Dissertations / Theses on the topic 'Facture toughness; Crack growth'

Thesis (Ph. D.)--Worcester Polytechnic Institute.
Keywords: Microstructure; Elastic-Plastic Fracture Mechanics; Crack closure; A356; J-integral; Conventionally cast and SSM Al-Si-Mg alloys; Residual stress; Heat treatment; Fatigue crack growth mechanisms; Threshold stress intensity factor; Plastic zone; Paris law; Fracture toughness; Roughness. Includes bibliographical references.

The main aim of this work was to investigate the fatigue crack growth resistance and fracture toughness of selectively reinforced Al alloys. In such bimaterials, the crack growth resistance is affected by the failure mechanism, the direction of crack approach to the interface and by the conflict between the elastic-plastic mismatch and residual stresses. When the crack approaches the interface from the composite side, in the A12124 based bimaterials, the fatigue crack growth rate is reduced below "composite only" values by the compressive residual stress, although the elastic-plastic mismatch was expected to cause the opposite effect. In the A16061 based bimaterials, although some crack deceleration is also observed, fatigue crack growth rates are above the "composite only" values presumably because these bimaterials have lower compressive residual stress and higher plastic mismatch near the interface. After crossing the interface, the crack driving force is affected by closure mechanisms developed on the composite side of the crack wake. Conversely, when the crack grows from the Al alloy side, for both A12124 and A16061 based bimaterials, the crack growth rate is mainly reduced by the elastic-plastic mismatch. After crossing the interface, the crack driving force is well described by the thermal residual stresses, unless a crack tip deflection reduces the Mode I near tip stresses. In a fracture toughness test, when the pre-crack tip is in the composite side of the A12124 based bimaterials, KQ(5%) values are increased above "composite only" values presumably due to the compressive residual stresses and despite the amplification of the crack driving force from the elastic-plastic mismatch. In the A16061 based bimaterials, due to the higher plastic mismatch and lower compressive residual stresses, KQ(5%) values are below "composite only" values. Additionally, for all bimaterials, KQ(5%) values increase if the pre-crack tip is closer to the interface. When the crack propagates, it extends to the interface, bifurcates and arrests. The load then had to be increased to promote the onset of plastic collapse. The crack tip blunting and deflection mechanism increases the toughness attained at the onset of plastic collapse of the bimaterials above "Al alloy only" values. Conversely, if the pre-crack tip is in the Al alloy side, the final failure is deduced to occur when damage accumulated on the composite side links to the pre-crack tip. When the pre-crack tip is at 2.0mm from the interface, for the A12124 based bimaterials, KQ(5%) values are in general lower than the "A12124 only" value due to the tensile residual stresses. For the A16061 based bimaterials, KQ(5%) values are as high as the "A16061 only" value presumably due to the higher plastic mismatch and lower tensile residual stress of such bimaterials. Additionally, for all bimaterials, KQ(5%) values increase if the precrack tip is at 0.5mm from the interface. If the pre-crack tip is at 2.0mm from the interface, Kerit and Scrit values of the bimaterial are higher than the "Al alloy only" value and this is deduced to be due to the increase in the elastic-plastic mismatch shielding and by delayed critical particle damage within the composite side. At 0.5mm from the interface, Keritt and Scrit values are reduced and this is deduced to be because both the near tip tensile residual stress is higher and critical particle damage occurs earlier on the composite side; moreover, the unreinforced Al alloy layer is thinner and the damage on the composite side is deduced to link more easily to the pre-crack tip. For a constant particle size, there is an optimum particle volume fraction in which both Kerit and Scrit values are maximised with respect to a specific pre-crack tip position.

The primary focus of this research is to evaluate the time-dependent crack growth in rocks using lab tests and numerical modeling and its application to geologic hazard problems. This research utilized Coconino sandstone and Columbia granite as the study materials and produced the subcritical crack growth parameters in both mode I and II loadings using the rock materials. The mode I loading test employs three different types of fracture mechanics tests: the Double Torsion (DT), the Wedge Splitting (WS), and the Double Cantilever Beam (DCB) test. Each test measured the mode I crack velocity. The DT test indirectly measured the crack velocity using the load relaxation method. The WS and DCB tests directly measured the crack velocity by monitoring using a video recording. The different mode I subcritical crack growth parameters obtained from the three tests are discussed. For the mode II loading test, this study developed a new shear fracture toughness test called the modified Punch-Through Shear (MPTS). The MPTS test conducted at different loading rates produced the mode II subcritical crack growth parameters. These fracture mechanics tests were calibrated and simulated using the distinct element method (DEM) and the finite element method (FEM). DEM analysis employed the particle flow code (PFC) to simulate the mixed mode crack growth and to match with the failure strength envelop of the triaxial compressive tests. FEM analysis employed the Phase2 program to analyze the crack tip stress distribution and the FRANC2D program to calculate the modes I and II stress intensity factors. The fracture mechanics tests and numerical modeling showed well the dependency of the mode II subcritical crack growth parameters according to confining pressure, loading rate, and the mode II fracture toughness. Finally, the UDEC modeling based on DEM is utilized in this study to forecast the long-term stability of the Coconino rock slope, as one of geologic hazards. The fracture mechanics approach is implemented in the program using the modes I and II subcritical crack growth parameters obtained from the lab tests and numerical modeling. Considering the progressive failure of rock bridges due to subcritical crack growth, the UDEC results predicted the stable condition of the Coconino rock cliff over 10,000 years. This result was validated by comparing it with the previous planar failure case.

Fatigue crack growth behavior of AA7050 T7451 aluminum alloy under mode II loading condition in two orientations was investigated. Compact shear specimens were prepared in TL and LT directions. A loading frame for mode II type of loading was manufactured. Using the loading frame and the specimen, KIIC values and mode II fatigue crack growth rates were calculated. Fractographic analysis of the fracture surfaces of both mode II fracture toughness test specimens and mode II fatigue crack growth test specimens were done to examine the effects of mode II load. KIIC values were measured between 1.3 and 1.5 times the KIC values for this alloy. As for mode II fatigue crack growth rates, TL orientation shows the highest mode II fatigue crack growth resistance.

Ou study focuses on the effects of phase transformations on crack propagation. We want to understand the changes of fracture toughness during welding. In this work, fracture toughness is expressed by J-integral. There are many experimental methods to obtain the critical toughness JIC but they are impractical for our investigation during phase transformation. That is the reason why we have proposed a method coupling mechanical tests, digital image correlation and finite element simulation. The fracture tests are implemented on pre-cracked single edge notched plate sample which is easy for machining and heat conduct during phase transformation. The tests are conducted at different temperatures until rupture. Digital image correlation gives us the displacement information on every sample. Each test is then simulated by finite element where the fracture toughness is evaluated by the method G-Theta at the crack propagation starting moment found by potential drop method and digital image correlation technical. Two materials have been studied, 15Cr-5Ni martensitic precipitation hardening stainless steel and 16MND5 ferritic low carbon steel. For these two materials, different test temperatures were chosen before, during and after phase transformation for testing and failure characterization of the mechanical behavior. Investigation result shows that metallurgical phase transformation has an influence on fracture toughness and further crack propagation. For 15-5PH, the result of J1C shows that the as received 15-5PH has higher fracture toughness than the one at 200°C. The toughness is also higher than the original material after one cycle heat treatment probably due to some residual austenite. Meanwhile, pure austenite 15-5PH at 200°C has higher fracture toughness than pure martensitic 15-5PH at 200°C. For 16MND5, the result also proves that the phase transformation affects fracture toughness. The as received material has bigger J1C than the situation where it was heated to 600°C. On the other hand, the material at 600°C just before isothermal bainite transformation after the austenitization during cooling process also has higher fracture toughness than the one at 600°C before austenitization. These two conclusions are consistent well with the result of 15-5PH. But the final situation of 16MND5 after one cycle heat treatment has a slightly smaller J1C than the receiving situation. It means that one cycle heat treatment hasn't an significant influence on 16MND5fracture toughness. Conclusions show that one should pay attention to the heating period before austenitization of the substrate material when people do the welding as the higher temperature will bring the lower fracture toughness during this process. While during cooling period, the fracture toughness doesn't change a lot during, before or after the cooling induced phase transformation. Even for 15-5PH, it has a better fracture toughness after the martensite transformation than before.

Orientador: Itamar Ferreira
Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica
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Resumo: Este trabalho propõe uma metodologia para avaliar pontualmente as variações de tenacidade à fratura e taxa de crescimento de trinca de fadiga ao longo da camada cementada de um aço SAE 4320. A pequena espessura dessas camadas impede a retirada de corpos de prova nas dimensões especificadas pelas normas de ensaios de tenacidade à fratura. Assim, para simular uma camada cementada retirou-se amostras de aços SAE 43xx variando-se apenas teor de carbono de 0,20 a 1,00%. Os corpos de prova após eletrodeposição de cobre foram tratados termicamente numa carga de cementação, têmpera e revenimento para serem submetidos aos efeitos térmicos sem absorção de carbono. Os resultados da análise microestrutural, dos ensaios de microdureza, de tração e de tenacidade à fratura e de taxa de crescimento de trinca de fadiga foram agrupados em um único gráfico e comparados com o perfil de cementação de peças de aço SAE 4320 tratadas nas mesmas condições. Foi confirmado que as propriedades de fadiga variam de forma inversamente proporcional à microdureza (HV1) e que a previsão do comportamento de uma trinca numa camada cementada pode ser feita por meio de equação ou diagrama que relacionam a microdureza HV1 com a tenacidade à fratura ou taxa de crescimento de trinca de fadiga (KIC ou da/dN x ??)
Abstract: The purpose of this work is to propose a methodology for evaluating the crack growth rate and the fracture toughness along the SAE 4320 steel carburized layer. Due to the small thickness of those layers, it is impossible to machine specimens from those layers in accordance with standards. For simulating the microstructures of the carburized layer in order to get samples for tensile and the fracture toughness testing, specimens of SAE 43xx, from 0.20 %C to 1.00 %C, steels melted in vacuum induction melting, hot rolled and have been machined, assuming the local influence just the variation of the content of carbon and considering that the contents of the other alloy elements are essentially constant. The specimens after electroplated copper layer were heat treated in an industrial load of carburizing, quenching, and tempering for they be submitted to the thermal effects without absorption of carbon. The results of the microstructure analysis and microhardness, crack growth rate, and the fracture toughness tests were placed in a single graph and compared with the profile of the carburizing of the steel SAE 4320 heat treated in the same conditions. It was confirmed that the crack growth rate and the fracture toughness varies inversely proportional to the microhardness (HV1) and that the forecast of the behavior of a crack in a carburized layer can be made through equation or it designs that relate the microhardness (HV1) with the fracture toughness (KIC or CTODC) and crack growth rate (da/dN X ??)
Doutorado
Materiais e Processos de Fabricação
Doutor em Engenharia Mecânica

O objetivo desta pesquisa foi verificar a influência de diferentes tamanhos de partículas de carga na tenacidade à fratura (KIc), nos parâmetros do crescimento subcrítico de trinca (n e f0) e de Weibull (m e 0), na longevidade estimada pelo diagrama tensão-probabilidade-tempo (SPT) e no limite de fadiga cíclica (LFC) de compósitos resinosos experimentais. Quatro compósitos foram preparados contendo 78% em massa (59% em volume) de conteúdo inorgânico, constituído por 67% de pó de vidro com diferentes tamanhos de partículas (d50 = 0,5; 0,9; 1,2 e 1,9 µm) e 11% de sílica pirogênica. Dados de KIc obtidos pelo método single-edge notched beam (25x5x2,8 mm; n=15) foram submetidos a ANOVA/teste de Tukey (p < 0,05). n e f0 foram determinados através do ensaio de fadiga dinâmica (10-2 a 102 MPa/s) utilizando um dispositivo de flexão biaxial (12x1,2 mm; n=10). Para determinar m e 0, mais 20 espécimes de cada compósito foram testados na taxa de 100 MPa/s. Os diagramas SPT foram obtidos a partir dos dados da fadiga dinâmica e análise de Weibull. No ensaio de fadiga cíclica, um dispositivo de flexão biaxial (12x1,2 mm) foi utilizado para se obter a resistência à flexão inicial (RFI; n=14) e o LFC (n=20). LFC foi obtido pelo método escada após 105 ciclos. Para todos os testes, os espécimes foram armazenados em água destilada a 37oC por 24h. Foi realizada a fractografia dos espécimes fraturados nas taxas 10-2 e 10-1 MPa/s da fadiga dinâmica e nos ensaios para determinação da RFI e LFC. Houve relação direta entre d50 e KIc (C0,5: 1,2±0,1b; C0,9: 1,3±0,1ab; C1,2: 1,3±0,1ab; C1,9: 1,4±0,2a, em MPa.m0,5). C0,5 (31,2±6,2a) e C1,9 (34,7±7,4a) apresentaram valores de n superiores a C0,9 (20,3±3,0b) e C1,2 (17,3±1,8b). C1,2 (166,42±0,01a) apresentou o maior valor de f0 (em MPa), seguido pelo C1,9 (159,82±0,02b), C0,9 (159,59±0,02c) e C0,5 (158,40±0,02d). Não houve diferença estatística entre os valores de m (6,6 a 10,6) e 0 (170,6 a 176,4 MPa) dos compósitos. As reduções na tensão de fratura para uma probabilidade de falha de 5% após 10 anos estimadas pelo diagramas SPT foram de aproximadamente 22% para C0,5 e C1,9 e 36% para C0,9 e C1,2. Não houve diferença estatística entre as médias de RFI (155,4 a 170,7 MPa). C0,5 (93,0±18,6a) apresentou o maior LFC (em MPa), seguido pelo C1,2 (91,8±11,1ab), C1,9 (87,2±3,0b) e C0,9 (82,5±8,0c). Defeitos sub-superficiais e superficiais foram as principais origens de fratura. A trinca se propagou pela matriz polimérica ao redor das partículas (deflexão de trinca) e todas as superfícies apresentaram características de fratura frágil. Como conclusão, compósitos com partículas maiores apresentaram maior KIC, enquanto que partículas menores contribuíram para um maior LFC. Compósitos com distribuição granulométrica mais ampla, independentemente do d50, apresentaram maior resistência ao SCG. Nos demais parâmetros e propriedades avaliados (m, 0 e RFI) não houve influência do tamanho das partículas.
The aim of this study was to verify the influence of different filler sizes in the fracture toughness (KIc), subcritical crack growth (n e f0) and Weibull (m e 0) parameters, longevity estimated by the strength-probability-time (SPT) diagram and cyclic fatigue limit (CFL) of experimental resin composites. Four composites were prepared, each one containing 78 w% (59 vol%) of inorganic content, in which 67 w% were glass powder with different filler sizes (d50 = 0.5; 0.9; 1.2 e 1.9 µm) and 11 w% were pyrogenic silica. KIc data was obtained by the single-edge notched beam test and submitted to ANOVA/Tukey tests (p < 0.05). n and f0 were determined by the dynamic fatigue test (10-2 a 102 MPa/s) using a biaxial flexural device (12x1.2 mm; n=10). 20 specimens of each composite were tested at 100 MPa/s to determine Weibull parameters. SPT diagrams were constructed using the dynamic fatigue and Weibull data. For the cyclic fatigue test, a biaxial flexural device (12x1.2 mm) was used to obtain the initial flexural strength (IFS; n=14) and CFL (n=20). CFL was determined by staircase method after 105 cycles. For all tests, the specimens were stored in distilled water at 37oC for 24h. It was done the fractography of the fractured specimens that was subjected to the 10-2 e 10-1 MPa/s rates of the dynamic fatigue and to the IFS and CFL tests. There was a direct relation between d50 e KIc (C0.5: 1.2±0.1b; C0.9: 1.3±0.1ab; C1.2: 1.3±0.1ab; C1.9: 1.4±0,2a, in MPa.m0,5). C0.5 (31.2±6.2a) and C1.9 (34.7±7.4a) presented higher n values than C0.9 (20.3±3.0b) and C1.2 (17.3±1.8b). C1.2 (166.42±0.01a) showed the highest f0 value (in MPa), followed by C1.9 (159.82±0.02b), C0.9 (159.59±0.02c) and C0.5 (158.40±0.02d). There were no statistical differences among the m (6.6 to 10.6) and 0 (170.6 to 176.4 MPa) values of the composites. The reductions in fracture stress at 5% failure probability for a lifetime of 10 years estimated by the SPT diagrams were approximately 22% for C0.5 and C1.9 and 36% for C0.9 and C1.2. There were no statistical differences among the IFS means (155.4 to 170.7 MPa). C0.5 (93.0±18.6a) showed the highest CFL (in MPa), followed by C1.2 (91.8±11.1ab), C1.9 (87.2±3.0b) and C0.9 (82.5±8.0c). Near-surface and surface flaws were the main fracture origins. The crack propagated by the polymeric matrix around the fillers (crack deflection) and all the fracture surfaces showed brittle fracture features. As conclusion, composites with large fillers presented the highest KIC, while the small fillers contributed to increase the CFL. Composites with broader granulometric size distribution, regardless of d50, showed higher resistance to SCG. There was no influence of the composites filler sizes in the others parameters and properties evaluated (m, 0 and IFS).

It was found that a significant improvement of mechanical properties of CFRPs can be achieved by the adjustment of the matrix properties such as toughness and CF/matrix adhesion via the chemical modification, as well as the physical modification by a small amount of cheap and environment-friendly nano fibers. Based on investigation of fracture mechanisms at macro/micro scale, the effects of matrix properties and nano fiber on the mechanical properties of CFRP have been discussed. Subsequently, the relationship has been characterized by a numerical model to show how to modulate the parameters of the matrix properties to achieve excellent fatigue properties of CFRP.
博士(工学)
Doctor of Philosophy in Engineering
同志社大学
Doshisha University