obtained fron the far-field of isochromatics was demonstrated. Experimental evidence corroborated this technique. The method was compared with other already existing experimental methods for the determination of K_I.     

Spannungsfaktoren eines Risses in der Umgebung eines Kreisloches und ihr Einfluß auf das Bruchverhalten

Stress Intensity Factors in the Neighbourhood of a Circular Hole and their Influence on Crack Behavior . A photoelastic method was developed to determine the stress intensity factors K_I and K_II for cracks subjected to mixed-mode loading. The constants in the near field expansion about the crack tip were computed using a non-linear optimization program to give a best fit to the observed isochromatics. Copying the latter onto an equal density film increased their sharpness and, thus, the accuracy of the determination. The method was applied to cracks lying perpendicular to the external stress near a circular hole in a plate under uniaxial tension and the results used to describe the paths of cracks in the neighbourhood of a hole.     

On the photoelastic determination of complex stress intensity factors

An improvement of the one-parameter extrapolation method of photoelastic determination of complex (mixed-mode) stress intensity factors at straight or curvilinear crack tips in a plane isotropic elastic medium due to Smith et al. [12, 13] can be achieved by measuring the absolute value of such a factor on the isochromatic fringes along properly selected polar directions and not at the maxima of the isochromatic fringes. In this way, the unknown value of the constant term of the stress field near the crack tip is taken into account. It is seen that it is always possible to find at least one appropriate polar direction to measure the absolute value of the stress intensity factor. In the case of Mode I stress intensity factors, these polar angles are = ± 120° and not = ± 90° as generally considered previously. Some numerical results are also presented in this special case and show the efficiency of the present method.     

Interactions of a sub-surface crack with a center of dilatation in an elastic half-plane

This paper examines the interaction between a crack parallel to the free surface of an elastic half-plane and an internal center of dilatation. The problem is decomposed into two auxiliary problems. When the center of dilatation approaches the crack tip, two kinds of singularity are analytically obtained. If the overburden stress and the friction on crack surface are neglected, both modes I and II stress intensity factors (K_I and K_II) are induced at the crack tips. The maximum of K_I and K_II occurs when the center of dilatation is located in front of the crack tips. The tensile cracking is likely to be prohibited by the overburden stress, while shear cracking remains possible even including the effects of both overburden and friction on the crack surface.     

Piezoelectric sensor for stress intensity factor measurement of two dimensional cracks

A piezoelectric sensor for the measurement of stress intensity factors (SIFs) of two dimensional cracks induced in a structure is developed. Two small pieces of piezoelectric elements are adhered near the crack tip so that the piezoelectric elements are placed close to each other and the crack tip’s position is between them. The electric currents from the piezoelectric elements are integrated by integration circuits and the output voltages which are proportional to the electric charge induced in the piezoelectric elements are measured. The SIFs of Mode I (K_I) as well as of Mode II (K_II) based on the piezoelectric constitutive law and fracture mechanics are calculated.     

Elastodynamic forms of caustics for running cracks under constant velocity

For the study of elastodynamic problems of propagating cracks it is necessary to evaluate the dynamic stress intensity factor K^d_I, which depends on the form of expressions for the stress components existing at the running crack tip at any instant of the propagation of the crack and the corresponding dynamic mechanical and optical properties of the material of the specimen under identical loading conditions. In this paper the distortion of the form of the corresponding reflected caustic from the lateral faces of a dynamically loaded transparent and optically inert specimen containing a transverse crack running under constant velocity was studied on the basis of complex potential elasticity theory and the influence of this form on the value of the dynamic stress intensity factor was given. The method was applied to the study of a propagating under Mode I crack in a PMMA specimen under various propagation velocities and the corresponding dynamic stress intensity factor K^d_I, evaluated.     

Stress intensity factors for coalescing and single corner flaws along a hole bore in a plate

The objective of this paper is to describe the effects of crack interaction on stress intensity factors for two symmetric coplanar corner flaws located along a hole bore. This numerical analysis employes the Finite Element-Alternating Method to determine Mode I stress intensity factors for single and coalescing corner flaws. Using single flaw stress intensity factors as a reference, analysis of crack size and shape effects on $\text{K}{}_{\mathrm{I}}$ for coalescing corner flaws indicates the stress intensity factor for crack points along the hole bore increases as the crack tip separation distance decreases. Interaction effects are not experienced by hole bore crack points when the crack tip separation distance is equal to or greater than half of the largest corner flaw dimension.     

A computational model and experimental validation of shielding and amplifying effects at a crack tip near perpendicular strength-mismatched interfaces

The stress field around the crack tip near an elastically matched but strength-mismatched interface body in a bimetallic system is influenced when the crack tip yield or cohesive zone spreads to the interface body. The concept of crack tip stress intensity parameter, K _tip, is therefore employed in fracture analysis of the bimetallic body. A computational model to determine K _tip is reviewed in this paper. The model, based upon i) Westergaard??s complex potentials coupled with Kolosov?CMuskhelishvili??s relations between a crack tip stress field and complex potentials and ii) Dugdale??s representation of the cohesive zone clearly indicates shielding or amplifying effects of strength mismatch across the interface, depending upon the direction of the strength gradient, over the crack tip. The model is successfully validated by conducting series of high cycle fatigue tests over Mode I cracks advancing towards various strength-mismatched interfaces in bimetallic compact tension specimens prepared by electron beam welding of elastically identical weak ASTM 4340 alloy and strong MDN 250 maraging steels.     

A theoretical analysis of the stress intensity factors varying along the front of a surface crack

Using an equivalent through-crack model (ETCM), a theoretical analysis of the stress intensity factors, K _I, along the front of semicircular and part-circular surface cracks under mode I loading is carried out to study the variation of K _I. The results of the theoretical calculation agree satisfactorily with the experimental data obtained by photoelastic stress freezing [1]. It means that the ETCM method can be used accurately to solve the surface crack problem and especially, to predict the elastic behavior of the crack on the free surface layer.     

Analysis of stress intensity factors of modes I,II and III for inclined surface cracks of arbitrary shape

The analysis of stress intensity factors K_I, K_II and K_III by the body force method is developed for an arbitrarily shaped surface crack. The stress intensity factors for basic problems as semielliptical cracks, rectangular cracks and triangular cracks inclined to tensile axis at the surface of a semiinfinite body are numerically calculated.Defining the polar coordinate system (r, θ) on the plane which is perpendicular to both the plane of crack and the line of crack front, we can determine the stress intensity factor K_gq which prescribes the stress field of the tangential stress σ_gq. The maximum value K_θmax of K_gq, along the crack front can be expressed by the approximate formula: K_{θ max} ≅ 0.650 σ₀√π√area_p; Poisson's ratio v = 0.3, where area_pis the crack area projected in the direction of the maximum principal stress σ₀. The limitation and application rule of the approximate formula is also described.     

An investigation of the edge-sliding mode in fracture mechanics

A boundary collocation procedure has been applied to the Williams stress function to determine the elastic stress distribution for the crack tip region of a finite, edge-cracked plate subjected to mode II loading at the crack tips. The asymmetric specimen selected was particularly suitable for the determination of plane strain fracture toughness for mode II loading. Numerical solutions for stress intensity factors for the edge-sliding mode obtained by the boundary collocation method were in close agreement with values obtained from photoelastic experiments.Fracture tests of several compact shear specimens of 2024-T4 aluminum were conducted in order to experimentally investigate the behavior of the edge-sliding mode. In each case a brittle shear failure was observed and mode II fracture toughness values were obtained. The average value for K_IIc obtained from two tests was 39.5 ksi(in)^{$\text{1}\text{2}$}. No K_Ic. data for 2024-T4 were available for comparison purposes; however, K_Ic values for a similar alloy, 2024-T351, have been reported as 34ksi(in)^{$\text{1}\text{2}$} which is only about 15 per cent below the corresponding K_IIc value.     

Slip initiation on frictional fractures

Direct shear tests and biaxial compression tests are conducted to investigate the onset of slip along a non-homogeneous frictional surface and to determine the effect of specimen thickness and confining stress on slip initiation and propagation. The specimens are made of two and three acrylic blocks with the contact surfaces between blocks having on their upper half a frictional strength smaller than on their lower half. This creates a “weak” surface on the upper half and a “strong” surface on the lower half. The specimens are then loaded in direct shear or biaxial compression with confining pressures ranging from 0.7 to 3.5 MPa. The onset of slip, slip propagation, and the stress field generated at the front and center of the blocks interfaces are monitored using a photoelastic technique where a thin photoelastic film is placed at the location where observations are made. The onset of slip at the weak-strong zone interface is treated as propagation of a frictional crack under Mode II loading. The critical stress intensity factor, K_IIC, at the onset of slip is obtained from photoelastic techniques. The results show a weak dependency of K_IIC on the normal stress applied and no influence of the specimen size for specimens thicker than 25.4 mm; for thinner specimens the K_IIC values are smaller because the boundaries of the specimen prevent the full development of the stress field ahead of the crack tip. The experiments show a linear increase of the critical energy release rate with normal stress which is explained with linear elastic fracture mechanics theories.     

A fracture mechanics model for the analysis of micro-pitting in regard to lubricated rolling–sliding contact problems

A computational model is presented for the analysis of micro-pitting in regard to lubricated rolling–sliding contact problems. This model assumes the appearance of an initial microcrack on the contact surface due to the mechanical or thermal treatment of the material, and as a consequence of an on-going process in early the stage of exploitation. The discretised model of the contacting mechanical elements is subjected to normal loading (Hertzian contact pressure), tangential loading (friction between contacting surfaces) and internal pressure to the crack surfaces. Crack propagation is predicted as follows: (1) using modified maximum tangential stress criterion, which takes into account the influence of stress intensity factors K_I and K_II, T-stress, stress on the crack’s surface caused by lubricant pressure inside the crack, and the critical distance ahead of the crack tip and (2) the classical maximum tangential stress criterion, which only takes into account the influence of the stress intensity factors K_I and K_II. The stress intensity factor based on these two criteria is then used in a short crack growth theory to determine the fatigue life of an initial crack to extent up to micro-pit. The developed model is applied to a real spur gear pair.     

Stress intensity factor analyses of interface cracks between dissimilar anisotropic materials using the finite element method

Delamination along an interface between dissimilar materials is the primary cause of failure in microstructures like electronic packages, micro-electro-mechanical systems (MEMS), and so on. Fracture mechanics is a powerful tool for the evaluation of delamination. However, many materials used in microstructures such as composite materials and single crystals are anisotropic materials. Stress intensity factors of an interface crack between dissimilar anisotropic materials, which were proposed by Hwu, are useful for evaluating the reliability of microstructures. However, numerical methods that can analyze the stress intensity factors of an interface crack between anisotropic materials have not been developed. We propose herein a new numerical method for the analysis of an interface crack between dissimilar anisotropic materials. The stress intensity factors of an interface crack are based on the generalized plane strain condition. The energy release rate is obtained by the virtual crack extension method in conjunction with the finite element method for the generalized plane strain condition. The energy release rate is separated into individual modes of the stress intensity factors K_I, K_II, and K_III, using the principal of superposition. The target problem to be solved is superposed on the asymptotic solution of displacement in the vicinity of an interface crack tip, which is described using the Stroh formalism. Analyses of the stress intensity factors of center interface cracks between semi-infinite dissimilar anisotropic media subjected to concentrated self-balanced loads on the center of crack surfaces and to uniform loads are demonstrated. The present method accurately provides mode-separated stress intensity factors using relatively coarse meshes for the finite element method.     

Finite element analysis of a subsurface crack

The problem of a subsurface crack parallel to the surface of a half space was studied by the finite element method. Without using the interface or gap elements over the crack faces, the crack faces would penetrate into each other for the traction-free boundary condition under shear loading, which is physically impossible. Using the gap elements, this problem was avoided, and a contact zone was observed near one crack tip. The size of the contact zone decreases but the maximum contact pressure at the closed crack tip increases as the crack approaches the surface. For tensile and shear loadings, both K _I (mode I stress intensity factor) and K _II (mode II stress intensity factor) increase as the crack approaches the surface. For shear loading there is no K _I at the closed tip and the K _I and K _II at the open tip are comparable as the crack approaches the surface.     

Crack tip shielding by asperity contact as determined by acoustic measurements

Asperity contact along the fracture surface of a crack is one of the mechanisms of crack closure. This contact shields the crack tip, in part, from the externally applied driving force. We have now succeeded in using information from acoustic transmission and diffraction experiments, obtained under plane strain conditions, to determine the size and density of the contacting asperities in the closure region. We have also succeeded in estimating values for the static stress across a partially closed crack as well as the stress intensity factor,K_I (local), which shields the crack tip below the stress intensity factor K_Iclosure at which the first contact during unloading occurs. It is suggested that when crack closure has an important influence on crack propagation, the shielding stress intensity factor provides information that can be used to estimate the fatigue crack propagation rate.     

Prediction of fatigue crack growth under constant amplitude loading and a single overload based on elasto-plastic crack tip stresses and strains

It is generally accepted that the fatigue crack growth (FCG) depends mainly on the stress intensity factor range (ΔK) and the maximum stress intensity factor (K_max). The two parameters are usually combined into one expression called often as the driving force and many various driving forces have been proposed up to date. The driving force can be successful as long as the stress intensity factors are appropriately correlated with the actual elasto-plastic crack tip stress-strain field. However, the correlation between the stress intensity factors and the crack tip stress-strain field is often influenced by residual stresses induced in due course.A two-parameter (ΔK_tot, K_max,tot) driving force based on the elasto-plastic crack tip stress-strain history has been proposed. The applied stress intensity factors (ΔK_appl, K_max,appl) were modified to the total stress intensity factors (ΔK_tot, K_max,tot) in order to account for the effect of the local crack tip stresses and strains on fatigue crack growth. The FCG was predicted by simulating the stress-strain response in the material volume adjacent to the crack tip and estimating the accumulated fatigue damage. The fatigue crack growth was regarded as a process of successive crack re-initiations in the crack tip region. The model was developed to predict the effect of the mean and residual stresses induced by the cyclic loading. The effect of variable amplitude loadings on FCG can be also quantified on the basis of the proposed model. A two-parameter driving force in the form of: was derived based on the local stresses and strains at the crack tip and the Smith-Watson-Topper (SWT) fatigue damage parameter: D = σ_maxΔε/2. The effect of the internal (residual) stress induced by the reversed cyclic plasticity manifested itself in the change of the resultant (total) stress intensity factors controlling the fatigue crack growth.The model was verified using experimental fatigue crack growth data for aluminum alloy 7075-T6 obtained under constant amplitude loading and a single overload.     

Corrosion Fracture of Structural Metallic Materials: Effect of Electrochemical Conditions in Crack

Abstract: The work is a compressed review based on the summarised results and the original approach for study of corrosion crack growth, taking into account local electrochemical conditions in the crack tip, which was developed at the Karpenko Physico‐Mechanical Institute of NASU. The model scheme of the pre‐fracture zone in the corrosion crack tip, which can be defined by the local values of pH of solution, electrode potential of metal E and stress intensity factor K_I is proposed. For its realisation, the special method and testing equipment for corrosion crack growth study and local electrochemical measurements in the crack were developed. The variation of the electrochemical conditions in corrosion cracks was studied, and it has been found that some stabilised levels of the pH and E values can be achieved in the tip of a non‐propagating and a propagating crack under static and cyclic loading during of exposure time. On this ground, the method for forecasting of the threshold stress intensity factor K_ISCC under stress corrosion cracking was proposed using these characteristic values of pH and E. This method was also adopted for the determination of the threshold stress intensity factor K_th under corrosion fatigue. The special method for determining corrosion fatigue crack growth rate diagrams based on consideration of extreme electrochemical conditions in the crack tip was developed. It has been proven that such diagrams reflect the extreme influence of the environmental factor on corrosion fracture of material, and they may be recommended as the base for the remaining lifetime calculation of the structural elements exploited under environmental conditions.     

Crack border stress and displacement equations revisited

It is more or less accepted in fracture mechanics that the elastic stress and displacements very near to the tip of a plane line crack can be approximated with sufficient accuracy, for all geometries and outer boundary loading conditions, by. a one-parameter representation, i.e. strictly in terms of the stress intensity factors K_I and/or K_II. It is shown here that this presumption which appears to be reasonable on face value, quantitatively speaking, is nevertheless unacceptable as a general proposition. The reason lies with the quite arbitrary practice of omitting the second term of the series representation for the stresses, a contribution which is independent of distance from the crack tip. It is not difficult to show by way of specific examples how such omission can lead to error of serious qualitative nature in the prediction of stress and displacement related quantities of interest.     

The evaluation of stress intensity factors in plate bending problems using the dual boundary element method

This paper discusses the application of the boundary element method for the determination of stress intensity factors in plate bending problems. A number of case studies having a range of plan forms, with different combinations of boundary conditions, crack configurations and loading conditions are presented to illustrate the effectiveness of the boundary element method for the fracture analysis of plates. Results of K_I, K_II and K_III stress intensity factors for linear elastic fracture mechanics are presented for the case studies considered. The J-integral method, the displacement extrapolation method, the quarter point approach and the stress extrapolation method have been used to determine the stress intensity factors. The boundary element results for the case studies considered in the paper have been compared with either analytical or finite element results and in all cases good agreement has been achieved.