Exploring the fracture toughness KIE and KIC of a medium-Strength steel plate using the surface-flaw test

The fracture toughness of a 30 CrMnSiA steel plate of three thicknesses (10,8 and 5 mm) and three widths (110,80 and 56 mm) has been investigated by using surface-flaw method under room temperature. It is not easy to compute the value of K_IE by the maximum applied load. But the values of K_IE and K_IC could be obtained easily, if the computation of the conditional applied load P₁₀ and P₅ based on the relative effective extension Δa/a₀ = 10% and 5% were adopted, together with the conditions of P_max/P₁₀ 1.2 and P_max/P₅ 1.3. The K_R — Δ_a curve, i.e. the resistance-curve described by the parameter K, has been plotted. The values of K_IC and K_IE are then the resistances corresponding to the real extensions of flaws of Δ/a₀ = 2 and 7%, respectively. These values so obtained are in good agreement with the computed values of K_IC and K_IE by using the conditional applied loads. The values of K_IC and K_IE so obtained are also in agreement with the value of K_IC converted from the J-integral and the effective value of K_IE computed by the maximum applied load, respectively.

An approximate relation between K_IC and K_IE has been found to be: K_IC = (0.85˜0.95)K_IE.

The requirements for the dimensions of specimens are: Thickness of plate: B 1.0(K_IC/σ_0.2)² or 1.25(K_ICσ_0.2)²]; Width of plate: 8 W/B 10, 4 W/2c 5; Effective length: l 2W.     

Comparison of fracture toughness test procedures for aluminum alloys

The Dynamic Tear (DT) test permits the measurement of fracture propagation energy across the toughness spectrum for metals which are definable by linear elastic analyses to those requiring gross plastic strains for fracture. The linear elastic fracture mechanics parameter K_ic provides a relationship between critical flaw size and stress level at which crack instability will occur. Unlike the DT test, the K_ic toughness test cannot be utilized for fracture under conditions of elastic-plastic or gross plastic strain.

A correlation has been developed between the DT test and the K_IC parameter for ahuminum alloys. The relationship may also be expressed in terms of β_ic-DT and _ic-DT. The K_ic values were determined with several specimen types and a comparison of the values for different specimens is provided.

The correspondence between K_ic and DT serves several purposes. It provides a frame of reference for DT values obtained from frangible metals that fracture under linear elastic conditions. Accordingly, it permits utilization of the inexpensive DT test to approximate the flaw size-stress instability conditions which otherwise must be determined by the more expensive K_ic test. Furthermore, through extrapolation, it is possible to utilize the DT test to estimate the critical flaw size under an elastic-plastic strain field.     

Studies on fracture toughness and fractographic features in Fe---Mn base alloys

Fractographic examinations of fracture surfaces of single edge crack plate tension fracture toughness test specimens of some new Fe---Mn base maraging alloys have been conducted. The interrelations between the fractographic features, fracture toughness and other mechanical properties of these alloys have been studied. It is observed that the width of the stretched zone between fatigue and rapid fracture is related to K/σ_ys of the material where K is either K_IC, K_Q or the stress intensity for onset of microscopic slow crack growth. The stretched zone width is approximately equal to the average dimple size. Also it is of the order of the process zone size (calculated by modified Krafft's model) and the critical crack opening displacement in plane strain condition. Hahn and Rosenfield's model to estimate K_Ic was found to show much higher values in those cases where the fracture mode was predominantly cleavage, quasicleavage or intergranular.     

Principle and method for determining fracture toughness of structural steel by side-cut se (B)

In this paper, the principle and method for determining fracture toughness indexes K_IC, δ_C and J_IC of structural steel by side-cut SE (B) are introduced. This method has many advantages: clear critical point, simple operation, stable date, less cost and will be valuable to use more frequently.     

On the influence of microstructure on crack propagation mechanisms and fracture toughness of metallic materials

A survey is given on the effect of microstructure on crack propagation mechanisms and fracture toughness.

The influence of inclusions and of the material's matrix are treated separately. An attempt was made to correlate some simple, but typical microstructures with corresponding crack propagation mechanisms and to establish a qualitative sequence of these microstructures with respect to their effect on K_IC. Because of the lack of sufficient experimental evidence this attempt is necessarily incomplete.

Finally, some K_IC-calculations are compared with measured values.     

Fracture toughness of turbine-generator rotor forgings

A comprehensive program is being conducted relative to applying fracture mechanics technology to large turbine-generator rotors. One facet of this program involves the determination of plane-strain fracture toughness (K_Ic) over a range of temperatures for various types of rotor steels. Data have been obtained for ten large production forgings, representing three alloys, using various types of compact K_IC and spin burst test specimens. These results demonstrate that valid K_IC data can be obtained in these types of intermediate-strength, high-toughness steels in the temperature range of practical interest. Data indicate that the plane-strain fracture toughness of these steels increases rapidly with increasing temperature and is rather high (K_tc/σ_YS > 1 in^1/2), in the application range. As a result, the critical defect sizes for catastrophic failure upon a single cycle of loading are relatively large. The plane-strain fracture toughness measurements, as well as the application of these data, are presented and discussed.     

Combined stress hypothesis for mixed-mode fracture toughness criterion

A new hypothesis is presented for determining the mixed-mode fracture toughness criterion of brittle materials such as rocks, cement and ceramics. The obtained criterion gives a reasonable result, which is in good agreement with published data. The data, obtained here for mixed-mode fracture toughness of flyash eement paste, confirm also the use of the hypothesis for the problem of fracture toughness, including negative K_IC.     

The scatter in KIC-results

Scatter in K_IC-results can often be quite extensive, and to make reliable interpretations of the results it is of great importance to understand the nature of it. Cleavage fracture in steels is of a statistical nature and therefore the scatter in K_IC-results will behave similarly.

Two different approaches, one based on a microstructural statistical model and an other based on the Weibull distribution are applied to evaluate the theoretical scatter in K_IC-results. With both methods it is shown that the theoretical value of the relative scatter described through the Weibull slope factor is constant and equal to four.

The reason for the discrepancy between the theoretical value and the experimentally determined values of the slope factor is shown to be caused by inadequate number of experimental K_IC-measurements. The existence of a lower limiting K_min value is verified and a simple procedure for conservative estimation of the K_Ic-mean and lower bound values is presented.     

Studies of the effect of metal particles on the fracture toughness of ceramic matrix composites

The purpose of this study was to describe the influence of metal particles on the fracture toughness of ceramic matrix composites. Here, alumina matrix composites with molybdenum particles have been investigated. The results presented show that the change of fracture toughness of a ceramic–metal composite can be controlled by the volume fraction of metallic phase and size of metal particles.

The model proposed in this paper describes the change of crack length and as a consequence, the change of K_IC value. The results of modelling calculations have been compared with experimentally measured K_IC values. This model is useful for simulation of crack length changes in the composites and to design a material with an optimum fracture toughness.     

Fabrication and mechanical properties of glass fibre reinforced thermoplastic elastomer composite

The paper investigates the effects of fabrication conditions on mechanical properties of glass fibre reinforced thermoplastic elastomer composites. The impregnation time was varied between 5 and 30 min and the cooling conditions were rapid and gradual cooling. Tensile testing was carried out on samples with different fibre orientations. Double Cantilever Beam (DCB) tests were carried out to evaluate the fracture toughness of the composites. The degree of crystallinity and morphology of the composite were studied by using differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). Impregnation of matrix resin into glass fibre was found to be complete before 30 min and tensile properties increased with increasing impregnation time. SEM micrographs of fractured surfaces revealed poor adhesion between the matrix and the reinforcing agent. Due to the flexible nature of the composite, the fracture toughness (G_IC) could not be determined because of the formation of ridges on the surface.     

Experimental investigation of fracture surface energy of a solid propellant under different loading rates

Fracture tests on solid propellants have been performed under three ranges of loading rate leading to fracture toughness results in terms of J_IC and (Andrews' parameter). Using two different specimen shapes, finite size effects have been pointed out (considering SENT sample) when dealing with Andrews' theory and a modified equation, taking into account the specimen compliance, is proposed. Significant influence of loading rate on J_IC is observed leading to few conclusions concerning fracture process of solid propellants.     

A comparison on the effect of the ratio a/w on the fracture behaviour between ductile and brittle materials

The effect of the ratio a/W on the fracture behaviour of ductile and brittle materials has been studied by measuring the crack-opening displacement and J-integral for ductile material and the stress intensity factor for brittle material in three-point bend specimens with shallow and deep notches. It is shown that, for ductile material, the values of δ_i and J_i, for specimens with shallow notches are larger than those of deep notches. On the contrary, for brittle material, the values of K_IC for specimens with shallow notches are smaller than those of deep notches. The reason for this is explained.     

Stress intensity factors and energy release rates of delaminations in composite laminates

Due to the oscillatory characteristics of stresses near interface crack tips, the stress intensity factor K_i, i = I, II, III, should be modified and the energy release rate G_i, i = 1, 2, 3, of each fracture mode calculated by the virtual crack closure method may not exist. Based upon a near-tip solution for interface cracks between dissimilar anisotropic media, a proper definition for the stress intensity factors and energy release rates for general anisotropic bimaterial interface cracks is provided in this paper, which is applicable for the delaminated composites. Moreover, this definition can be reduced to the classical definition for a crack tip in homogeneous media when the two materials become the same. A simple quadratic relation between K_i and _Gi is derived, which is further reduced explicitly for orthotropic bimaterials. The influence of fiber orientation and the coupling among opening, shearing and tearing mode fracture are studied numerically. The results show that the classical stress intensity factors and energy release rates are still the dominant stress intensity and energy release rate of the mixed mode condition induced by the interface.     

Dynamic fracture toughness parameters for HY-80 and HY-130 steels and their weldments

Lower bound dynamic fracture toughness parameters for HY-80 and HY-130 steel and their weld metals are identified. Specific values of the parameters K_Id and K_Im obtained from direct measurements are reported together with estimates inferred from the large body of Charpy energy, nil ductility transition temperature and dynamic tear energy measurements. The emphasis is on reasonable lower bound values at 30°F, the lowest anticipated service temperature, for use in elastodynamic analyses of crack growth initiation, propagation, and arrest in ship structures. For these conditions, it has been found that the ratio K_Id/ σ_Y is approximately equal to 2 in^1/2 for HY-80 steel. For HY-130 steel and the HY-80 and HY-130 weld metals under these same conditions, K_Id/ σ_Y is approximately 1 in^1/2. Consequently, HY-80 plate appears to be substantially more resistant to fracture under dynamic loading than are the other three grades examined.     

Application of instrumented impact testing for studying dynamic fracture behaviour of rotor steels

The viability of the instrumented Charpy impact testing for studying dynamic fracture behaviour of rotor steels is investigated. This encompasses determination of dynamic fracture toughness (K_Id) and dynamic J-integral (J_Id), establishing correlation between oscilloscope profiles and fracture morphology of the ruptured samples and identifying fracture mechanisms involved. The predicted oscilloscope profiles for common fracture modes, their experimental counterparts, and the inferences drawn from these concerning operating fracture mechanisms are in good accord with the fractographic observations made on broken samples. Thus, the respective oscillographs vividly manifest the observed variations in the fracture processes. Fracture mechanics analysis of load-time and energy-time records of pre-cracked Charpy samples gave dynamic fracture toughness (K_Id) values of 43, 74 and 124MN/m3/2, and dynamic J-integral (J_Id) values of 0.008, 0.03 and 0.06 MJ/m² at −180°, 26° and 96°C respectively. It is possible that the deduced J_Id values correspond to a small but finite amount of crack extension instead of Zero Crack extension, in line with the emerging trends of J_Id estimation. Apart from increasing with temperature, both parameters recorded a true transition around 35°C which is attributed to the combined influence of a change in the fracture mode and relaxation of crack tip constraint. Another significant outcome of this investigation concerns about the existence of a minimum crack depth ratio for valid J_Id determination which, based on a detailed fractographic study, is interpreted in terms of the collective influence of crack tip plasticity and notch constraint.     

Dynamic fracture toughness at crack initiation, propagation and arrest for two pipe-line steels

The influences of temperature and loading rate on fracture toughness of two pipe-line steels at initiation, K_1d, and at arrest, K_1a, and on stretch zone height were measured using specific techniques. Particular attention was given to the mechanism of delamination, typical for the gas internal pressure pipe fracture.     

Influence of specimen size and configuration on the plastic zone size, toughness and crack growth

The main purpose of this investigation is to evaluate the effect of the thickness, width, aspect ratio and geometry of the fracture toughness specimen on the resultant displacement due to growth of plastic zone and crack.

The analytical part evaluates the effect of the width, aspect ratio, geometry and flow properties on the displacement due to the growth of plastic zone as well as the crack. The experimental part evaluates the effect of thickness and width of a compact tension specimen on the displacement and on the thickness direction contraction due to the growth of the plastic zone.

The main result of the investigation is that the plastic zone size decreases and the constraint to yielding increases as the width of a CT specimen increases. Based on this and other analytical and experimental result, a new procedure for the determination of K_IC has been proposed. The procedure is verified by experimental data obtained by other workers. The procedure overcomes the limitation of ASTM E399 for the determination of K_IC.     

Weight function calculations for mixedmode fracture problems with the virtual crack extension technique

An efficient finite element method is presented for calculating the stress intensity factors (K_I and K_II) and the weight functions for mixed-mode cracks with one virtual crack extension. The computational efficiency is enhanced through the use of singular elements and the application of colinear virtual crack extension (VCE) technique to symmetric mesh in cracktip neighborhood. This symmetric mesh in crack-tip vicinity permits the analytical separation of strain energy release rate into G_I for Mode I and G_II for Mode II for the mixed fracture problems with the colinear virtual crack extension.

Rice's displacement derivative representation of weight function vector for symmetric crack has been extended to the mixed fracture mode at nodal location (x_i,y_i) with crack length (a) and inclination angle (β) as h_I(II)(x_i, y_i, a, β) = (H/2K_I(II)(∂U_I(II)(x_i, y_i, a, β/∂a).

This equation permits explicit determination of weight functions for the entire structure of a given asymmetric crack geometry with colinear VCE technique. The explicit weight functions for mixed fracture mode depend strongly on the constraint conditions. The method of obtaining the required stress intensity factors of a given asymmetric crack geometry, from the weight function concept under the selected constraint conditions, which are different from constraint conditions used in the available weight functions for the same crack geometry, is also presented in this paper. This is accomplished by combining the predetermined explicit weight functions with the self-equilibrium forces at their application locations. These self-equilibrium forces include both the applied surface tractions and the reaction forces induced from the constraint conditions.     

Effect of electroslag refining on the fracture toughness and fatigue crack propagation rates in heat treated AISI 4340 steel

The AISI 4340 steel has been electroslag refined and the improvement in mechanical properties has been assessed. Electroslag refining (ESR) has improved tensile ductility, plane strain fracture toughness, Charpy fracture energy, and has decreased fatigue crack growth rates. The K_IC values for the ESR steel are nearly twice those estimated in the unrefined steel and higher than those obtained in the vacuum arc remelted steel. Fatigue crack growth rates in region I and in region III are found to be decreased considerably in the ESR steel, while they are unaffected in region II. Measurements on heat treated samples have shown that the ESR steel has a better response to heat treatment. Both the suggested heat treatments namely austenitizing at 1140–1470 K as well as the conventional heat treatment of austenitizing at 1140 K have been followed. The improvement in the mechanical properties of ESR steel has been explained on the basis of removal of nonmetallic inclusions and reduction in sulfur content in the steel.     

Relationship between microstructure and fracture behavior of bioabsorbable HA/PLLA composites

Hydroxyapatite particles of four different shapes, that is, micro, nano, spherical and plate, were used to fabricate hydroxyapatite filled poly(l-lactic acid) (HA/PLLA) composites. Effects of HA particle shape on the fracture behavior of HA/PLLA were investigated by mode I fracture testing, fracture surface measurement and scanning electron microscopy. It was found that the micro-HA/PLLA has the highest critical energy release rate, G_IC, with the largest surface roughness, while G_IC of the nano-HA/PLLA was lowest corresponding to the smallest surface roughness. The micro-HA/PLLA composites exhibited interfacial debonding and local ductile deformation of the PLLA matrix, indicating higher fracture energy and therefore, the highest G_IC. On the other hand, the nano-HA/PLLA composites showed brittle fracture surface due to nano-scale interaction between PLLA fibrils and primary HA particles, corresponding to lower fracture energy and hence the lowest G_IC.