FATIGUE AT NOTCHES SUBJECTED TO REVERSED TORSION AND STATIC AXIAL LOADS

Reversed torsion with and without a superimposed end load has been applied to 1% Cr-Mo-V steel specimens containing sharp notches. Crack propagation was monitored by a sensitive d.c. potential drop system that measured crack depths between 25 μm and 0.6 mm from the root of the notch. Stress intensity factors do not satisfactorily correlate all the crack growth data but a strain intensity factor which is a function of material properties and notch plastic zone size shows a significant improvement and provides a single upper bound solution for both ambient and elevated temperatures. This solution permits designers to make safe lifetime assessments. At room temperature cracks initially propagate by mode II along the surface, and mode III radially but at low stresses crack growth is continued by mode I propagation. At higher stresses a transition to mode I cracking is avoided. Elevated temperature causes a brittle layer to form and in this case cracks initially propagate by mode I which then translates to mode III cracking at high stresses. Mode III thresholds are significantly higher than mode I thresholds but a constrained shear strain zone, as found at the root of notches subjected to torsion, permits the initiation and generation of a mode III crack. The application of an axial load enhances the mode III crack propagation rate since this increases the effective crack tip intensification factor.     

Interface crack in periodically layered bimaterial composite

A directional crack growth prediction in a compressed homogenous elastic isotropic material under plane strain conditions is considered. The conditions at the parent crack tip are evaluated for a straight stationary crack. Remote load is a combined biaxial compressive normal stress and pure shear. Crack surfaces are assumed to be frictionless and to remain closed during the kink formation wherefore the mode I stress intensity factor K _I is vanishing. Hence the mode II stress intensity factor K _II remains as the single stress intensity variable for the kinked crack. An expression for the local mode II stress intensity factor k ₂ at the tip of a straight kink has been calculated numerically with an integral equation using the solution scheme proposed by Lo (1978) and refined by He and Hutchinson (1989). The confidence of the solution is strengthened by verifications with a boundary element method and by particular analytical solutions. The expression has been found as a function of the mode II stress intensity factor K _II of the parent crack, the direction and length of the kink, and the difference between the remote compressive normal stresses perpendicular to, and parallel with, the plane of the parent crack. Based on the expression, initial crack growth directions have been suggested. At a sufficiently high non-isotropic compressive normal stress, so that the crack remains closed, the crack is predicted to extend along a curved path that maximizes the mode II stress intensity factor k ₂. Only at an isotropic remote compressive normal stress the crack will continue straight ahead without change of the direction. Further, an analysis of the shape of the crack path has revealed that the propagation path is, according the model, required to be described by a function y=cx , where the exponent is equal to 3/2. In that case, when =3/2, predicts the analytical model a propagation path that is self-similar (i.e. the curvature c is independent of any length of a crack extension), and which can be described by a function of only the mode II stress intensity factor K _II at the parent crack tip and the difference between the remote compressive normal stress perpendicular to, and parallel with, the parent crack plane. Comparisons with curved shear cracks in brittle materials reported in literature provide limited support for the model discussed.     

The strip dielectric breakdown model

This paper reports on the analysis of the strip dielectric breakdown (DB) model for an electrically impermeable crack in a piezoelectric medium based on the general linear constitutive equations. The DB model assumes that the electric field in a strip ahead of the crack tip is equal to the dielectric breakdown strength, which is in analogy with the classical Dugdale model for plastic yielding. Using the Stroh formalism and the dislocation modeling of a crack, we derived the relationship between the DB strip size and applied mechanical and electrical loads, the intensity factors of stresses and electric displacement, and the local energy release rate. Based on the results, we discussed the effect of electric fields on fracture of a transversely isotropic piezoelectric ceramic by applying the local energy release rate as a failure criterion. It is shown that for an impermeable crack perpendicular to the poling direction, a positive electric field will assist an applied mechanical stress to propagate the crack, while a negative electric field will retard crack propagation. However, for an impermeable crack parallel to the poling direction, it is found that the applied electric field does not change the mode I stress intensity factor and the local energy release rate, i.e., the applied electric field has no effect on the crack growth.     

Evaluation of fatigue crack propagation by mode I and mixed mode in 1050 aluminium

The mechanism of mixed‐mode fatigue crack propagation was investigated in pure aluminum. Push‐pull fatigue tests were performed using two types of specimens. One was a round bar specimen having a blind hole, one was a plate specimen having a slit. The slit direction cut in the specimen was perpendicular or inclined 45 degrees relative to the centre of the specimen axis. In both cases, cracks propagated by mode I or by the mixed mode combining mode I and shear mode, depending on the testing conditions. In these cases the crack propagation rate was evaluated with a modified effective stress intensity factor range. Crack propagation retardation was observed in some specimens. However, it was found that the crack propagation rate could also be evaluated by the effective stress intensity factor range independent of the crack propagation mode.     

Connecting the essential work of fracture, stress intensity factor, Hill’s criterion in mixed mode I/II loading

Ductile sheet structures are frequently subjected to mixed mode loading, resulting that the structure is under the influence of a mixed mode stress field. Instances of interest are when stable crack growth occurs and when the crack-tip is propagating in this complex mixed-mode condition, prior to final fracture. Purposely designed apparatus was built to test thin-sheets of steel (Grade: DX51D) under mixed-mode I/II. These tests, under plane stress conditions, also investigated the effect of thickness on the specific essential work of fracture or the fracture toughness of the material under quasi-static cracking conditions. The fracture toughness is evaluated under incremental mixed-mode loading conditions. The direction of the propagating crack path and fracture type were observed and discussed as the loading mixity was varied. Whilst the specific essential work of fracture or fracture toughness was obtained using the energy approach, the theoretical analysis of the fracture type and direction of crack path were based on the crack tip stresses and fracture criterions of maximum hoop stress and maximum shear stress along with the utilisation of Hill’s theory. For mixed-mode I/II loading, the variation in the fracture toughness contributions ratios are evaluated and used predicatively using the established energy criterion approach to the crack tip stress intensity approach. The comparison between the theoretical directions of the crack path, failure mode propagation are in good agreement with those obtained from experimental testing indicating the definite link between both approaches.     

Some comments on surface cracks in rails

The present work considers the problem of whether a shallow angle surface crack on a rail may propagate either parallel or perpendicular to the surface. After referring to a classification of crack‐like defects, a distinct surface crack with a typical length of 1 mm and more, inclined to the surface by an angle of approx. 30°, is introduced. Then various strain and stress states are discussed (eigenstress, residual and load stress state) which may control the crack growth. Stress intensity factor equations are provided for the internal and load stress states. In particular, the deformation process due to a single pass (overrolling) by a wheel is investigated. Recommendations are presented on how to relate the stress intensity factor ranges to the actual deformation process. For a typical loading condition, the positive part of the mode I stress intensity factor range is near to the effective threshold value of a rail steel. The influence of the material and its strength on the crack propagation behaviour is discussed qualitatively.     

K‐dominance of static crack tip in functionally gradient materials

K‐dominance of static crack tip in functionally gradient materials (FGMs) with a crack oriented along the direction of the elastic gradient is studied through coherent gradient sensing (CGS), digital speckle correlation method (DSCM) and finite element method (FEM). In the direction of crack propagation, the shear modulus has a linear variation with constant mass density and Poisson's ratio. First, the CGS and DSCM governing equations related to the measurements and the elastic solutions at mode I crack in FGMs are obtained in terms of the stress intensity factor, material constants and graded index. Secondly, two kinds of FGMs specimens and one homogenous specimen are prepared to observe the influences of the property variation on the K‐dominance. Then, CGS and DSCM experiments using three‐point‐bending of FGMs and homogenous beams are performed. Thirdly, based on the results of the experiments, the stress intensity factors of three kinds of specimens are calculated by CGS and DSCM. Meanwhile, the stress intensity factors are obtained by FEM. Finally, comparing the results from CGS, DSCM and FEM, the K‐dominance of mode‐I static crack tip in FGMs is discussed in detail.     

Fatigue crack growth of a railway wheel

Typically, fatigue crack propagation in railway wheels is initiated at some subsurface defect and occurs under mixed mode (I–II) conditions. For a Spanish AVE train wheel, fatigue crack growth characterization of the steel in mode I, mixed mode I–II, and evaluation of crack path starting from an assumed flaw are presented and discussed.Mode I fatigue crack growth rate measurement were performed in compact tension C(T) specimens according to the ASTM E647 standard. Three different load ratios were used, and fatigue crack growth thresholds were determined according to two different procedures. Load shedding and constant maximum stress intensity factor with increasing load ratio R were used for evaluation of fatigue crack growth threshold.To model a crack growth scenario in a railway wheel, mixed mode I–II fatigue crack growth tests were performed using CTS specimens. Fatigue crack growth rates and propagation direction of a crack subjected to mixed mode loading were measured. A finite element analysis was performed in order to obtain the K_I and K_II values for the tested loading angles. The crack propagation direction for the tested mixed mode loading conditions was experimentally measured and numerically calculated, and the obtained results were then compared in order to validate the used numerical techniques.The modelled crack growth, up to final fracture in the wheel, is consistent with the expectation for the type of initial damage considered.     

Path prediction of I + III mixed mode fatigue crack propagation

In this paper, compact tension specimens with tilted cracks under monotonic fatigue loading were tested to investigate I + III mixed mode fatigue crack propagation in the material of No. 45 steel with the emphasis on the propagation rate expression and the path prediction. It is found that during the mode transformation process, the crack propagation rate is still controlled by the mode I stress intensity factor; and Paris equation also holds for the relationship between and ΔK_I . Crack propagation path can be predicted only when both the crack mode transformation rate and propagation rate are available.     

Der Einfluß von Festigkeit und Druckeigenspannungen auf die Wechselfestigkeit von Stählen bei höheren Temperaturen

Influence of Hardness and Comprehensive Residual Stresses on the Fatigue Limit of Steels under Elevated Temperatures The room temperature fatigue behaviour under alternating stresses of bcc steels is characterized by two stationary states existing below two different reversed stress limits: Below the one no crack initiation occurs, below the other no crack propagation can be found even after an unlimited number of stress cycles. The fatigue endurance of unnotched parts is determined by the crack initiation conditions that can be improved by higher hardness of the material. The fatigue strength of notched parts under reversed stresses is decidently determined by the minimum stress required to propagate a crack; this stress can be raised by compressive residual stresses. – At elevated temperatures these two stationary states are not further existent and there are no alternating stress amplitudes that can be endured either without crack initiation or without crack propagation to fracture. Both influencing parameters hardness and compressive residual stresses are dependend on the temperature, this can be explained by Snoek's and by Cottrell's mechanisms and with the temperature depending release of residual stresses corresponding to the temperature sensitive yield point.     

A study of the propagation of an embedded crack in a composite laminate of finite thickness

In this paper, the mechanism for the propagation of a crack embedded in the central layer of a composite laminate is studied based on energy criteria. As the crack may propagate in the transverse direction or in the tunneling direction, the critical stresses for these two propagations are presented. The theoretical analysis is applied to a fibre-reinforced composite laminate. Critical stresses for the initiation of crack propagation are calculated taking into account the influence of the adjacent ply angle and the crack size. It is found that for the considered typical fibre-reinforced composite laminate, the critical stress for the transverse propagation is less than that for the tunneling propagation. Therefore, transverse cracking is a more possible fracture mode in composite laminates with initial crack-like defects. This finding supports the calculation of the in situ transverse strength based upon the transverse crack propagation.     

含圆孔缺陷三点弯曲梁的裂纹扩展特性实验研究

采用动态焦散线实验系统,对含圆孔缺陷的PMMA材料进行冲击断裂力学实验,研究三点弯曲梁中不同直径和位置的圆孔缺陷对扩展裂纹的影响。实验结果表明:扩展裂纹与圆孔缺陷相互作用前,呈现Ⅰ型拉伸断裂,扩展路径平直;与圆孔缺陷相互作用后,贯通萌生的次裂纹沿直线继续扩展,未贯通的裂纹偏移扩展。扩展裂纹与路径上圆孔缺陷贯通过程中,裂纹扩展速度和动态应力强度因子快速降为零,裂纹的扩展受到抑制,且圆孔直径越大、距离越近,抑制作用越显著;贯通萌生次生裂纹的起裂速度和起裂韧度,随着圆孔缺陷直径的增大而变大。扩展裂纹与偏置圆孔缺陷相互作用过程中,当圆孔缺陷直径越大、偏置距离越小,裂纹起偏距离越短,最大偏移量越大,并且扩展裂纹动态应力强度因子和扩展速度局部小幅增大。研究结果为分析动态裂纹扩展特征和材料破坏模式提供借鉴。     

Crack paths under mixed mode loading

Long fatigue cracks that initially experience mixed mode displacements usually change direction in response to cyclic elastic stresses. Eventually the cracks tend to orient themselves into a pure mode I condition, but the path that they take can be complex and chaotic. In this paper, we report on recent developments in techniques for tracking the crack path as it grows and evaluating the strength of the mixed mode crack tip stress field.     

Fatigue crack propagation assessment based on residual stresses obtained through cut-compliance technique

Crack growth rate versus crack length curves of heavily overloaded parent material specimens and fatigue crack propagation curves of friction‐stir‐welded aluminium samples are presented. It is shown that in both cases the residual stresses have a strong effect on the crack propagation behaviour under constant and variable amplitude loading. As a simplified engineering approach, it is assumed in this paper, that in both cases residual stresses are the main and only factor influencing crack growth. Therefore fatigue crack propagation predictions are performed by adding the residual stresses to the applied loading and by neglecting the possible effects of overloading and friction stir welding on the parent material properties. For a quantitative assessment of the residual stress effects, the stress intensity factor due to residual stresses K_res is determined directly with the so‐called cut‐compliance method (incremental slitting). These measurements are particularly suited as input parameters for the software packages AFGROW and NASGRO 3.0, which are widely used for fatigue crack growth predictions under constant and variable amplitude loading. The prediction made in terms of crack propagation rates versus crack length and crack length versus cycles generally shows a good agreement with the measured values.     

Crack propagation from a pre-existing flaw at a notch root. I. Introduction and general form of the stress intensity factors at the initial crack tip

This paper and its companion are devoted to the study of crack kinking from some small pre-existing crack originating from a notch root (the notch root radius being zero). Both the notch boundaries and the initial crack are allowed to be curved; also, the geometry of the body and the loading are totally arbitrary. The ingredients required are knowledge of the stress intensity factors at the initial crack tip and use of a suitable mixed mode propagation criterion. This paper is devoted to the first point, and more specifically to establishing the general (that is, not yet fully explicit) form of the formulae giving these stress intensity factors. The method used is based on changes of scale (homogeneity properties of the equations of elasticity) on the one hand, and on continuity of the displacement and stresses at a given, fixed point with respect to the crack length on the other hand. The formulae derived for the stress intensity factors at the tip of the small crack are of universal value: they apply to any situation, whatever the geometry of the body, the notch and the crack and whatever the loading, the stress intensity factors depending always only upon the `stress intensity factor of the notch' (the multiplicative coefficient of the singular stress field near the notch root in the absence of the crack), the length of the crack, the aperture angle of the notch and the angle between its bisecting line and the direction of the crack.     

Prediction of fatigue crack growth path in mechanical joints using a weight function approach

Cracks often initiate from the mechanical joints which are widely used in structural components. It has been reported that cracks in mechanical joints are under mixed‐mode condition and there is a critical angle at which mode I stress intensity factor becomes maximum. The crack propagates in an arbitrary direction and the prediction of fatigue crack growth path is needed to provide against crack propagation and examine safety. In this study, mixed‐mode fatigue crack growth tests are performed for horizontal and critical inclined cracks in mechanical joints. Fatigue crack growth paths are predicted using a weight function approach and maximum tangential stress criterion.     

The preferred fatigue crack propagation mode in a M250 maraging steel loaded in shear

Macroscopic torsional fatigue cracks are shown to propagate in shear, in plain tubular specimens, in the M250 maraging steel, for stress ranges from 90% down to 40% of the yield stress. This cannot be explained in terms of microcrack coalescence for the smallest stress range, for which microcracks are scarce. The kinetics and mechanisms of mode II fatigue crack growth are thus investigated, using precracked CTS or tubular specimens. For a high Δ K _II , slowly decelerating mode II propagation takes place for a distance that increases with Δ K _II before branching occurs. Friction stresses along the crack flanks shield the applied load and explain this deceleration. An inverse analytical procedure is used to derive the effective stress intensity factor, allowance being made for friction effects, from displacement profiles measured from microgrids using a scanning electron microscope. The measured crack growth rates correlate much better with the effective stress intensity factor than with the nominal Δ K _II value. The crack paths observed in torsion are discussed in terms of maximum crack velocity.     

Computation of the stress intensity factors for repaired cracks with bonded composite patch in mode I and mixed mode

In this study, the finite element method is used to analyse the behaviour of repaired cracks with bonded composite patches in mode I and mixed mode by computing the stress intensity factors at the crack tip. The effects of the patch size and the adhesive properties on the stress intensity factors variation were highlighted. The plot of the stress intensity factors according to the crack length in mode I, shows that the stress intensity factor exhibits an asymptotic behaviour as the crack length increases. In mixed mode, the obtained results show that the Mode I stress intensity factor is more affected by the presence of the patch than that of mode II.     

Shear mode fatigue crack growth in 1050 aluminium

The shear mode crack growth mechanism in 1050 aluminium was investigated using pre‐cracked specimens. A small blind hole was drilled in the centre section of the specimens in order to predetermine the crack initiation position, and a push–pull fatigue test was used to make a pre‐crack. Crack propagation tests were carried out using both push–pull and cyclic torsion with a static axial load. With push–pull testing, the main crack grew by a mixed mode. It is thus apparent that shear deformation affects the fatigue crack growth in pure aluminium. In tests using cyclic torsion, the fatigue crack grew by a shear mode. The micro‐cracks initiated perpendicular and parallel to the main crack's growth direction during the cyclic torsion tests. However, the growth direction of the main crack was not changed by the coalescence of the main crack and the micro‐cracks. Shear mode crack growth tends to occur in aluminium. The crack growth behaviour is related to a material's slip systems. The number of slip planes in aluminium is smaller than that of steel and the friction stress during edge dislocation motion of aluminium is lower than many other materials. Correlation between the crack propagation rate and the stress intensity factor range was almost the same in both push–pull and cyclic torsion with tension in this study.     

In-situ Observation of Initiation and Propagation of Cleavage Microcrack in TiAl

Nucleating and propagating of nancrack formed in dislocation free zone (DFZ) for the brittle TiAl alloy has been studied through in-situ tensile test in TEM and analyzed using microfracture mechanics. The resufts show that a lot of dislocations can be emitted from a crack tip when the applied stress intensity Kla i5 larger than the stress intensity for dislocatin emission Kle=1.4 M Pa·m1/2 and a dislocation free zone, which smetimes is a close zone, can form after reaching equilibrium. The DFZ is a elastic zone with large strain and then the stress in the DFZmight equal to the cohesive strength σth because the crack tip is still sharp. When Kla is larger than the stress intensity for nanocrack nucleation Kli =2.4 M Pa·m1/2, the stress within a certain range in the DFZ would equal to σth and then a nanocrack initiates in the DFZ or sometimes at the notch tip. The nanocrack formed in the DFZ is stable and can propagate a small distance in cleavage mode through multiplication and movement of dislocation in the plastic zone, during keeping constant displacement. Increasing Kla can make the crack stably propagate continuously or discontinuously and it means that the stre5s intensity for crack propagation, Klp, is larger than Kli. Therefre, Kle 相似文献