2D modelling of inclined intergranular stress corrosion crack paths

Inclined high pH stress corrosion cracking (SCC) is a type of intergranular environmental cracking in gas pipelines, which differs from typical SCC by propagating at an angle from the wall direction. Investigations of Australian and Canadian inclined SCC colonies have not provided a clear indicator of a cause for the abnormal crack growth direction. This paper addresses the possibility of crack tip strain enhanced electrochemistry causing the inclination. Potentiodynamic tests were conducted to quantify the influence of strain on the electrochemistry, and strain was found to increase current density up to 300% in the SCC region. A model was developed that incorporates crack tip strain driven SCC growth, which showed good agreement with field grown cracks, and the aspect ratio of the grains was shown to have an effect on the inclination angle. The results indicate that crack tip strain enhanced electrochemistry is a plausible cause for inclined SCC.     

Micro-mechanical theory of macroscopic stress-corrosion cracking in unidirectional GFRP

A micro-mechanical theory of macroscopic stress-corrosion cracking in a unidirectional glass fibre-reinforced polymer composite is proposed. It is based on the premise that under tensile loading, the time-dependent failure of the composite is controlled by the initiation and growth of a crack from a pre-existing inherent surface flaw in a glass fibre. A physical model is constructed and an equation is derived for the macroscopic crack growth rate as a function of the apparent crack tip stress intensity factor for mode I. Emphasis is placed on the significance of the size of inherent surface flaw and the existence of matrix crack bridging in the crack wake. There exists a threshold value of the stress intensity factor below which matrix cracking does not occur. For the limiting case, where the glass fibre is free of inherent surface flaws and matrix crack bridging is negligible, the relationship between the macroscopic crack growth rate and the apparent crack tip stress intensity factor is given by a simple power law to the power of two.     

Effect of acetic acids on the corrosion crack growth of 3.5NiCrMoV steels in high temperature water: synergistic interaction between stress corrosion and corrosion fatigue

Stress Corrosion Cracking (SCC) tests (pH: 3 ~ 5) and Corrosion Fatigue (CF) tests (R = 0.2, 0.1 Hz) were conducted to evaluate the effect of acetic acid on the corrosion crack growth behavior in high temperature water at 150°C. Acetic acid significantly influenced the corrosion fatigue cracking behavior of turbine disc steels in high temperature water. The CF crack growth rates of turbine disc steels increase until the organic acid concentration reaches a critical saturation value (between pH 4 and pH 3) because of the crack tip sharpening. Below the critical value of pH, the CF crack growth rates decreases because of the crack tip blunting. The corrosion fatigue crack growth rate is accelerated by the interaction of the fatigue and the stress corrosion in the test environment. The synergistic interaction should be accounted for in the realistic prediction of the corrosion fatigue life of turbine steel (3.5NiCrMoV steels) in high temperature water of acetic acid solution. With the high temperature corrosion fatigue data obtained in this study, it is possible to assess the life of turbine components in high temperature and high pressure.     

A shear band decohesion model for small fatigue carck growth in an ultra-fine grain aluminium alloy

A study of small fatigue crack growth behaviour of an ultra-fine grain size aluminum alloy IN 9052 has been carried out. Specimens were tested in tension–tension at R0.1 in laboratory air and in the vacuum chamber of a field emission gun scanning electron microscope. Loading and unloading experiments were carried out within the SEM to study the displacements of the crack faces, the shape change at the crack tip, the shear bands around the crack tip and the fatigue crack growth mechanism. The in-situ SEM observations revealed that shear bands formed in the crack tip region were directly associated with the growth mechanism of the crack. The shear bands localized the decohesion in the crack tip region and the cracking along the shear bands was observed to occur during the loading part of the load cycle. The overall behaviour of the crack tip region subjected to cyclic loading is summarized by a qualitative model for small crack growth in an ultra-fine grained material.     

ESEM observations of SCC initiation for 4340 high strength steel in distilled water

The stress corrosion cracking (SCC) initiation process for 4340 high strength steel in distilled water at room temperature was studied using a new kind of instrument: an environmental scanning electron microscope (ESEM). It was found that the applied stress accelerated oxide film formation which has an important influence on the subsequent SCC initiation. SCC was observed to initiate in the following circumstances: (1) cracking of a thick oxide film leading to SCC initiation along metal grain boundaries, (2) the initiation of pits initiating SCC in the metal and (3) SCC initiating from the edge of the specimen.All these three SCC initiation circumstances are consistent with the following model which couples SCC initiation with cracking of a surface protective oxide. There is a dynamic interaction between oxide formation, the applied stress, oxide cracking, pitting and the initiation of SCC. An aspect of the dynamic interaction is cracks forming in a protective surface oxide because of the applied stress, exposing to the water bare metal at the oxide crack tip, and oxidation of the bare metal causing crack healing. Oxide crack healing would be competing with the initiation of intergranular SCC if an oxide crack meets the metal surface at a grain boundary. If the intergranular SCC penetration is sufficiently fast along the metal grain boundary, then the crack yaws open preventing healing of the oxide crack. If intergranular SCC penetration is not sufficiently fast, then the oxidation process could produce sufficient oxide to fill both the stress corrosion crack and the oxide crack; in this case there would be initiation of SCC but only limited propagation of SCC. Stress-induced cracks in very thin oxide can induce pits which initiate SCC, and under some conditions such stress induced cracks in a thin oxide can directly initiate SCC.     

风力机叶片复合材料裂尖温度场及微观损伤研究

依据热力耦合建立含微缺陷叶片的裂尖温度场数值模型,并研究了微缺陷叶片断裂微观损伤方式。首先,建立裂尖温度场数学模型需要确定塑性区范围和塑性区内的内热流密度函数。基于正交各向异性复合材料裂纹尖端应力场和Tsai-Wu屈服准则理论推导,得到含微缺陷风电叶片Ⅰ/Ⅱ复合型裂纹的塑性区范围;内热流密度函数按照裂纹扩散规律构造。其次,利用电子扫描电镜技术对叶片试件的断口失效微观结构进行检测。通过红外热像仪监测微缺陷叶片试件表面温度实验,验证了裂尖温度场计算模型的准确性;确定计算温度场模型中内热流密度函数幂数为2;通过显微技术发现含气泡缺陷的叶片试件有纤维断裂、基体开裂损伤方式。     

An analysis of competing toughening mechanisms in layered and particulate solids

The relative potency of common toughening mechanisms is explored for layered solids and particulate solids, with an emphasis on crack multiplication and plasticity. First, the enhancement in toughness due to a parallel array of cracks in an elastic solid is explored, and the stability of co-operative cracking is quantified. Second, the degree of synergistic toughening is determined for combined crack penetration and crack kinking at the tip of a macroscopic, mode I crack; specifically, the asymptotic problem of self-similar crack advance (penetration mode) versus $90^{\circ }$ symmetric kinking is considered for an isotropic, homogeneous solid with weak interfaces. Each interface is treated as a cohesive zone of finite strength and toughness. Third, the degree of toughening associated with crack multiplication is assessed for a particulate solid comprising isotropic elastic grains of hexagonal shape, bonded by cohesive zones of finite strength and toughness. The study concludes with the prediction of R-curves for a mode I crack in a multi-layer stack of elastic and elastic–plastic solids. A detailed comparison of the potency of the above mechanisms and their practical application are given. In broad terms, crack tip kinking can be highly potent, whereas multiple cracking is difficult to activate under quasi-static conditions. Plastic dissipation can give a significant toughening in multi-layers especially at the nanoscale.     

Damage indices for failure of concrete beams under fatigue

In this study, an analytical method is proposed to correlate local damage variables such as relative crack depth and crack tip opening displacement with a newly defined global damage index for a concrete beam under fatigue loading. This global damage index may be used to assess the response of a degraded concrete beam under service loading. The damage is assumed to appear in the form of a major crack that propagates under constant amplitude fatigue loading. The progressive cracking phenomenon is modeled within a finite element framework using a crack beam element, which takes into account the compliance variation due to discrete cracking within the member. The flexural stiffness degradation of the member is computed based on an Eigen analysis of the global stiffness matrix. It is seen that the degree of flexural stiffness degradation due to discrete cracking is the same for geometrically similar specimens when the relative crack depth is used as a local damage parameter. Further, in order to improve the accuracy of the response prediction using the above global damage index, another global damage parameter is defined based on the nature of applied loading.     

Estimating cyclic corrosion cracking resistance for titanium alloys

Conclusions 1. Cyclic cracking resistance tests for titanium alloys, as for steels, are affected not only by the state of stress and strain but also by the electrochemical conditions at the crack tip.2. Cyclic corrosion cracking tests require one to consider the electrochemical conditions at the crack tip.3. These methods have been tested in corrosion crack stability tests, which involved monitoring the electrochemical conditions at the surface of the specimen, which do not unambiguously define the corrosion cracking resistance for titanium alloys in a particular medium.4. It is possible to derive invariant fatigue failure diagrams for titanium alloys in a given medium only if one provides constant conditions at the crack tip during growth.5. The electrochemical conditions at the crack tip can be characterized reasonably fully (integrally) for titanium alloys, as for steels, by means of the pH and the electrode potential.6. The type of alloy governs the electrochemical characteristics at the tip of a stationary statically loaded crack and a growing one.7. To select basic fatigue-failure diagrams for a corrosive medium, one can use the methodology developed previously for steels, which is based on invariant diagrams in air and in the medium, where one examines the effects of extremal working conditions and the electrochemical conditions at the crack tip.Karpenko Physicomechanics Institute, Ukrainian Academy of Sciences, L'viv. Translated from Fiziko-Khimicheskaya Mekhanika Materialov, Vol. 29, No. 2, pp. 33–42, March–April, 1993.     

A threshold fatigue crack closure model: Part I – model development

A fatigue crack closure model is developed that includes the effects of, and interactions between, the three closure mechanisms most likely to occur at threshold; plasticity, roughness, and oxide. This model, herein referred to as the CROP model (for Closure, Roughness, Oxide, and Plasticity), also includes the effects of out‐of‐plane cracking and multi‐axial loading. These features make the CROP closure model uniquely suited for, but not limited to, threshold applications. Rough cracks are idealized here as two‐dimensional sawtooths, whose geometry induces mixed‐mode crack‐tip stresses. Continuum mechanics and crack‐tip dislocation concepts are combined to relate crack face displacements to crack‐tip loads. Geometric criteria are used to determine closure loads from crack‐face displacements. Finite element results, used to verify model predictions, provide critical information about the locations where crack closure occurs. The CROP model is verified with experimental data in part II of this paper.     

Progress in failure analysis of constrained shrinkage cracking in reinforced concretes

Shrinkage-induced cracking in constrained concrete slabs is an important failure mode for concrete structures. Several empirical relations have been reported in earlier studies. This paper develops a mechanics-based relationship for shrinkage-induced cracking through a shear-lag model that can be used to analyze the stress field, crack width, and the final crack spacing for cracked concrete slabs. The present model prediction is observed to be close to the empirical relation based on long-term observations.     

Analysis of multiple cracks in laminate composites under anti-plane static loads

This paper investigates multiple cracking of a laminate composite subjected to anti‐plane loads. The laminate composite is made up of a central layer sandwiched between two layers of different properties. There is a periodic array of cracks in the central layer along the central axis of the medium. A singular integral equation is formulated in terms of the crack‐face displacement. The model developed is applied to the analysis of fibre multiple cracking in fibre‐matrix laminate composites. It is also applied to the analysis of matrix cracking in fibre‐matrix laminate composites. Numerical results have been given for the effects of crack spacing and constituent volume fraction on the crack tip field intensity factor and stress.     

带有空间裂纹的拉伸试件电磁热止裂及机械性能测试

首先应用ZL-2超强脉冲电流发生装置对带有预制裂纹的标准拉伸试件进行脉冲放电止裂。放电后裂纹尖端熔化形成堆焊和高压应力区,使裂纹尖端钝化,达到了止裂的目的,采用数值模拟确定了止裂工艺参数。对止裂后的拉伸试件通过微机控制电子万能试验机进行了拉伸实验,研究结果表明:电磁热裂纹止裂有效提高了试件的抗拉强度,放电电压是影响其机械性能的最主要因素。     

基于灰色理论的高强铝合金应力腐蚀开裂预测模型的建立与应用

采用3.5%NaC1溶液中预制裂纹的方法测试了2124高强铝合金的应力腐蚀裂纹扩展长度随时间的变化,获得了裂纹扩展速率随腐蚀时间的变换规律及应力腐蚀断裂韧性界限值,并对断口进行分析.根据裂纹扩展的基本规律,运用灰色理论GM(1,1)模型,依据2124铝合金应力腐蚀开裂裂纹扩展长度的原始数据进行了灰色预测,并对预测结果进...     

A level set approach to model directed nanocrack patterns

Recent experiments revealed an exciting possibility of making nanowires by filling nanosacle cracks in a thin film. Exploration and practical application of the method would rely on the modeling capability to predict complex nanocracks and their geometries in heterogeneous films. This paper proposes a level set approach to investigate the formation of nanocrack patterns, which allows precise prediction of the direction of crack extension, geometry of the crack tip, and interaction between crack and other phases. The approach does not require explicit front tracking and allows for the simulation of complex crack patterns and crack intersection. An efficient iterative Fourier spectral method is applied to solve the elastic field. The propagation of the crack interface is determined by the competition between the elastic and interfacial energies. This paper investigates the cracking process in a thin film with etched spaces and stiff phases. Numerical simulations reveal that designed pre-patterns can effectively direct crack extension and suggest a significant degree of experimental control in the formation of nanocrack patterns.     

A statistical micromechanical model of multiple cracking for ultra high toughness cementitious composites

A new statistical micromechanical model of multiple cracking is proposed in which a general expression of the fiber bridging stress laws in the crack plane is established. In this model, the random distribution properties of fibers are considered. And the Weibull function is adopted to represent the flaw size distribution. The relationships of stress versus strain and crack width versus strain are proposed. The formulas of the crack width, crack space, strain capacity and fracture energy density at the end of multiple cracking processes are also deduced. The validity of the proposed model was demonstrated by experimental results.     

The role of crazes in the crack growth of polyethylene

Brittle slow crack growth, or stress cracking, is a major concern in many applications of polyethylene materials. Using a constant tensile load test and removing specimens prior to complete failure, details of the crack tip region can be discerned in both butene and hexene copolymerized polyethylene. In both the presence and absence of an accelerating environment (Igepal CO-630), it was found that crazes formed at the crack tip, although secondary crazes were also evident in the specimens removed from the Igepal. Multiple crack arrest lines were clearly evident, suggesting a stick-slip mechanism under static load. The appearance of the craze zone at the crack tip can be explained through invoking an interlamellar failure model.     

Singular and non-singular approaches for predicting fatigue crack growth behavior

In this work, three classes of mechanisms that can cause load sequence effects on fatigue crack growth are discussed: mechanisms acting before, at or after the crack tip. After reviewing the crack closure idea, which is based on what happens behind the crack tip, quantitative models are proposed to predict the effects at the crack tip due to crack bifurcation. To predict the behavior ahead of the crack tip, a damage accumulation model is proposed. In this model, fatigue cracking is assumed caused by the sequential failure of volume elements or tiny εN specimens in front of the crack tip, calculated by damage accumulation concepts. The crack is treated as a sharp notch with a small, but not zero radius, avoiding the physically unrealistic singularity at its tip. The crack stress concentration factor and a strain concentration rule are used to calculate the notch root strain and to shift the origin of a modified HRR field, resulting in a non-singular model of the strain distribution ahead of the crack tip. In this way, the damage caused by each load cycle, including the effects of residual stresses, can be calculated at each element ahead of the crack tip using the correct hysteresis loops caused by the loading. The proposed approach is experimentally validated and extended to predict fatigue crack growth under variable amplitude loading, assuming that the width of the volume element broken at each cycle is equal to the region ahead of the crack tip that suffers damage beyond its critical value. The reasonable predictions of the measured fatigue crack growth behavior in steel specimens under service loads corroborate this simple and clear way to correlate da/dN and εN properties.     

Investigation of the crack growth behavior of Inconel 718 by high temperature Moiré interferometry

The effect of environment on creep crack growth behaviors of many nickel-base superalloys is a well-documented and serious problem. Stress accelerated grain boundary oxidation (SAGBO) is accepted as the prior mechanism of the environment effect. In this paper, the crack growth behavior of Inconel 718 was investigated by high temperature moiré interferometry (HTMI), coupled with SEM/EDAX. Based on the results obtained from this research, the mechanism is proposed to be caused by the segregated Nb, which couples with the oxygen diffusing into the grain boundaries in front of the crack tip and forms an NbO layer on the grain boundaries, thereby causing the brittle elastic cracking behavior.     

铈离子对高强铝合金应力腐蚀开裂的缓蚀作用

基于慢应变速率拉伸实验(SSRT),采用恒电流极化、电化学噪声(ECN)与电化学阻抗(EIS)等方法,研究7A04铝合金在3.5%(质量分数)NaCl水溶液中的应力腐蚀开裂(SCC)行为以及Ce~(3+)对其SCC的缓蚀作用,探讨Ce~(3+)对裂纹孕育与发展过程的抑制机理。结果表明:无论是阳极还是阴极极化,均会促进7A04的SCC倾向,前者增加了裂尖的阳极溶解,后者则加速了裂尖的氢脆效应。Ce~(3+)的加入能延缓7A04的SCC断裂时间,但其有效性仅限于裂纹的萌生阶段。由于Ce~(3+)能够抑制铝合金表面的亚稳态点蚀发育和长大,因而使裂纹的孕育时间显著延长,降低了SCC的敏感性。不过一旦裂纹进入扩展阶段或者试样表面有预裂纹,则由于Ce~(3+)很难迁移到裂纹尖端或在裂尖区难以成膜,不能对裂纹的生长起到有效抑制作用,因而无法降低7A04的SCC发展速率。SEM分析表明7A04铝合金光滑试样SCC主要源于亚稳态或稳态点蚀的诱导作用。