Bending modified J–Q theory and crack-tip constraint quantification

It is well known that the J–Q theory can characterize the crack-tip fields and quantify constraint levels for various geometry and loading configurations in elastic–plastic materials, but it fails at bending-dominant large deformation. This drawback seriously restricts its applications to fracture constraint analysis. A modification of J–Q theory is developed as a three-term solution with an additional term to address the global bending stress to offset this restriction. The nonlinear bending stress is approximately linearized in the region of interest under large-scale yielding (LSY), with the linearization factor determined using a two-point matching method at each loading for a specific cracked geometry in bending. To validate the proposed solution, detailed elastic–plastic finite element analysis (FEA) is conducted under plane strain conditions for three conventional bending specimens with different crack lengths for X80 pipeline steel. These include single edge notched bend (SENB), single edge notched tension (SENT) and compact tension (CT) specimens from small-scale yielding (SSY) to LSY. Results show that the bending modified J–Q solution can well match FEA results of crack-tip stress fields for all bending specimens at all deformation levels from SSY to LSY, with the modified Q being a load- and distance-independent constraint parameter under LSY. Therefore, the modified parameter Q can be effectively used to quantify crack-tip constraint for bending geometries. Its application to fracture constraint analysis is demonstrated by determining constraint corrected J–R curves.     

J–Q characterized stress fields of surface-cracked metallic liners – II. Composite overwrapped pressure vessels

Two-parameter J–Q elastic–plastic crack front fields are developed for surface-cracked metallic liners of composite overwrapped pressure vessels (COPV). Uniaxial tensile data from 6061-T6 aluminum coupon specimens for the metallic liner and anisotropic elastic material properties for the filament wound carbon fiber epoxy are used in three-dimensional finite element models. Modified boundary layer (MBL) finite element solutions are used to evaluate near tip dominance and parameterization limits. Semicircular surface cracks of varying depths inserted in the inner liner surface are investigated. J and Q crack front distributions, and the corresponding parameterization limits, and near tip triaxiality trends are obtained and the effects of elastic–plastic material discontinuity of the heterogeneous joint and the biaxiality of stresses are evaluated. J–Q predicted fields maintain accuracy for higher far-field loads and lower near tip deformations compared to the liner only models for angles near the free surface. However, for the critical crack growth region, Q does not maintain a radially independent measure of constraint for loads seen in a typical COPV; therefore, these fracture predictors may not be applicable. In the COPV, large-scale yielding marks a transition where triaxiality is higher as a function of constraint compared to the linear relationship common to homogeneous structures. Results from this study will facilitate the implementation of proof test logic and accurate fracture prediction of COPV liners with emphasis on geometric limits and fracture specimen applicability.     

Ductile crack growth and constraint in pipelines subject to combined loadings

An important failure mode of offshore pipelines is ductile fracture of the pipe wall triggered by a hypothetical welding defect. In this study, pipelines having an external part-through semi-circumferential crack of various sizes, subject to combined internal pressure and inelastic bending are considered. This is done to assess the response of pipelines during both their installation and operational conditions. Detailed 3D nonlinear finite element (FE) models of pipelines are developed. A row of elements ahead of the initial crack front are modeled using a voided plasticity material model, which enables simulation of crack growth and the subsequent fracture failure mode (denoted by the critical curvature, κ_crit). After discussing the typical response characteristics of such pipelines, the FE model is used to parametrically investigate the influence of varying pipe and crack dimensions, and also the internal pressure levels, on κ_crit. In the second part of this paper, the crack tip constraint ahead of a growing crack in such pipes is evaluated and systematically compared to the crack tip constraint of both the traditionally used deeply cracked Single Edge Notch Bend (SENB) specimens and the constraint-matched Single Edge Notch Tensile (SENT) specimens. This is achieved by comparing the crack resistance curves (R-curves) along with stress triaxiality and equivalent plastic strain fields evaluated ahead of a growing crack of the three systems. The results present grounds for justification of usage of SENT specimens in fracture assessment of such pipes as an alternative to the traditional overly conservative SENB specimens.     

Crack-tip constraint in mode II deformation

Studies of cracked specimens loaded in mode I have shown that the stresses near the crack tip depend significantly on the level of constraint. The stresses can be determined near the crack tip using the HRR solution, but only for high constraint specimens. For other levels of constraint, O'Dowd and Shih's Q parameter may be used to adjust the stresses derived from the HRR solution. Only limited research has been carried out to study the effect of constraint in mode II. In this paper a mode II boundary layer formulation is used to study the effect of far field elastic stresses on the size and shape of the plastic zone around the crack tip and on the stresses inside the plastic zone. It is shown that in mode II, both positive and negative values of remote T-stress influence the tangential stress along the direction of maximum tangential stress. In the spirit of O'Dowd and Shih, a dimensionless parameter Q _II is introduced to quantify the constraint for mode II specimens failing by brittle fracture. The relation between Q _II and T/₀ is determined for different values of the strain hardening coefficient n. To investigate the range of validity of the Q–T diagram for real specimens, the constraint parameter Q _II is calculated directly from finite element analysis for three mode II specimens and compared with the evaluation using the Q–T diagram.     

Effect of residual stresses on crack behaviour in single edge bending specimens

Residual stresses due to manufacturing processes, such as welding, change the load bearing capacity of cracked components. The effects of residual stresses on crack behaviour in single edge bending specimens were investigated using Finite element analyses. Three parameters (J, Q and R) were used to study the crack behaviour. The J‐integral predicts the size scale over which large stresses and strains exist, the constraint parameter Q describes the crack‐tip constraint as a result of geometry, loading mode and crack depth and the constraint parameter R is used to describe the constraint resulting from residual stresses. To carry out a systematic investigation on the effect of residual stresses on the J‐integral and crack‐tip constraints, models under different combinations of residual stresses and external loads with different crack depths were analysed. It has been shown that the crack‐tip constraint R increased by tensile residual stresses around the crack‐tip. On the other hand, the constraint parameter R decreased and tended to zero at high external load levels.     

Three‐dimensional analyses of in‐plane and out‐of‐plane crack‐tip constraint characterization for fracture specimens

Three‐dimensional elastic–plastic finite element analyses have been conducted for 21 experimental specimens with different in‐plane and out‐of‐plane constraints in the literature. The distributions of five constraint parameters (namely T‐stress, Q, h, T_z and A_p) along crack fronts (specimen thickness) for the specimens were calculated. The capability and applicability of the parameters for characterizing in‐plane and out‐of‐plane crack‐tip constraints and establishing unified correlation with fracture toughness of a steel were investigated. The results show that the four constraint parameters (T‐stress, Q, h and T_z) based on crack‐tip stress fields are only sensitive to in‐plane or out‐of‐plane constraints. Therefore, the monotonic unified correlation curves with fracture toughness (toughness loci) cannot obtained by using them. The parameter A_p based on crack‐tip equivalent plastic strain is sensitive to both in‐plane and out‐of‐plane constraints, and may effectively characterize both of them. The monotonic unified correlation curves with fracture toughness can be obtained by using A_p. In structural integrity assessments, the correlation curves may be used in the failure assessment diagram (FAD) methodology for incorporating both in‐plane and out‐of‐plane constraint effects in structures for improving accuracy.     

Residual stress induced crack tip constraint

This paper studies the effect of welding residual stresses on the near tip stress field in single edge notched bending and tensile specimens. A combined effect of mechanical stresses by the applied load and residual stress on the crack tip constraint is analyzed. Three initial residual stress distributions were considered. It has been shown that the crack tip stress field is strongly influenced by the residual stresses and a new parameter, R, is proposed to characterize the residual stress induced crack tip constraint. The results therefore suggest a three-parameter approach (CTOD, Q and R) to characterize the crack tip stress field in the presence of residual stress where CTOD sets the size scale over which large stresses and large strains develop, and the geometry constraint parameter Q and the new residual stress induced constraint parameter R control the actual crack tip constraint level. For the cases analyzed, R is in general positive, which indicates that residual stress can enhance the crack tip constraint. However, the results also indicate that the R decreases towards zero and the effect of residual stress on crack tip constraint can be neglected when a full plastic condition is approached in the specimen.     

Constraint Loss under Dynamic Loading in Rate Independent Plastic Solids

The objectives of this paper are to examine the loss of crack tip constraint in dynamically loaded fracture specimens and to assess whether it can lead to enhancement in the fracture toughness at high loading rates which has been observed in several experimental studies. To this end, 2-D plane strain finite element analyses of single edge notched (tension) specimen and three point bend specimen subjected to time varying loads are performed. The material is assumed to obey the small strain J ₂ flow theory of plasticity with rate independent behaviour. The results demonstrate that a valid J–Q field exists under dynamic loading irrespective of the crack length and specimen geometry. Further, the constraint parameter Q becomes strongly negative at high loading rates, particularly in deeply cracked specimens. The variation of dynamic fracture toughness K _dc with stress intensity rate K for cleavage cracking is predicted using a simple critical stress criterion. It is found that inertia-driven constraint loss can substantially enhance K _dc for .     

Fully plastic crack-tip fields for plane strain shallow-cracked specimens under pure bending

Detailed finite element (PE) analyses are performed to study the effect of crack depth on crack-tip constraint at full yielding for pure bending of plane strain single-edge-cracked specimens. Analyses are based on small-strain formulations and perfect plasticity. The crack depth a/W ranges from 0.1 to 0.7, and the deformation is applied up to the limiting state of full plasticity where crack-tip stresses reach steady-state limiting values.At load levels smaller than the limit load (contained yielding), the crack-tip constraint (stress triaxiality) gradually decreases as a/W decreases, but, at load levels close to the limit load (or at the limit load), it decreases very sharply. In terms of a/W, tractable closed-form approximations for fully plastic crack-tip stress and strain fields are proposed, and fully plastic values of crack-tip stresses are re-phrased in terms of the Q-parameter [1, 2]. The role of crack-tip strains on fracture of shallow-cracked bending specimens is briefly discussed.     

Effect of lattice orientation on crack tip constraint in ductile single crystals

In this work, the effect of lattice orientation on the fields prevailing near a notch tip is investigated pertaining to various constraint levels in FCC single crystals. A modified boundary layer formulation is employed and numerical solutions under mode I, plane strain conditions are generated by assuming an elastic–perfectly plastic FCC single crystal. The analysis is carried out corresponding to different lattice orientations with respect to the notch line. It is found that the near‐tip deformation field, especially the development of kink or slip shear bands is sensitive to the constraint level. The stress distribution and the size and shape of the plastic zone near the notch tip are also strongly influenced by the level of T ‐stress. The present results clearly establish that ductile single crystal fracture geometries would progressively lose crack tip constraint as the T ‐stress becomes more negative irrespective of lattice orientation. Also, the near‐tip field for a range of constraint levels can be characterized by two‐parameters such as K–T or J–Q as in isotropic plastic solids.     

J-A 2 Characterization of Crack-Tip Fields: Extent of J-A 2 Dominance and Size Requirements

The requirements for J-dominance, limits of the single-parameter criterion to characterize the fracture of engineering structures, and two-parameter fracture analyses are first reviewed. Through comparison, it is argued that the two-parameter fracture methodology based on the J-A ₂ theory is a reasonable extension of the single parameter (J-integral) fracture methodology. Consequently the extent of J-A ₂ dominance in various specimens under either tension or bending is investigated in detail in this paper. Using the J ₂ flow theory of plasticity and within the small-strain framework, full field finite element solutions are obtained for both deep and shallow crack geometries of single edge notch bar under pure bending [SEN(B)] and central cracked panel in uniform tension [CC(T)]. These crack-tip stresses are compared with those in the HRR singularity fields and the J-A ₂ asymptotic fields at the same level of applied J. The comparison indicates that the size R of the region dominated by the J-A ₂ field is much larger than that of the HRR field around the crack tip. Except for deeply-cracked SEN(B) in low hardening material (n=10) under fully plastic conditions, the numerical results near the crack tip in both SEN(B) and CC(T) match very well with the J-A ₂ asymptotic solutions in the area of interest 1<r/(J/σ₀)<5 from well-contained to large scale plasticity. The implications of these results on the minimal specimen size requirements essential to a two-parameter fracture criterion based on the J-A ₂ asymptotic solution are then discussed. This revised version was published online in August 2006 with corrections to the Cover Date.     

Interfacial crack-tip constraints and <Emphasis Type="Italic">J</Emphasis>-integral for bi-materials with plastic hardening mismatch

This paper investigates interfacial crack tip stress fields and the J-integral for bi-materials with plastic hardening mismatch via detailed elastic-plastic finite element analyses. For small scale yielding, the modified boundary layer formulation with the elastic T-stress is employed. For fully plastic yielding, plane strain single-edge- cracked specimens under pure bending are considered. Interfacial crack tip stress fields are explained by modified Prandtl slip-line fields. It is found that, for bi-materials consisting of two elastic-plastic materials, increasing plastic hardening mismatch increases both crack-tip stress constraint in the lower hardening material and the J-contribution there. The implication of asymmetric J-integral in bi-materials is also discussed.     

A constraint based parameter for quantifying the crack tip stress fields in welded joints

By means of finite element analyses of plane strain crack tip stress fields from homogeneous and heterogeneous modified boundary layer formulations, as well as homogeneous and mismatched full field solutions, a new constraint parameter β_m has been established for overmatched welded joints, allowing the material mismatching effect on the crack tip stress fields to be quantified. In the case of complete specimens, both geometry and material mismatching affect the crack tip stress fields, and a total constraint parameter β_T can be defined. This approach allows to quantify the stress fields directly from the values of the remote applied load.     

Engineering critical assessment for offshore pipelines with 3-D elliptical embedded cracks

Offshore pipelines are usually constructed by girth welding method, while weldments may naturally contain surface or embedded defects. Most existing fracture assessment procedures based on the load-controlled method are not explicitly designed for situations with large plastic strain. In this paper, the nonlinear elastic plastic fracture response of pipeline girth weld with embedded cracks is investigated through 3-D finite element analysis combined with submodeling technique. Strain-based estimation formulas for crack tip opening displacement are proposed for the pure bending load as well as the bending combined with the internal pressure. Furthermore, comparisons of fracture assessment between BS7910 and finite element analysis in the current study are made for various crack sizes.     

The strain-hardening effect in HRR plane fields according to T-criterion

The strain-hardening effect on fracture is investigated with the aid of the T-criterion using HRR stress fields [1–3] around a crack tip in a power hardening material. Using the appropriate components of strain energy density for the elastic-plastic as well as a nearly elastic expression of the T-criterion, we find the fracture angles, as well as fracture stresses in materials possessing an elastic extended up to a perfectly plastic behavior, by considering plane mixed-mode deformation at the crack tip.Significant influence of the strain hardening coefficient, n on the fracture stress, as well as the hardening parameter mainly appeared in plane strain conditions. This phenomenon was observed almost independently of the solution applied, which provides a nearly elastic or an elastic-plastic expression of the T-criterion describing the fracture conditions.     

Correlation of material constraint with fracture toughness of interface regions in a dissimilar metal welded joint

In this work, the constraint parameter A_p based on crack‐tip equivalent plastic strain was calculated by finite element analyses for the cracks located at different locations in two interface regions in a dissimilar metal weld joint (DMWJ). The capabilities of the parameter A_p for characterizing material constraint and establishing correlation of material constraint with fracture toughness of the interface region cracks have been examined. The results show that the parameter A_p can characterize material constraint effect caused by material mismatch and initial crack positions in the interface regions. Based on the A_p, the correlation lines and formulae of material constraint with fracture toughness of the interface region cracks in the DMWJ can be established, and they may be used for obtaining material constraint‐dependent fracture toughness for the interface region cracks. The results in this work combining with those in the previous studies indicate that the parameter A_p may be a unified constraint parameter that can characterize both geometry constraint (including in‐plane and out‐of‐plane constraints) and material constraint, and it may be used in accurate fracture assessments of welded components with different geometry and material constraints.     

Probabilistic fracture assessment of surface cracked pipes using strain-based approach

Simplified strain-based fracture mechanics equations, established for external surface cracked pipelines subjected to an external bending load, are presented and used in probabilistic assessment of a pipeline girth weld. The model takes into account several parameters, such as variation in crack depth, crack length, internal pressure and material hardening. The critical strain from ductile tearing in the cracked pipeline is found by using the tangency criterion. The reliability problem is solved using first and second order reliability methods for different pipe dimensions and load levels.     

A new constraint based fracture criterion for surface cracks

A new methodology for predicting the location of maximum crack extension along a surface crack front in ductile materials is presented. Three-dimensional elastic-plastic finite element analyses were used to determine the variations of a constraint parameter (α_h) based on the average opening stress in the crack tip plastic zone and the J-integral distributions along the crack front for many surface crack configurations. Monotonic tension and bending loads are considered. The crack front constraint parameter is combined with the J-integral to characterize fracture, the critical fracture location being the location for which the product Jα_h is a maximum. The criterion is verified with test results from surface cracked specimens.