J and CTOD estimation formulas for C(T) fracture specimens including effects of weld strength overmatch

This work focuses on an evaluation procedure to determine the elastic?Cplastic J-integral and Crack Tip Opening Displacement (CTOD) fracture toughness based upon the ??-method for C(T) fracture specimens made of homogeneous and welded steels. The primary objective of this investigation is to enlarge on previous developments of J and CTOD estimation procedures for this crack configuration while, at the same time, addressing effects of strength mismatch on the plastic ??-factors. The present analyses enable the introduction of a larger set of factors ?? for a wide range of crack sizes (as measured by the a/W-ratio) and material properties, including different levels of weld strength mismatch, applicable to pipeline and pressure vessel steels. Very detailed non-linear finite element analyses for plane-strain and 3-D models of C(T) fracture specimens with centerline-cracked welds provide the evolution of load with increased load-line and crack mouth opening displacement required for the estimation procedure. Overall, the present study, when taken together with previous investigations, provides a fairly extensive body of results to determine parameters J and CTOD for different materials using C(T) specimens with varying overmatch conditions.     

The non-constant CTOD/CTOA in stable crack extension under plane-strain conditions

Contrary to the previous work that successfully applied the constant CTOD/CTOA fracture criteria to relatively thin structures, this paper demonstrates that the initial non-constant portion of the CTOD/CTOA plays an essential role in predicting fracture behavior under plane-strain conditions. Three- and two-dimensional finite element analyses indicate that a severe underestimation of the load would occur as the crack extends if a constant CTOD/CTOA criterion were used. However, the use of a simplified, bilinear CTOD/CTOA criterion to approximate its non-constant portion will closely duplicate the test data. Furthermore, using the experimental data from J-integral tests with various crack length to specimen width ratios (a/W), it is demonstrated that the critical CTOD/CTOA is crack tip constraint dependent. The initial high values of the CTOD/CTOA are in fact a natural consequence of crack growth process that is reflected by, and consistent with, the J-resistance (J-R) curve and its slope (tearing modulus).     

A crack propagation criterion based on ΔCTOD measured with 2D‐digital image correlation technique

The fatigue cracks growth rate of a forged HSLA steel (AISI 4130) was investigated using thin single edge notch tensile specimen to simulate the crack development on a diesel train crankshafts. The effect of load ratio, R, was investigated at room temperature. Fatigue fracture surfaces were examined by scanning electron microscopy. An approach based on the crack tip opening displacement range (ΔCTOD) was proposed as fatigue crack propagation criterion. ΔCTOD measurements were carried out using 2D‐digital image correlation techniques. J‐integral values were estimated using ΔCTOD. Under test conditions investigated, it was found that the use of ΔCTOD as a fatigue crack growth driving force parameter is relevant and could describe the crack propagation behaviour, under different load ratio R.     

Effects of crack depth on elastic-plastic fracture toughness

Short crack test specimens (a/W 0.50) are frequently employed when conventional deep crack specimens are either inappropriate or impossible to obtain, for example, in testing of particular microstructures in weldments and in-service structures containing shallow surface flaws. Values of elastic-plastic fracture toughness, here characterized by the crack tip opening displacement (CTOD), are presented for square (cross-section) three-point bend specimens with a/W ratios of 0.15 and 0.50 throughout the lower-shelf and lower-transition regions. Three dimensional, finite-element analyses are employed to correlate the measured load and crack mouth opening displacement (CMOD) values to the corresponding CTOD values, thus eliminating a major source of experimental difficulty in previous studies of shallow crack specimens. In the lower-transition region, where extensive plasticity (but no ductile crack growth) precedes brittle fracture, critical CTOD values for short crack specimens are significantly larger (factor of 2–3) than the CTOD values for deep crack specimens at identical temperatures. Short crack specimens are shown to exhibit increased toughness at the initiation of ductile tearing and decreased brittle-to-ductile transition temperatures. Numerical analyses for the two a/W ratios reveal large differences in stress fields ahead of the crack tip at identical CTOD levels which verify the experimentally observed differences in critical CTOD values. Correlations of the predicted stresses with measured critical CTOD values demonstrate the limitations of single-parameter fracture mechanics (as currently developed) to characterize the response.     

Study of elastic-plastic fracture toughness determination

The elastic-plastic fracture toughness viaJ-integral and crack tip opening displacement (CTOD) has been obtained in two structural steels using several fitting equations representing the resistance curve of the material. The toughness is determined as the values corresponding to the critical stretched zone width (SZW) on theR-curves and with respect to 0.2 mm crack growth. The SZW measurements were performed by scanning electron microscopy. The various toughness values have been compared and the importance of using appropriateR-curves based on physical considerations has been pointed out. TheJ-CTOD relationship during the blunting process has been experimentally investigated from load-displacement records of the fracture test.     

高强船体钢双丝埋弧焊焊接接头CTOD试验研究

根据GB／T2358—1994标准,对16ram厚的高强船体钢焊接接头的焊缝中心-40℃的裂纹尖端张开位移（CTOD）进行测试,绝大部分试样的断裂韧性值是有效合格的,其CTOD值大于0．15mm,符合DNV验收标准。试验结果表明,在给定的双丝埋弧焊接工艺下,该钢种焊缝低温韧性好。该钢种中等厚度双丝埋弧焊焊接接头可以在不进行焊后热处理的情况下使用。     

THE ETM METHOD FOR ASSESSING THE SIGNIFICANCE OF CRACK-LIKE DEFECTS IN ENGINEERING STRUCTURES

The Engineering Flaw Assessment Method, EFAM, is presently being developed at GKSS. It consists of several individual documents for determining material properties and the crack driving force. The present paper briefly describes the document EFAM ETM 97 which provides guidance for estimating the crack tip opening displacement (CTOD) and the J-integral as driving force parameters for homogeneous structures. The CTOD and J can be expressed as functions of applied force or applied strain.     

Effects of weld strength mismatch on <Emphasis Type="Italic">J</Emphasis> and CTOD estimation procedure for SE(B) specimens

This work examines the effect of weld strength mismatch on fracture toughness measurements defined by J and CTOD fracture parameters using single edge notch bend (SE(B)) specimens. A central objective of the present study is to enlarge on previous developments of J and CTOD estimation procedures for welded bend specimens based upon plastic eta factors (η) and plastic rotational factors (r _p ). Very detailed non-linear finite element analyses for plane-strain models of standard SE(B) fracture specimens with a notch located at the center of square groove welds and in the heat affected zone provide the evolution of load with increased crack mouth opening displacement required for the estimation procedure. One key result emerging from the analyses is that levels of weld strength mismatch within the range ±20% mismatch do not affect significantly J and CTOD estimation expressions applicable to homogeneous materials, particularly for deeply cracked fracture specimens with relatively large weld grooves. The present study provides additional understanding on the effect of weld strength mismatch on J and CTOD toughness measurements while, at the same time, adding a fairly extensive body of results to determine parameters J and CTOD for different materials using bend specimens with varying geometries and mismatch levels.     

The effect of specimen thickness on the experimental and finite element characterization of CTOD in extra deep drawn steel sheets

Recent experimental results by us have indicated that the load-drop technique can serve as a valid fracture criterion for predicting elastic-plastic fracture in extra deep drawn (EDD) steel sheets or in predominantly plane stress conditions. The purpose of this investigation is to examine the validity of aJ-integral as a fracture parameter and theJ-CTOD relation for the determination of critical CTOD in predominantly plane stress fracture (CTOD-crack tip opening displacement). Fracture tests were performed and experimental results were generated on fracture behaviour of EDD (0·06%C) steel sheets with CT specimens and using ‘load-drop’ as a fracture criterion. Critical CTOD was determined by using theJ-CTOD relation in addition to several existing techniques. A full 3-D finite element model was formulated to verify the critical load, critical CTOD and plastic-zone size. The critical CTOD was shown to increase with increasing specimen thickness and appeared to be approaching a higher limiting value. The characteristic features of predominantly plane stress fracture or general yielding fracture mechanics are summarized in conclusion     

DAMAGE MECHANICS APPROACH TO REMOVE THE CONSTRAINT DEPENDENCE OF ELASTIC–PLASTIC FRACTURE TOUGHNESS

It is now generally agreed that the applicability of a one-parameter J-based ductile fracture approach is limited to so-called high constraint crack geometries, and that the elastic-plastic fracture toughness J_1c, is not a material constant but strongly specimen geometry constraint-dependent. In this paper, the constraint effect on elastic-plastic fracture toughness is investigated by use of a continuum damage mechanics approach. Based on a new local damage theory for ductile fracture(proposed by the author) which has a clear physical meaning and can describe both deformation and constraint effects on ductile fracture, a relationship is described between the conventional elastic-plastic fracture toughness, J_1c, and crack tip constraint, characterized by crack tip stress triaxiality T. Then, a new parameter J_dc (and associated criterion, J_d=J_dc) for ductile fracture is proposed. Experiments show that toughness variation with specimen geometry constraint changes can effectively be removed by use of the constraint correction procedure proposed in this paper, and that the new parameter J_dc is a material constant independent of specimen geometry (constraint). This parameter can serve as a new parameter to differentiate the elastic-plastic fracture toughness of engineering materials, which provides a new approach for fracture assessments of structures. It is not necessary to determine which laboratory specimen matches the structural constraint; rather, any specimen geometry can be tested to measure the size-independent fracture toughness J_dc. The potential advantage is clear and the results are very encouraging.     

Mechanisms and modeling of low cycle fatigue crack propagation in a pressure vessel steel Q345

The fatigue process near crack is governed by highly concentrated strain and stress in the crack tip region. Based on the theory of elastic–plastic fracture mechanics, we explore the cyclic J-integral as breakthrough point, an analytical model is presented in this paper to determine the CTOD for cracked component subjected to cyclic axial in-plane loading. A simple fracture mechanism based model for fatigue crack growth assumes a linear correlation between the cyclic crack tip opening displacement (ΔCTOD) and the crack growth rate (da/dN). In order to validate the model and to calibrate the model parameters, the low cycle fatigue crack propagation experiment was carried out for CT specimen made of Q345 steel. The effects of stress ratio and crack closure on fatigue crack growth were investigated by elastic–plastic finite element stress–strain analysis of a cracked component. A good comparison has been found between predictions and experimental results, which shows that the crack opening displacement is able to characterize the crack tip state at large scale yielding constant amplitude fatigue crack growth.     

A framework to correlate a/W ratio effects on elastic-plastic fracture toughness (J c )

Single edge-notched bend (SENB) specimens containing shallow cracks (a/W < 0.2) are commonly employed for fracture testing of ferritic materials in the lower-transition region where extensive plasticity (but no significant ductile crack growth) precedes unstable fracture. Critical J-values J _c ) for shallow crack specimens are significantly larger (factor of 2–3) than the J _c )-values for corresponding deep crack specimens at identical temperatures. The increase of fracture toughness arises from the loss of constraint that occurs when the gross plastic zones of bending impinge on the otherwise autonomous crack-tip plastic zones. Consequently, SENB specimens with small and large a/W ratios loaded to the same J-value have markedly different crack-tip stresses under large-scale plasticity. Detailed, plane-strain finite-element analyses and a local stress-based criterion for cleavage fracture are combined to establish specimen size requirements (deformation limits) for testing in the transition region which assure a single parameter characterization of the crack-tip stress field. Moreover, these analyses provide a framework to correlate J _c )-values with a/W ratio once the deformation limits are exceeded. The correlation procedure is shown to remove the geometry dependence of fracture toughness values for an A36 steel in the transition region across a/W ratios and to reduce the scatter of toughness values for nominally identical specimens.     

Resistance Against the Intrinsic Rate of Fracture Mechanics Parameters for Polymeric Materials Under Moderate Impact Loading

This study contributes towards understanding crack toughness as resistance against the intrinsic rate of fracture mechanics parameters. Up to now only few investigations have been done under moderate impact loading conditions. Based on experimental investigations using the crack resistance (R) concept, it has been shown that the stop block method combined with the multiple-specimen technique is a unique method for polymers under impact loading conditions in comparison with different R-curve methods. Other methods for the determination of R curve such as the low-blow technique are normally not applicable for polymers due to their time-dependent mechanical properties. The crack-tip opening displacement (CTOD) rate is a measurement of the rate sensibility of stable fracture process depending on the type of deformation, which can provide deep insights into the micromechanics and activation mechanisms during the fracture processes. In the polymeric materials mostly investigated, one can understand the stable crack propagation with three-stage processes; crack-tip blunting/crack initiation, non-stationary stable crack growth and steady-state stable crack growth (an equilibrium state). In this stable crack propagation, the values of normalized CTOD rate converge rapidly to a ‘matrix’-specific threshold. The stop block method in the multiple-specimen technique assures the criteria of the time-independent strain field around the crack tip and constant crack speed therewith and the J-integral is a valid toughness parameter.     

A review of the J and I integrals and their implications for crack growth resistance and toughness in ductile fracture

The application of the J and the I-integrals to ductile fracture are discussed. It is shown that, because of the finite size of the fracture process zone (FPZ), the initiation value of the J-integral is specimen dependent even if the plastic constraint conditions are constant. The paradox that the I-integral for steady state elasto-plastic crack growth is apparently zero is examined. It is shown that, if the FPZ at the crack tip is modelled, the I-integral is equal to the work performed in its fracture. Thus it is essential to model the fracture process zone in ductile fracture. The I-integral is then used to demonstrate that the breakdown in applicability of the J-integral to crack growth in ductile fracture is as much due to the inclusion in the J-integral of progressively more work performed in the plastic zone as it is to non-proportional deformation during unloading behind the crack tip. Thus J _R -curves combine the essential work of fracture performed in the FPZ with the plastic work performed outside of the FPZ. These two work terms scale differently and produce size and geometry dependence. It is suggested that the future direction of modelling in ductile fracture should be to include the FPZ. Strides have already been made in this direction.     

The Use of Crack-Tip Opening Displacement for Testing of the Hydrogen Embrittlement of High-Strength Steels

Stress-corrosion cracks are, as a rule, brittle and often encountered under stresses much lower than the yield strength. For this reason, the methods of linear elastic fracture mechanics (LEFM) can be used for the investigation of stress-corrosion cracking (SCC). However, in some cases, these methods are inapplicable, and it is necessary to use the methods of so-called elastoplastic fracture mechanics (EPFM). In the EPFM approach, the J-integral is the most commonly used parameter for correlating crack initiation and propagation but the crack-tip opening displacement (CTOD) and crack-tip opening angle (CTOA) prove to be promising alternatives, especially for thin-sheet materials. Since both these parameters are connected with the crack geometry and, hence, reflect the level of strain at the crack tip, they appear to be useful correlation parameters for the cases of SCC, where the level of strain in the vicinity of the crack tip and, in particular, the strain rate, are the determining variables of the process. The hydrogen embrittlement of a higher-strength structural steel and welded joints of a C-Mn steel is assessed by using the CTOA and CTOD methodologies. In constant-extension-rate tests (CERT), fatigue precracked specimens were loaded with various low strain rates and electrolytically charged with hydrogen. It was discovered that hydrogen embrittlement significantly affects the crack-growth resistance curves (R-curves) thus generated and the opening angle for which the crack propagates into the material.__________Published in Fizyko-Khimichna Mekhanika Materialiv, Vol. 40, No. 6, pp. 35–40, November–December, 2004.     

Mechanical heterogeneity and validity of J-dominance in welded joints

Fracture criterion of the J-integral finds wide application in the integrity evaluation of welded components, but there exist some confused problems such as the dependence of the fracture toughness on the strength mis-matching and specimen geometry which need to be clarified. It is rough and unsuitable to attribute the variation of J-integral fracture parameter simply to the effect of mechanical heterogeneity. In the present paper, a two-dimensional finite element method is employed to analyze the distribution and variation of crack tip field of welded joints with different strength mis-matching in four kinds of specimen geometry, and then the validity of J-dominance in welded joints is investigated. It is found that the crack tip field of mis-matched joint is different from that of either the weld metal or base metal of which the joint is composed, but it is situated between those of weld metal and base metal. Under the plane strain, there is obvious difference in stress triaxiality for different strength mis-matched joints. The validity of J-dominance in welded joint can not be obtained by comparing whether the stress triaxiality meets that required by the HRR solution because of the existence of mechanical inhomogeneity. By ascertaining if the stress triaxiality of welded joint near the crack tip is dependent of specimen geometry, the conclusion can be arrived at: for plane stress the validity of J-dominance is valid, whilst for plane strain the validity of J-dominance is lost. Based on the above, attempt has been made to point out that the influence of mechanical heterogeneity on the fracture toughness of weldment arises from the variation of constraint intensity-crack tip stress triaxiality. Compared with the effect of mechanical heterogeneity on the stress triaxiality, the losing of validity of J-dominance in mis-matched joint under plane strain may play a more critical role in the variation of J-integral fracture parameter of weldment.     

Constraint-corrected fracture failure criterion based on CTOD/CTOA

In engineering design, a difficulty has always existed in those standard laboratory tests that cannot accurately predict the behavior of large structures like pipelines due to the different constraint levels. At present, extensive work has been done to characterize the constraint effects on fracture toughness by introducing a second parameter, while the systematic research on constrained transformation is inadequate. To address this issue, the ductile fracture process of X65 SENB specimen is simulated through the finite-element method coupled with the Gurson–Tvergaard–Needelman model. The parameters crack tip opening displacement (CTOD) and crack tip opening angle (CTOA) are chosen to characterize the fracture behaviors. The effects of specimen thickness on fracture toughness based on CTOD/CTOA and constraints ahead of crack tips in SENB specimen are studied. The results indicate that the critical values of CTOD/CTOA decrease with the increase of specimen thickness, but the constraint parameters are opposite. Furthermore, it finds that there is a near linear relationship between critical values of CTOD/CTOA and the stress constraint ahead of the crack tip. Thus, a constraint-corrected fracture failure criterion based on CTOD/CTOA is proposed, which can be used for the prediction and simulation of stable tearing crack growth in specimens and structures, made of this steel with any thickness value.     

Characterization of fracture toughness of high strength low alloy steel weldments using stretch zone width measurements

Most of the industrial applications involving use of high-strength low-alloy steels require good weldability. Thus it is important to characterize the properties of the welded steels, especially the heat affected zone. Attempts have been made to characterize the fracture toughness of the HAZ by the use of theJ-integral and the crack opening displacement. In the present study, the effect of addition of titanium, vanadium and niobium, as well as combinations of these, on the fracture toughness of the heat affected zone of welded steel plates is examined. Six compositions were used in this study. Three-point bending specimens as well as tensile specimens were prepared. The fracture surfaces were examined in a scanning electron microscope to determine the fracture mode as well as the extent of the stretch zone as the crack blunts. Calculation of the fracture toughness parameter,J _lc, is carried out through a quantitative stereofractographic analysis of the stretch zone at the crack tip. The results show that there is a marked increase inJ _lc due to the addition of the various alloying elements. Generally, the addition of niobium and titanium alone produce the highestJ _lc due to the extent of grain refinement that these elements produce.     

The measurements of fracture toughness of ductile materials

Near tip strain is proposed as a ductile fracture criterion. This criterion was used to study the onset of slow growth of surface crack. The data from two batches, B and C, of fully annealed 2024-0 aluminum alloy and HY-80 steel substantiated the proposed criterion. The measured fracture toughness at the onset of surface crack growth are 280, 110 and 800 ksi √in. for these three materials respectively. It was demonstrated that the measurement can be made easily with a small foil resistance strain gage. The near tip strain criterion was compared with both crack surface opening displacement and J-integral criteria.     

Accounting for constraint effects in fracture mechanics analysis of floating production, storage and off-loading vessels and ships

Research has been performed to study the effect of constraint dependent fracture toughness of parent metal and HAZ for steels applied for fabrication of oil and gas floating production, storage and off-loading (FPSO) vessels and ships. A test method was employed to study the HAZ crack tip opening displacement (CTOD) fracture toughness at various levels of constraint avoiding excessive scatter usually associated with conventional HAZ CTOD testing, which may obscure effects of constraint.The objective of the research was to determine the material dependent constraint parameters in Ainsworth and O'Dowd's constraint modified fracture assessment approach and to develop a method based on information from the literature pertaining to the structural constraint in plates with semi-elliptical surface cracks. Results due to Wang and Parks and Nakamura and Parks computed using line-spring and FE analyses were used to establish polynomial expressions for the structural constraint in tension and bending applicable to fracture assessment of shallow fatigue cracks initiated at weld toes in floating offshore structures such as FPSOs.The results of the analyses clearly show that fracture assessment of semi-elliptical surface cracks in tension would be overly conservative if constraint effects are not accounted for in the Option 1 or Option 2 fracture assessment curves or in fracture toughness. It was also found from the tests conducted on specially prepared wide-plate test specimens, that the constraint modified Option 1 curve was conservative for fracture assessment of semi-elliptical surface cracks located in the HAZ of a 500 MPa minimum specified yield strength quenched and tempered steel for offshore application.