Ductile to Brittle Transition Depth During Single-Grit Scratching on Alumina Ceramics

Variable-depth single-grit scratch experiments have been conducted on three different grain size alumina ceramics. The extent of induced damage as a function of depth of groove was measured. At low depth, the scratch groove appeared smooth with minimal brittle damage, indicating a ductile mode of deformation. With increased depth, brittle cracking extended beyond the scratch groove. The transition depth from the predominantly ductile mode of deformation to the predominantly brittle mode was measured and compared with an analytical model that estimates the plastic zone size surrounding a scratch in brittle materials. It was found that the ductile to brittle transition depth increases with decreasing grain size.     

A fatigue crack initiation map for polycarbonate

The mechanisms of fatigue crack initiation for various stress levels and thicknesses have been determined for single-edge notched specimens of polycarbonate and used to assemble a map. Three basic fatigue crack initiation mechanisms were identified and named as cooperative ductile (the damage zone formed ahead of crack consisting of yielded material), solo-crack brittle (very little damage zone development), and cooperative brittle (identified as a cloud of microcracks or crazes that developed at the notch tip). With a given applied stress and within the same failure mechanism, the values of the number of cycles to crack initiation decrease with increase in thickness. The transition from cooperative ductile to solo-crack brittle initiation mechanisms is sudden with increasing thickness. Transition from cooperative ductile to cooperative brittle with decreasing stress was less well defined. Regions where combinations of mechanisms were observed are also identified in the map. © 1993 John Wiley & Sons, Inc.     

Surface embrittlement of ductile polymers: A fracture mechanics analysis

The embrittlement of ductile polymers resulting from outdoor weathering or aging or from the application of brittle surface coatings is explained using fracture mechanics principles. It is shown that in order for surface embrittlement to occur, the brittle surface should have a dynamic stress intensity factor at the brittle/ductile interface that exceeds the arrest toughness of the ductile polymer. This phenomenon is modeled using duplex tensile specimens fabricated from poly(methylmethacrylate) (brittle layer) and polycarbonate (ductile substrate) as well as from styrene-acrylonitrile and acrylonitrile-butadiene-styrene copolymers.     

Scratch with double-tip tool: Crack behavior during simultaneous double scratch on BK7 glass

Over the past decade, successive double-scratch tests have been extensively performed to study the grinding mechanism of brittle materials. However, the grits sometimes interact with the surface simultaneously. In this study, double tips with a tip separation of 0.6–1.8 μm are fabricated by focused ion beam. Subsequently, double-scratch tests on BK7 optical glass are conducted using the double-tip scratch tool with a scratch depth of 200–600 nm. The typical crack system and its evolution mechanism for double-tip scratch are discovered, before being explained using an analytical stress model. The ductile–brittle transition and the material-removal mechanism are discussed. An influential radius for the interference between cracks and the stress field in the double scratch is obtained, which can serve as a reference for the design of textured grinding wheels. Subsequently, the advantages and disadvantages of double-tip scratches are discussed considering different applications, such as microstructure fabrication and grinding.     

The effect of particles on failure modes of filled polymers

The effect of rigid particles on the fracture mode of polymers that yield with necking was analyzed theoretically with a model of regularly arrayed spherical particles. The adhesion between a polymer and particles was assumed to be weak, and particles were assumed to debond from the polymer before necking. A linear decrease in engineering draw stress with an increase in the filler content was derived. An increase in filler content leads to a transition in deformation mechanism. The transition depends on the ability of the polymer to strain-harden. If the ability to strain-harden is insignificant and the engineering fracture stress (strenght) of the polymer is lower than its yield stress, the transition is from ductile to brittle fracture. If the ability to strain-harden is essential and the strength of the unfilled polymer is higher than its yield stress, the transition (ductile-to-ductile) is from neck propagation to uniform ductile yield. The critical filler contents were determined for both transitions from the properties of an unfilled polymer. The ductile-to-ductile transition without embrittlement is possible if the strength of the unfilled polymer is higher than its yield stress. Results for polymers filled by weakly bonded particles were compared with polymers filled by particles that debond after the yield stress.     

Elastic stress field model and micro-crack evolution for isotropic brittle materials during single grit scratching

An analytical model for the elastic stress field in isotropic hard and brittle materials during scratching is presented. The model considers the entire elastic stress field and the effect of material densification that was ignored in past studies, and is developed under a cylindrical coordinate system to make the modeling process simpler. Based on the model's predictions, the location and sequence of crack nucleation are estimated and the associated mechanisms are discussed. A single grit scratching experiment with an increasing scratch depth up to 2 µm is conducted for two types of optical glasses representing isotropic brittle materials: fused silica and BK7 glasses. It is found that the model's predictions correlate well with experimental data. Median cracks are found to be formed first during scratching, and the corresponding depth of the scratch sets the basis for determining the critical depth for brittle to ductile machining. Lateral cracks are initiated in the plastic yielding region and deflect to the work surface to cause material removal, while Hertzian cracks interact with lateral cracks to help remove lateral-cracked material. Furthermore, it is found that, owing to its open network molecular structure, fused silica has a much worse ductile machinability than the BK7 glass.     

The notch sensitivity of polymeric materials

Stress–strain tests were made on about five dozen polymeric materials using unnotched and notched specimens containing six different types of notches. Notches decrease the strength, but they decrease the elongation to break even more drastically in general. Notch sensitivity factors are defined for strength and for energy to fracture in such a manner that the greater the notch sensitivity factor, the greater is the effect of a notch relative to the unnotched material. The notch sensitivity factor for breaking (or yield) strength is not the same as the notch sensitivity factor for energy to fracture as measured by the area under the stress–strain curve. Brittle polymers and composites tend to have greater notch sensitivity factors for strength than ductile polymers. For brittle polymers, the notch sensitivity factor for energy to fracture tends to increase with the elongation to break of the unnotched polymer. Notches generally are more detrimental to ductile polymers than to brittle ones as far as the energy to fracture is concerned. For ductile polymers, the shape of the stress–strain curve is important in determining the sensitivity to notches. The ratio of the upper to lower yield strengths should be small for low notch sensitivity. It is desirable to have the breaking strength greater than the yield strength. Glass fibers and filler in ductile matrices increase the notch sensitivity for strength but decrease the sensitivity for energy to fracture relative to the unfilled polymer. Rubber–filled polymers have a reduced notch sensitivity for strength relative to the unfilled polymer, but the notch sensitivity for energy to fracture may be either increased or decreased, depending upon the system. The energy to fracture for notched specimens correlates better with Izod impact strength than does the energy to fracture for unnotched specimens. It is recommended that notched stress–strain specimens be routinely measured along with unnotched specimens.     

Correlation of Tensile Properties of Tough Amorphous Polymers with Internal Friction

Abstract

The ultimate stress-strain behavior of five tough amorphous polymers was studied at temperatures from 4.2 to 300°K using an Instron tensile tester which was adapted for cryogenic measurements. The polymers were found to fail by one of three modes depending upon test temperature and sample pretreatment condition. The transition from a general ductile behavior to brittle fracture was accompanied by a maximum in toughness which could be correlated with the γ transition in these polymers. At still lower temperatures there was a change in the brittle failure which correlated with the magnitude of the internal friction intensity of δ = 0.007 – 0.020. This transition in brittle fracture mode was characterized by a maximum in the brittle fracture stress. It is proposed that the brittle fracture at very low temperature occurs at abnormally low stresses due to stress concentrations factors which can not be relieved since molecular mobility becomes greatly restricted under these cryogenic conditions.     

On the improvement of the ductile removal ability of brittle KDP crystal via temperature effect

Brittle KH₂PO₄ (KDP) crystal is difficult-to-machine because of its low fracture resistance whereby brittle cracks can be easily introduced in machining processes. To achieve ductile machining without any cracks, this type of materials is generally processed by some ultra-precision machining techniques at ambient temperature with nanoscale material removal, yielding low machining efficiency and high processing cost. Recently, thermal-assisted techniques have been used to successfully facilitate the machining of some difficult-to-machine materials, like superalloys, but little effort has been made to explore whether the temperature effect can contribute to the ductile machinability of brittle materials yet. Thus, the aim of this study is to figure out the specific role of temperature in the deformation behaviours of brittle KDP crystal by nano indentation/scratch methods. It is found that compared with those at ambient temperature (AT, i.e. 23 °C), the hardness and Elastic modulus of KDP crystal at elevated temperature (ET, i.e. 160 °C) decrease substantially by 21.4% and 32.5%, respectively, while the fracture toughness increases greatly by 15.5%, implying a higher ability of ductile deformation at ET. Meanwhile, the scratch length within ductile removal has been identified to be extended more than 4 times by increasing temperature from AT to ET. Both the quantity and size of brittle features (e.g., cracks and chunk removal) show a reducing trend with the increase of temperature. To uncover the underlying mechanism of this phenomenon, an updated stress field model is proposed to analyze the scratch-induced stress distribution by considering the evolution of material property at various temperature. These presented results are significant for the future design of specific thermal-assisted processing techniques for machining brittle materials efficiently.     

Scratch behavior of boron nitride nanotube/boron nitride nanoplatelet hybrid reinforced ZrB2-SiC composites

Spherical instrumented scratch behavior of ZrB₂-SiC composites with and without hybrid boron nitride nanotubes (BNNTs) and boron nitride nanoplatelets (BNNPs) was investigated in this research. Typical brittle fracture such as microcracks both in and beyond the residual groove and grain dislodgement was observed in ZrB₂-SiC composite, while hybrid BN nanofiller reinforced ZrB₂-SiC composite exhibited predominantly ductile deformation. The peculiar three-dimensional hybrid structure in which BNNPs retain their high specific surface area and de-bundled BNNTs extend as tentacles contributes to the improved tolerance to brittle damage. Additionally, easier grain sliding due to BN hybrid nanofillers located at grain boundaries and these BN hybrid nanofillers attached on the scratch surface would provide significant self-lubricating effect to reduce lateral force during scratch and to alleviate contact damage.     

The brittle-to-ductile transition in microlayer composites

The brittle-to-ductile transition in continuous microlayer composites of polycarbonate (PC) and styrene–acrylonitrile copolymer (SAN) was investigated under the triaxial tensile stress state achieved at a semicircular notch. The availability of microlayer compositions with variations in the proportion of the components and also variations in the total number of alternating layers made it possible to examine the transition from SAN-like, relatively brittle behavior, to PC-like properties where the ductile component dominated yield and failure. Examination of the damage zone that formed at the notch root revealed that cavitational mechanisms dominated in the brittle composites that were those with the highest proportion of SAN and fewest number of layers. Shear-yielding modes characteristic of PC dominated the damage zone of the ductile composites. Cavitational mechanisms were almost totally absent in these compositions that included those with the highest proportion of PC and the largest number of layers. A broad range of transitional behavior was observed with intermediate compositions where elements of both cavitational mechanisms and shear modes were superimposed. These compositions provided an opportunity to examine the interaction of cavitational and shear processes at the macro- and microscales. © 1993 John Wiley & Sons, Inc.     

Study on mechanism of chip formation of grinding plasma-sprayed alumina ceramic coating

The mechanisms of ductile–brittle transition and surface/subsurface crack damage during the grinding of plasma–sprayed alumina ceramic coatings were investigated in an experiment and simulation on single diamond abrasive grain cutting. We observed that the brittle damage modes of alumina ceramic include boundary cracks, median cracks and lateral fractures. The normal force of the abrasive grain results in the initiation of median cracks, whereas the tangential force of the abrasive grain results in the propagation of median cracks in the direction of the abrasive grain cutting. Some cracks propagate downward to form machined surface cracks, whereas others propagate to the unmachined surface of the workpiece to produce brittle removal. Owing to the alternating tensile and compressive stresses, the material in contact with the top of the abrasive grain fractures continuously, forming the main morphology of the machined surface. The geometry and cutting depth of the abrasive grain have a significant influence on the ductile–brittle transition, whereas the cutting speed of the abrasive grain have no significant influence. On one hand, the stress concentration at the pore defects result in crack propagation to the deep layer; on the other hand, it reduces the local strength of the surface material, produces brittle fracturing, and interrupts crack propagation. The pores exposed on the machined surface and the broken morphology around them are important factors for reducing the surface roughness. Experimental observations show that the machined surface morphology of the alumina ceramic coating is composed of brittle fracturing, ductile cutting and plowing, cracks, original pores, and unmelted particles.     

Evaluation of the weld-line strength of thermoplastics by compact tension test

In order to understand the relationship between processing conditions and the properties of weld-lines on a molecular level, it is necessary to evaluate the true strength of the weld-line that is not affected by the V-shape notch on the surface of the weld-line zone. In this experiment, the weld-line strength of several brittle, ductile, or phase-separated polymers was evaluated using the compact tension test by measuring the critical stress intensity factor, K_IC, or the critical J-value, J_IC, and the results were compared with those obtained by tensile testing. For brittle polymers such as poly(methyl methacrylate) (PMMA) or styrene acrylonitrile copolymer (SAN), the value of the weld-line factor, i.e., the strength ratio between the welded and the non-welded specimen, is higher than that measured by tensile testing, because of the notch sensitivity of brittle thermoplastics and the notch dependence of tensile strength. On the other hand, in the case of ductile polymers such as polycarbonate (PC), the weld-line factor is similar for both the tensile and compact tension tests. However, the dependency of the weld-line factor on melt temperature is more obvious in the compact tension test. From these results, it seems that the compact tension test is more appropriate for measuring the interfacial adhesion strength across the weld-line, which excludes the notch effect.     

Tensile mechanical behavior of linear high‐density polyethylenes modified with organic peroxide

The molecular structure of several high‐density polyethylenes of different molecular weights and vinyl contents was modified without altering their thermoplastic character using an organic peroxide. Chain linking was the main chemical event that occurred during the modification process. Samples of these polymers were crystallized from the melt, generating materials with different morphologies. Two crystallization procedures were followed: slow cooling and quenching. The density and crystallinity of the polymers were found to be slightly dependent on the molecular structures generated by the modification process. Tensile tests were performed at room temperature to evaluate the mechanical behavior of the polymers. The mechanical response of some of the slowly cooled samples changed from brittle to ductile when increasing concentrations of peroxide were added to the formulation. All the quenched samples displayed ductile behavior. The elastic modulus and yield stress were found to increase linearly with the crystallinity of the polymers independently of the molecular structure generated by the modification process. The molecular weight of the modified polymers appears to be the main structural property that influences the draw ratio after break and the ultimate tensile stress of the samples. The draw ratio diminishes, while the ultimate tensile stress increases with the molecular weight of the polymers, irrespective of the evolution of other molecular parameters.     

Toughenability of polymers

We demonstrate that all solid polymers are intrinsically brittle and will undergo a ductile to brittle fracture transition based on the nature of their bonding alone. The most effective way of avoiding a ductile to brittle transition is to reduce the plastic resistance to delay reaching the brittle strength which in unoriented polymers is governed by intrinsic cavitation. While a number of possibilities for this exist, the most widely used techniques involve incorporation of rubbery particles that can cavitate or rigid particles that can debond prior to plastic flow. In both approaches the continuous homo-polymer is transformed into a quasi-regular cellular solid that is much more capable of undergoing large local plastic flow by ligament stretching between cavitated particles and is less susceptible to the propagation of brittle cracks under the usual conditions of tensile straining. Under impact conditions, however, in a notched sample which concentrates the strain rate at the notch root, the plastic resistance of the stretching ligaments rises sharply due to two separate but related effects. First, by an increase in the shear modulus due to the high frequency nature of the Izod impact test to fracture, viewed as a quarter cycle oscillation, which directly elevates the flow resistance and second, by the further effect of increase due to the much increased plastic strain rate. At the notch root then, the plastically stretching and strain hardening ligaments are left with a much reduced capacity to strain further before the cavitation stress is reached. While rubber particle-modified polymers can still exhibit considerable toughening, rigid-particle-modified polymers suffer severely from clustering of rigid particles into super critical flaws that trigger brittle response, much like what is encountered in structural steels.Based on their known mechanical response in neat form six, semi-crystalline polymers have been analyzed in detail to evaluate their potential for toughening under impact conditions. The results correlate very well with the experimental findings.     

A model for service life of polyethylene pipe exhibiting ductile–brittle transition in failure mode

This article proposes a model for predicting failure time of stressed polyethylene pipe materials that exhibit a failure mode transition from brittle to ductile as stress is increased. The model is based on data obtained using the constant tensile load (CTL) test and takes into account stress-versus-failure-time behavior in both brittle and ductile regimes, as well as in the transition regime. The model permits quantification of the ductile–brittle transition behavior not only from the standpoint of the location of the transition but also its breadth. It is illustrated that knowledge of these two separate parameters opens new avenues for understanding the molecular basis of the transition process. This research was conducted under the sponsorship of the Gas Research Institute.     

Use of a nanoindentation fatigue test to characterize the ductile–brittle transition

When considering grinding of minerals, scaling effect induces competition between plastic deformation and fracture in brittle solids. The competition can be sketched by a critical size of the material, which characterizes the ductile–brittle transition. A first approach using Vickers indentation gives a good approximation of the critical size through an extrapolation from the macroscopic to the microscopic scales. Nanoindentation tests confirm this experimental value. According to the grain size compared to the indent size, it can reasonably be said that the mode of damage is deformation-induced intragranular microfracture. This technique also enables to perform cyclic indentations to examine calcite fatigue resistance. Repeated loadings with a nanoindenter on CaCO₃ polycrystalline samples produce cumulative mechanical damage. It is also shown that the transition between ductile and brittle behaviour depends on the number of indentation cycles. The ductile domain can be reduced when the material is exposed to a fatigue process.     

Environmental etch performance, and scratch and mar of automotive clearcoats

Environmental etch damage to automotive coatings, and scratch and mar of these coatings are an important element of customer satisfaction as well as a significant warranty repair consideration for automotive companies. The conditions that result in environmental etch are examined and a laboratory test proposed. Data from this test are compared to automotive hoods exposed in Florida. The performance of various crosslinking chemistries is discussed and the requirements for improved environmental etch are outlined. Scratch and mar performance of these systems is also reviewed. We have found that coatings respond to physical stress by elastic recovery, by plastic flow and by brittle fracture. Classifying types of damage in this way is important for understanding the chemistry needed for improved scratch and mar of coatings.     

Localisation phenomena in glassy polymers: influence of thermal and mechanical history

The macroscopic deformation behaviour of amorphous polymers is dominated by localisation phenomena like necking and crazing. Finite element simulations show that the details of the intrinsic post-yield behaviour, strain softening and strain hardening, determine the severity of strain localisations. In order to perform these numerical simulations an accurate constitutive model is required. The compressible Leonov model is, for this purpose, extended to include temperature effects. Experimentally it is demonstrated that by a small increase in strain softening (by annealing of polycarbonate) or substantial decrease (by mechanical rejuvenation of polystyrene), transitions from ductile to brittle and, respectively, brittle to ductile can be realised. An analytical stability analysis is performed that predicts stable or unstable neck growth dependent on the ratio between yield stress and hardening modulus. The extensive simulations and experimental results lead to the conclusion that in order to macroscopically delocalise strain, and thus improve toughness, one has to reduce strain softening or enhance strain hardening, either by improving the intrinsic behaviour of polymers, or by creating an optimised micro-structure.     

Analysis of ductile and brittle failures from creep rupture testing of high-density polyethylene (HDPE) pipes

A comprehensive analysis of ductile and brittle failures from creep rupture testing of a wide spectrum of HDPE pipes was conducted. The analysis indicates that the ductile failure of such pipes is primarily driven by the yield stress of the polymer (or pipe). Examination of ductile failure data at multiple temperatures indicates a systematic improvement in performance with increasing temperature. It is proposed that testing at higher (above-ambient) temperatures leads to progressive relaxation of the residual stresses in the pipe; this causes the pipe to perform better as residual stresses are known to help accelerate the fracture process. Finally, our investigation indicates no correlation, whatsoever, between brittle failures in pressurized pipes and the PENT (Pennsylvania edge-notch tensile test; ASTM F1473) failure times. Therefore, one has to be extremely cautious in interpreting the true value of the PENT test when developing polymers and pipes for high-performance pressure pipe applications.