Fracture behaviour of 2D-weaved, silica–silica continuous fibre-reinforced, ceramic–matrix composites (CFCCs)

Significantly improved fracture resistance (in terms of fracture toughness and fracture energy) can be imparted to monolithic ceramics by adopting composite design methodology based on fibre reinforcement technology. The present paper describes the fracture behaviour of one such fibre-reinforced material, namely the silica–silica based continuous fibre-reinforced, ceramic–matrix composite (CFCC) in two orthogonal notch orientations of crack divider and crack arrester orientations. Different fracture resistance parameters have been evaluated to provide a quantitative treatment of the observed fracture behaviour. From this study, it has been concluded that the overall fracture resistance of the CFCC is best reflected by total fracture energy release rate (J_c), which parameter encompasses most of the fracture events/processes. The J_c values of the composite are found to be more than an order of magnitude higher than the energy values corresponding to the plane strain fracture toughness (J_KQ, derived from K_Ic, the plane strain fracture toughness) and >200% higher than elastic–plastic fracture toughness (J_Ic). Apart from this, the composite is found to exhibit high degree of anisotropy in the fracture resistance and also, a significant variation in the relative degree of shear component with crack extension.     

The mechanics and mechanisms of fracture in stress corrosion cracking of aluminium alloys

A fracture mechanics approach to stress corrosion cracking is highlighted. The mechanisms of stress corrosion cracking is presented. Experiments on 2024 and 7075 aluminium alloys are carried out to determine their mechanical properties, microstructure and plane strain fracture toughness (K_IC). Stress corrosion cracking tests, namely, cantilever beam tests as well as wedge opening loading tests using sea water as a corrosive medium, are conducted to establish the critical stress intensity factor for stress corrosion cracking (K_ISCC) for each aluminium alloy. It is found that the K_ISCC is in the range of (1/5) to (1/6) of the plane strain fracture toughness, K_IC, depending on the alloy. The scanning electron microscopy of fracture surfaces reveals a great dependence of the cracking and/or pit severity on the applied stress intensity factor. A brief discussion on the dislocation's role in stress corrosion cracking is given.     

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.     

Fatigue crack initiation and growth under mixed mode loading in aluminum alloys 2017-T3 and 7075-T6

Fatigue crack initiation and growth characteristics under mixed mode loading have been investigated on aluminum alloys 2017-T3 and 7075-T6, using a newly developed apparatus for mixed mode loading tests. In 2017-T3, the fatigue crack initiation and growth characteristics from a precrack under mixed mode loading are divided into three regions—shear mode growth, tensile mode growth and no growth—on the ΔK_I-ΔK_II plane. The shear mode growth is observed in the region expressed approximately by ΔK_II > 3MPa√m and ΔK_II/ΔK_I > 1.6. In 7075-T6, the condition of shear mode crack initiation is expressed by ΔK_II > 8 MPa√m and ΔK_II/ΔK_I > 1.6, and continuous crack growth in shear mode is observed only in the case of ΔK_I/ΔK_II, 0. The threshold condition of fatigue crack growth in tensile mode is described by the maximum tensile stress criterion, which is given by Δσ_θmax √2πr 1.6MPa√m, in both aluminum alloys. The direction of shear mode crack growth approaches the plane in which K_I decreases and K_II increases towards the maximum with crack growth. da/dN-ΔK_II relations of the curved cracks growing in shear mode under mixed mode loading agree well with the da/dN-ΔK_II relation of a straight crack under pure mode II loading.     

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.     

Fatigue and fracture of a 200 ksi grade maraging steel proposed for use in military bridging

Maraging steel containing 18 per cent nickel offers apparent advantages of high strength, weldability, corrosion resistance and toughness. In view of the suitability of the material for bridge construction, a study of the fatigue crack growth and fracture properties was undertaken. A proposed bridge design contained hinged sections of 4 in. and 2 in. Thickness for female and male jaws, and thin welded girders manufactured from plate material 0.18 in thick.

Plane strain fracture toughness tests were carried out on samples taken from the 4 in. And 2 in. Sections using 3 point-bend and compact tension specimens. K_Q values of approximately 75 ksi √in. For the 4 in. samples and 110 ksi √in. For the 2 in. Samples were obtained.

Plane stress fracture toughness tests were conducted on center cracked sheets up to 11 in. in width. Using critical crack lengths determined by compliance measurements, K_C values in excess of 400 ksi √in. have been obtained in specimens of up to 0.180 in. Thickness. Fatigue crack growth rates were determined from these specimens prior to fracture testing.

In both plane strain and plane stress failure modes, laboratory results are in agreement with those estimated from the failure of experimental structures.     

A theoretical approach for evaluating the plane strain fracture toughness of ductile metals

Fracture Mechanics of Ductile Metals (FMDM) theory is used to obtain the plane strain fracture toughness, K_lc, for different materials. The traditional approach for obtaining the K_lc value is to conduct several standard tests on cracked plates that are costly and time consuming. The fracture toughness value provided by the FMDM theory depends on the stress-strain curve for the material in question, and this is readily available in MIL-HDBK-5 and other reliable sources. The results of the plane strain fracture toughness (K_lc) values provided by the FMDM theory were compared with the experimental data and it was concluded that the two are in excellent agreement. It is proposed that, in the interest of economy and convenience, K_lc testing could be replaced by the FMDM theory.     

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.     

Contributions of internal hydrogen and room-temperature creep to the abnormal fatigue cracking of Ti6246 at high Kmax

This study aims at explaining the absence of a threshold for crack propagation in an /β titanium alloy during cyclic tests performed with constant K_max and increasing K_min, if K_max is higher than 60–70% of K_Ic. Tensile, creep as well as fatigue crack growth tests are performed on specimens with various hydrogen content. SIMS analyses of hydrogen content around the tip of a crack developed in the abnormal regime are made. Solute hydrogen is shown to segregate at the crack tip and to enhance room-temperature creep, strain localisation and decohesion along /β interfaces.     

Application of the double slip plane crack model to temperature and strain rate sensitive BCC metals

The double slip plane crack model proposed by Weertman, Lin and Thomson (1982) has been applied to model the effect of temperature and strain rate on the stress intensity factor at a crack tip in temperature and strain rate sensitive materials. Increase in temperature or decrease in strain rate (as well as a decrease in slip plane spacing) are shown to increase the shielding of the crack tip by dislocation distributions on the slip planes. Furthermore, the effect of temperature on the fracture toughness, K_llc, at various strain rates was shown to exhibit the same sigmoidal shaped curve seen for K_lc data in typical alloy steels.     

Supersmall punch test to estimate fracture toughness JIc and its application to radiation embrittlement of 2.25Cr-1Mo steel

A supersmall punch test has been used to extract fracture strain information on irradiated 2.25Cr-1Mo steel from transmission electron microscopy disc specimens as small as 3 mm in diameter and 0.25 mm in thickness. The test is based on driving a steel ball punch through a clamped specimen. The size effect of biaxial equivalent fracture strain of various kinds of materials and irradiated steel has been demonstrated. The results of fracture strain obtained from specimens 3 mm in diameter has been related almost linearly to the fracture toughness J_Ic for elastic and plastic behaviour. The relationship between fracture strain and fracture toughness J_Ic has been verified for the irradiated nuclear pressure vessel steel 2.25Cr-1Mo so that large amounts of irradiation space in nuclear reactor could be saved.     

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.     

Fundamental aspects of nano-reinforced composites

The present paper highlights the potential of the CNTs as nanofillers in polymers, but also stresses out the limitations and challenges one has to face dealing with nanoparticles in general. The relation between particle size, separation and volume content is described analytically. The dominating effect of manufacturing route (sonication, mech. stirring and calendering) and surface properties of carbon nanotubes (CNTs), influencing the resulting degree of dispersion and interfacial adhesion, were intensively investigated by transmission electron microscopy (TEM). The resulting (fracture) mechanical properties of the CNT/epoxy composites were investigated for volume contents below 1%. The fracture toughness K_Ic turned out to be significantly increased (45%) adding only 0.3% of amino-functionalised double-walled carbon nanotubes (DWCNT-NH₂).     

Influence of in-plane fibre orientation on mode I interlaminar fracture toughness of stitched glass/polyester composites

The influence of in-plane fibre orientation on the mode I interlaminar fracture toughness, G_Ic of unstitched and stitched glass/polyester composites is investigated in this paper. The G_Ic of planar specimens depends on the fibre orientation, θ in the layers adjacent to the fracture plane, in addition to the property of matrix material. The mode I fracture toughness and fracture behavior of unstitched and stitched 0/0, 30/−30, 45/−45, 60/−60, 90/90 and 0/90 interfaces of unidirectional fibre mats (UD) and 30/−30, 45/−45 and 90/90 interfaces of woven roving mats (WRM) are studied. WRM layer orientation is represented by the direction of warp fibres. Stitching is done by untwisted Kevlar fibre roving of Tex 175 g/km at the stitch densities (number of stitches per unit area) of 10.24 and 20.48 stitches/inch². The specimens having same stitch density, but different stitch distributions are prepared, and the influence of stitch distribution on G_Ic is studied. Double cantilever beam (DCB) tests are carried out and the G_Ic is determined using modified beam theory. The G_Ic of both unstitched and stitched specimens increases with increase in orientation angle, θ upto 45° above which it decreases. The G_Ic values of unstitched 45/−45 delamination interface is around 2.4 times that of the unstitched 0/0 interfaces. The influence of fibre orientation on G_Ic is clearly observed in unstitched specimens, whereas in the stitched specimens, stitching plays an important role in improving the G_Ic and suppresses the influence of fibre orientation; degree of suppression increases with increasing stitch density. When the value of θ is above 45°, transverse cracks are observed in the delamination interface surrounded by UD layers; while in the delamination interface surrounded by WRM layers, transverse cracks are not initiated irrespective of the fibre orientation angle.     

An analysis of the crack tip fields in a ductile three-point bend specimen subjected to impact loading

Analyses of an impact fracture test of a precracked, three-point beam of HY100 steel were performed to determine the dynamic fracture toughness. During impact, the crack tip opening displacement (CTOD) 100 μm behind the crack tip was measured using an optical measuring device called the interferometric strain/displacement gage. Since fracture initiates when stress wave effects dominate, a numerical simulation of the fracture event was conducted to obtain relevant near crack tip field parameters. The specimen was modeled by a plane stress finite element simulation using a rate sensitive elastoplastic material law. Since the simulated CTOD was to be compared with the measured CTOD in a region of residual strains due to crack closure, this effect was included in the model. The simulation produces a CTOD versus time response within 10% of the observed response, indicating that the other field quantities (such as the J-integral) should also be reliable. The loading rate /.K₁ was approximately 8 × 10⁶MPa√m/sec. If the fracture initiation time is assumed to coincide with the time at which the simulated and observed CTOD curves diverge, then the impact fracture toughness is 56% higher than the static fracture toughness.     

Dynamic fracture toughness of heavy section, narrow gap, gas tungsten arc weldments

Dynamic fracture toughness tests were performed on three, ASME SA533 Gr A Cl 2 narrow gap, gas tungsten arc weldments (minimum yield strength equals 70 ksi, 485 MPa). Linear elastic K_Id results were obtained at low temperatures while J-integral techniques were utilized to evaluate dynamic fracture toughness over the transition and upper shelf temperature ranges. Loading rates in terms of K averaged 4.41 × 10⁴ksi√(in.)/sec (4.88 × 10⁴MPa√(m)/sec). Tensile, Charpy impact and drop weight nil ductility transition (NDT) tests were also performed. The dynamic fracture toughness of both stress relieved (24 hr at 1125°F, 607°C) plus quenched and tempered SA533 Gr A Cl 2 narrow gap, gas tungsten arc weldments: (a) easily transcended the ASME specified minimum reference toughness K_IR curve, and (b) significantly exceeded the fracture toughness demonstrated by lower strength, stress relieved (3/3.5 hr at 1125°F, 607°F) SA533 Gr A Cl 2 automatic submerged arc weldments.     

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.     

Double cantilever beam testing of multidirectional laminates

Several difficulties in the double cantilever beam (DCB) tests of multidirectional laminates often prevent valid measurements of the mode I critical strain energy release rate G_Ic. In this paper, several DCB specimens were analysed with 3D finite element models. The results showed that the undesired effects of residual stresses and of mode-mixity can be minimised. An interlaminar stress based fracture criterion predicts that the G_Ic of multidirectional specimens is typically 10–40% higher than the G_Ic of unidirectional [0°]_n laminates. This agrees with the few valid experimental data available.     

Comparative study of the fracture behavior of flow-molded GMT-PP with random and chopped-fiber mats

The fracture toughness, K_Q, of hot-flow compression-molded glass-mat-reinforced thermoplastic polypropylene (GMT-PP) with random (R) and chopped (C) fiber mats was determined on single-edge-notched specimens loaded in tension (SEN-T) at ambient temperature. The development of damage was assessed by location of the acoustic emission (AE) activity in specimens cut from the side and central parts of the molded plaques and loaded along (L) and transverse (T) to the flow direction. The molding-induced anisotropy was clearly reflected in the K_Q values, which were considerably higher in the L than in the T orientation, especially for specimens cut from the side of the plaque. The toughness response of GMT-PPs with R and C mats was similar however. It was found that the fracture toughness calculated by considering non-linearity in the force vs. displacement curve according to ASTM E 399 is the best estimate for the initiation value. The damage zone and its development was estimated by considering the located AE events. AE served also to trace the differences in the failure mode as a function of mat type and loading ranges.     

The unusual near-threshold FCG behavior of a single crystal superalloy and the resolved shear stress as the crack driving force

An investigation of the fatigue crack growth (FCG) behavior of PWA 1480 single crystal nickel base superalloy was conducted. Typical Paris region behavior was observed above a δK of 8 MPa√m. However, below that stress intensity range, the alloy exhibited highly unusual behavior. This behavior consisted of a region where the crack growth rate became essentially independent of the applied stress intensity. The transition in the FCG behavior was related to a change in the observed crack growth mechanisms. In the Paris region, fatigue failure occurred along {111} facets, however at the lower stress intensities, (001) fatigue failure was observed. A mechanism was proposed, based on barriers to dislocation motion, to explain the changes in the observed FCG behavior. The FCG data were also evaluated in terms of a recently proposed stress intensity parameter, K_rss. This parameter, based on the resolved shear stresses on the slip planes, quantified the crack driving force as well as the mode I ΔK, and at the same time was also able to predict the microscopic crack path under different stress states.