The static and dynamic low-temperature crack-toughness performance of seven structural steels

To properly describe the crack-toughness behavior of steels in a quantitative manner, a study was undertaken to establish the effects of strain rate and low temperature on the K_ic values of seven structural steels. Steels having room-temperature yield strengths ranging from 40 to 250 ksi-ABS-C, A302-B, HY-80, A517-F, HY-130(T), 18Ni(180), and 18Ni(250) steels-were evaluated for static and dynamic loading over the range of temperatures for which K_ic values were attainable.

The results indicate that for the ABS-C, A302-B, HY-80, and A517-F steels, an increase in strain rate of approximately six orders of magnitude caused a decrease in the K_ic values measured at the same test temperatures. No significant effect was observed for the HY-130T and 18NI(250) steels. However, the most significant effect of the increased strain rate was the increase in the threshold temperature below which plane-strain behavior occurred.

When all steels — except the 18Ni(180) maraging steel, for which insufficient valid data were obtained were compared on the basis of equivalent critical flaw-size behavior, the crack-toughness performance in terms of _ic/σ_ys for dynamic loading could be separated into three groups. The HY-80 and HY-130(T) steels were best, the ABS-C, A302-B, and A517-F steels were intermediate in performance, and the 18Ni-(250) maraging steel was the poorest. These groupings of performance prevailed over a relatively wide range of test temperatures. As a means of accounting for the differences in strain rate, the K_ic/σ_ys values for all steels investigated were plotted in terms of the rate-temperature parameter, Tln A/ε, which superimposed most of the static crack-toughness performance data into these same levels of performance. In addition, the results of the investigation substantiated the interpretation that the nil-ductility-transition temperature measured in the drop-weight test is the upper limit of dynamic plane-strain crack-toughness behavior for 1-in.-thick plates.

In general, the results of the present investigation provide a quantitative comparison of the plane-strain crack-toughness performance of 1-in.-thick plates of seven structurel steels under both static and dynamic loading conditions. Because of the increase in temperature range over which K_ic behavior occurs with increased strain rate, dynamic loading can be an especially significant factor in the performance of structural steels, particularly those having yield strengths less than approximately 140 ksi.     

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.     

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.     

Fatigue crack growth characteristics of rotor steels

Room temperature fatigue crack growth rate data were generated for Ni-Mo-V (ASTM A469, Cl-4), Cr-Mo-V (ASTM A470, Cl-8) and Ni-Cr-Mo-V (ASTM A471, Cl-4 and a 156,000 psi yield strength grade) rotor forging steels. Testing was conducted with WOL type compact toughness specimens and the results presented in terms of fracture mechanics parameters. Data show that the Ni-Cr-Mo-V steels exhibit slower fatigue crack growth rates at a given stress intensity range (ΔK) than do the Ni-Mo-V steels. In addition, the Cr-Mo-V steel was found to exhibit slower growth rates than the other alloys at ΔK levels below 40 ksi √in but somewhat foster rates at ΔK levels in excess of 45 ksi √in. The fatigue crack growth rate properties of the alloys studied conform to the generalized fracture mechanics crack growth rate law where da/dN = C₀ΔK^R. It was noted that the fatigue crack growth rate parameters n and C₀ tend to decrease and increase, respectively, with increasing material toughness, K_ic.     

Inference of critical cod from Charpy V test result

Correlation between the Charpy absorbed energy and critical COD is investigated to obtain a useful method for estimating critical COD from Charpy V data. The round bar tension test, Charpy V-notch test and static 3-point bend test with fatigue notched specimen are carried out using mild steel, 785 MPa grade high strength steel and A5083 aluminum alloy. Correlation is found between W'_c/σ_Y and δ_c as well as between EW'_c/σ_Y² and Eδ_c/σ_Y, where W'_c is the Charpy absorbed energy obtained by considering temperature difference between the Charpy transition temperature and COD transition temperature. The symbols σ_Y, δ_c and E are yield strength, critical COD and Young's modulus, respectively. The correlations are established for various kinds of metals and over a wide temperature range including not only upper shelf range but also the transition range.     

A model for predicting fatigue crack growth behaviour of a low alloy steel at low temperatures

In the present study, a model to predict the fatigue crack growth (FCG) behaviour at low temperatures is proposed for a low alloy steel (16 Mn). The experimental results indicate that fatigue ductile-brittle transition (FDBT) occurs in 16 Mn steel and the FDBT temperature (T_FDBT) is about 130 K. When T > T_FDBT, the FCG mechanism in the intermediate region is the formation of ductile striation and the FCG rates decrease with decreasing temperature. When T ≈ T_FDBT, the FCG mechanism changes into microcleavage and the fatigue fracture toughness K_fc of the steel decreases sharply. The FCG rates tend to increase as the temperature is further reduced. The test data of the FCG rates are well fitted by the formula developed by Zheng and Hirt. An approximate method to predict ΔK_th of the steel at low temperatures is proposed and then a general expression of the FCG rates is given at temperatures ranging from room temperature to T_FDBT. By means of the expressions proposed in this paper, the FCG rates at low temperatures can be predicted from the tensile properties if the endurance limit σ₋₁ and δk_th, at room temperature are known. Finally, a model for FDBT is tentatively proposed. Using this model, one can predict T_FDBT from the ductile-brittle transition curve determined from impact or slow bending tests of cracked Charpy specimens.     

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.     

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.     

Strain energy density fracture criterion in elastodynamic mixed mode crack propagation

Sih's fracture criterion based on strain energy density, S, for mixed mode crack extension under static loading is extended to dynamic mixed mode, K_I and K_II, crack propagation. Influence of the second order term, σ_ox, which represents the non-singular constant stress acting parallel to the direction of crack propagation, on the S distribution surrounding the crack tip, is demonstrated. Numerical studies show that positive σ_ox enhances the fracture angle and negative σ_oxreduces the fracture angle irrespective of the sign of K_II/K_I, when S is measured at a critical distance r_c from the crack tip. This fracture criterion is verified by the crack curving results of dynamic photoelastic fracture specimens. Omission of σ_ox term leads to predicted fracture angles which are at variance with experimental data.     

Hardness, internal stress and fracture toughness of epitaxial AlxGa1−xAs films

Vickers microhardness indentations of 10 μm (001) oriented epilayers of Al_xGa_1−xAs on GaAs substrates have been utilized to evaluate the hardness H_v, the internal stress, and the fracture toughness K_Ic of the layers as a function of their composition parameter x. The hardness H_v varies linearly according to: (6.9-2.2x) GPa and K_Ic increases linearly with x according to: K_1c = (0.44+1.30x) MPa m^1/2. The influence of the substrate on these measurements was found to be negligible for the layer thickness (10 μm) and the indentation load (0.25 N) used, disregarding internal stresses.

Internal film stresses were evaluated by the bimorph buckling method, and were found to depend on the composition parameter according to σ = 0.13x GPa. These stresses did not notably affect the H_v measurements, but for K_Ic corrections as large as 25% had to be made.

The radial cracks observed were of the shallow Palmqvist type. In contradiction to previous reports on this type of cracking, it was found to initiate during unloading, not during loading, and a physical explanation for this deviation is given. No deep radial/median cracks were observed. It was found important to use expressions based on the correct crack geometry in the K_Ic evaluation. Also, a simple theory for the influence of internal stresses on the K_Ic results has been developed.     

On the effect of sampling volume on the microscopic cleavage fracture stress

Reported observations of an experimental variation in the microscopic fracture stress for transgranular cleavage (σ^*_f) with specimen geometry and size are quantitatively examined in terms of a weakest-link statistical model for brittle fracture, wherein failure coincides with the critical propagation of a particle microcrack into the matrix. By analysing the onset of fracture in the ‘sharp-crack’ (K_Ic) specimen, the ‘rounded-notch’ (Charpy) specimen, and the uniaxial tensile specimen, it is shown that values of σ^*_f are reduced progressively in the ‘sharp-crack’, notched and unnotched geometries and with increasing specimen size, consistent with an increase in statistical sampling volume. Quantitative predictions for the magnitude of this variation are given for a low strength steel.     

Sintering behavior and microwave dielectric properties of Bi3(Nb1−xTax)O7 solid solutions

Solid solutions of Bi₃(Nb_1−xTa_x)O₇ (x = 0.0, 0.3, 0.7, 1) were synthesized using solid state reaction method and their microwave dielectric properties were first reported. Pure phase of fluorite-type could be obtained after calcined at 700 °C (2 h)⁻¹ between 0 ≤ x ≤ 1 and Bi₃(Nb_1−xTa_x)O₇ ceramics could be well densified below 990 °C. As x increased from 0.0 to 1.0, saturated density of Bi₃(Nb_1−xTa_x)O₇ ceramics increased from 8.2 to 9.1 g cm⁻³, microwave permittivity decreased from 95 to 65 while Q_f values increasing from 230 to 560 GHz. Substitution of Ta for Nb modified temperature coefficient of resonant frequency τ_f from −113 ppm °C⁻¹ of Bi₃NbO₇ to −70 ppm °C⁻¹ of Bi₃TaO₇. Microwave permittivity, Q_f values and τ_f values were found to correlate strongly with the structure parameters of fluorite solid solutions and the correlation between them was discussed in detail. Considering the low densified temperature and good microwave dielectric proprieties, solid solutions of Bi₃(Nb_1−xTa_x)O₇ ceramics could be a good candidate for low temperature co-fired ceramics application.     

The mixed mode I/II fracture behaviour of lightly tempered HY130 steel at room temperature

The mixed mode I/II fracture behaviour at room temperature of HY130 steel tempered at 350°C has been investigated using edge-cracked bend bar specimens loaded in anti-symmetric and symmetric four point bend configurations. In all cases fracture occurred by a localized shear decohesion mechanism that could not be characterized by the stress intensity factors, K_I and K_II, but for which the crack tip displacements, δ_I, and δ_II, appear to provide a first level of characterization. The results suggest that fracture is described by a maximum shear criterion, and this is consistent with the present understanding of fibrous fracture micro-mechanisms in the material.     

Calculation of the ferrite volume in some dual phase steels

The relation between the γ/γ + boundary temperature, T, and the equivalent values of [Cr] and [Ni], as well as the variation of the ferrite volume, V_f, with the temperature in + γ dual-phase steels have been studied. With the aid of a computer, the regressive expressions derived from the experimental results are: T (°C) = T₃ + 21.2 [Cr] − 15.8 [Ni] + 223; V_f (%) = 0.715 exp [0.015(T − T_δ)] − exp[0.015(T_c − T_δ)] + 1.85 exp [0.0083(T − T_c]).     

Fatigue crack growth thresholds-the influence of Young''s modulus and fracture surface roughness

In the present investigation it is shown that the effective fatigue threshold is uniquely correlated to the Young's modulus for a wide range of metallic and composite materials (ΔK_th,eff=1.64·10⁻²·E). It is also demonstrated that the crack closure level K_cl increases with increased roughness of the fracture surface . K_cl and are quantitatively related via the equation for steels with widely different mechanical properties and grain sizes (120 MPa<R_p<1100 MPa, 1 μm<λ<100 μm). This relation can be extended to materials other than steels (e.g. aluminium and WC-Co alloys) by normalising against Young's modulus. The roughness value represents the standard deviation of height of the fracture surface and is shown to be simply related to the length and angle distributions of the linear length elements constituting the fracture profile.     

Regression-based CVN–KIC Models for hot work tool steels

Dies and tools used in hot metal forming (extrusion, forging, rolling, etc.) are exposed to high pressures, elevated temperatures, and thermo-mechanical fatigue. The most common mode of in-service die failure is fatigue fracture (brittle failure through crack propagation). Reliable determination of fracture toughness of the die material is thus critically important. However, as die steels have a combination of high-hardness and high-strength, and are used at elevated temperatures, standard plane-strain fracture toughness (K_IC) testing methods become impracticable. Alternate testing procedures such as the Charpy impact energy (CVN), together with empirical/semi-empirical correlations of K_IC to other data, are then more viable and economical. Experimental data (values of K_IC, CVN, and HRC) of H13 steels have been collected through an exhaustive literature search. This data set has been augmented through in-house experimentation: samples variously heat treated (different tempering temperatures and times, and both air-cooling and oil-quenching), and tested at different working temperatures. Linear and quadratic models are proposed for determination of fracture toughness, based on experimental (in-house) and published values of Charpy impact energy (CVN) and Rockwell hardness (HRC), both at room and at elevated temperatures.     

A simple procedure for the accurate determination of stress intensity factors by finite element method

A simple procedure for the accurate determination of stress intensity factors K_I, K_II by the conventional finite element method is proposed. The first step of the method is to calculate the stress σ₂ of the plate without a crack. The second step is to calculate the stress σ_tip, of the plate with the crack. The value of (σ_tip−σ_g) at the crack tip element is regarded to have the intimate relation with K_I, K_II K_I, and K_II are determined from the value of (σ_tip−σ_g) and a standard solution. It is shown that the results obtained for many problems by the proposed method are in excellent coincidence with the analytical solutions. The error is below 1–3% for the most cases.     

Crack rotation factor and dynamic fracture measurement

A linear relationship between the cross-head displacement S or pendulum displacement in the Charpy test and the crack mouth opening displacement V has been found in the paper for several polymers and a mild steel. The crack opening displacement δ is material and crack-length dependent and it decreases with increasing crack length. Through analysis the dynamic fracture toughness K_Id can be measured from the P-S (the load and the cross-head displacement) curve, which is very easy to obtain in static or dynamic tests.     

Lower-bound fracture toughness of a reactor-pressure-vessel steel

The fracture toughness of A508 steel was measured at a temperature slightly below RT_NDT. Several methods of data analysis were used, and the stored-elastic-energy approach of Seidl was found to provide the lowest and most reproducible k_ic values. Although this method has theoretical drawbacks, it is argued that its results are consistent with current understanding of the relations between fracture toughness and microstructure.