Characterization of fracture behavior of a Ti alloyed supermartensitic 12%Cr stainless steel using Charpy instrumented impact tests

In this work, the toughness of a Ti-alloyed supermartensitic stainless steel with 12%Cr was evaluated by instrumented Charpy impact tests at − 46 °C. The material was heat treated by quenching and tempering at 500 °C or 650 °C. The temper embrittlement phenomena was detected in the specimen tempered at 500 °C, while the specimens as quenched and quenched and tempered at 650 °C presented a ductile fracture with high impact energy values. The predominance of cleavage fracture instead of intergranular cracks suggests that the temper embrittlement was caused by fine and disperse precipitation observed in the specimen tempered at 500 °C. The dynamic initiation fracture toughness (J_Id) was calculated from the force versus deflection curves using three different methods suggested in the literature to obtain the initiation energy.     

Effects of hydrogen on the properties of bainitic steel crossing

The microstructures on the damaged surfaces of two served bainitic steel crossings were investigated using optical microscope and scanning electron microscope (SEM). The tensile properties of the bainitic steel with different contents of hydrogen were measured. The results showed that the plasticity of the bainitic steel, such as the reduction of area and elongation, decreases sharply with the increase of hydrogen content. There was a critical content of hydrogen without the hydrogen embrittlement for the commercial bainitic steel used for crossing, which was 7 × 10^?5 wt%. When the content of hydrogen in a bainitic steel was lower than the critical value, during the used process of the crossings, the wear failure appeared during the early stage; however, the fatigue spalling appeared in the end of the process. When the content of hydrogen was higher than the critical, brittle fracture was responsible for the failure of the crossing in a short time during use.     

Liquid metal induced embrittlement of a nitrided clutch shell of a motorbike

The failure mechanism of a clutch shell made from SPCC nitrided steel was analyzed. The component sustained multiple brittle fractures during assembly. Under SEM examination, the fracture surface was found to have facet and cleavage grain appearance. It was predicted that the cleavage fractures started from sites of intergranular fractures. XRD results showed that the nitriding layer contained Fe₃N (60 wt.%) and Fe₄N (40 wt.%). It is noted that Fe₃N is more brittle than Fe₄N. An impact test was carried out to compare the impact resistance of the failed and normal components. EDS analysis was also carried out, and it was found that the fracture surface contained zinc, which was not an element specified for the SPCC steel or the nitriding salt. As the salt bath nitriding process operated at a temperature higher than the melting point of zinc, failure was most likely due to liquid metal zinc induced embrittlement, as a result of localized salt bath material contamination with zinc.     

Evaluation of stress corrosion cracking and hydrogen embrittlement in an API grade steel

Stress corrosion cracking (SCC) and hydrogen embrittlement (HE) of pipeline steels in contact with soil was investigated. Different soils were prepared in order to determine their physical, chemical and bacteriological characteristics. Slow strain rate testing was carried out by using aqueous extracts from soil samples and NS4 standard solution. Stress vs. strain curves of API 5L grade X46 steel were obtained at different electrode potentials (E_corr, 100 mV below E_corr and 300 mV below E_corr) with 9 × 10⁻⁶ s⁻¹ and 9 × 10⁻⁷ s⁻¹ strain rate. In addition, the hydrogen permeation tests were carried out in order to evaluate the susceptibility of hydrogen penetrates into theses steels. The results demonstrated the incidence of cracking and their dependence on the potential imposed. In that case, cracking occurred by stress corrosion cracking (SCC) and the hydrogen embrittlement (HE) had an important contribution to cracking initiation and propagation. Cracking morphology was similar to the SCC reported on field condition where transgranular cracking were detected in a pipeline collapsed by land creeping. It was important to point out that even under cathodic potentials the material showed the incidence of secondary cracking and a significant reduction of ductility.     

Experimental study of hydrogen embrittlement on AISI 304 stainless steels and Rayleigh wave characterization

Many failures due to hydrogen embrittlement or hydrogen damage are widely reported in oil and refinery industry. Despite many ultrasonic testing methods have been developed to assess hydrogen embrittlement, they are applied well to serious hydrogen attack instead of earlier degradation. This paper aims to characterize nascent hydrogen embrittlement of AISI 304 austenitic stainless steels under cathodic hydrogenation using Rayleigh wave. After cathodic hydrogen charging of AISI 304 stainless steel, XRD and metallographic examination show that martensite transformation occurs within the subsurface region of the specimens. Microhardness testing indicates that hydrogen leads to hardening of the material. It is found that Rayleigh wave are better to inspect local degradation than bulk waves. Rayleigh wave velocity of 5 MHz and 10 MHz decreases significantly with cathodic charging time, while longitudinal wave velocity changes not. Acoustic velocity change is due to elastic modulus reduction resulting from hydrogen-induced phase transformation in the subsurface region.     

New technique for bonding hydroxyapatite ceramics and magnesium alloy by hydrothermal hot-pressing method

The solidification of hydroxyapatite (HA:Ca₁₀(PO₄)₆(OH)₂) and its bonding with Magnesium (Mg) alloys (AZ31; Mg–3Al–1Zn) were achieved simultaneously by using a hydrothermal hot-pressing method at a low temperature as low as 150 °C with no special surface treatment of Mg alloy. A mixture of calcium hydrogen phosphate dihydrate and calcium hydroxide was used as a starting powder material for solidifying HA. 3-point bending tests were conducted to obtain an estimate of the fracture toughness for the HA/Mg interface as well as for the HA ceramics only. The fracture toughness tests showed that the induced crack from the pre-crack tip deviated from the HA/Mg interface and propagated into the HA. The fracture toughness determined on the bonded HA/Mg specimen was close to that of the HA ceramics only (0.30 MPam^1/2).     

Crack Tip Opening Displacement in atomistic modeling of fracture of silicon

We analyze the fracture of single crystal silicon simulated by atomistic modeling with ReaxFF first principles based reactive force field. The simulations are performed at three temperatures: 500 K, 800 K and 1200 K, capturing both brittle and ductile behavior for the selected crystallographic orientation with (1 0 0) as the fracture plane. Three failure mechanisms are observed: bond breaking, amorphization and emission of dislocations. We demonstrate that the Crack Tip Opening Displacement (CTOD) gives a realistic estimate of the fracture toughness of brittle fracture, linking continuum mechanics fracture theory with the direct crack tip atomistic approach. We discuss the physics based mechanisms of failure in silicon in view of the CTOD measurements.     

Effects of inter-critical temperatures on martensite morphology,volume fraction and mechanical properties of dual-phase steels obtained from direct and continuous annealing cycles

Homogenizing and normalizing heat treatments were performed on low carbon–manganese steel. Then, direct and continuous annealing heat treatments were carried out at 800 °C, 770 °C, 750 °C and 725 °C. Finally; dual phase ferrite–martensite steel was obtained. Thereafter, hardness and tensile tests were applied at ambient temperature, and impact tests for the initial sample and the dual-phase steels obtained from continuous and direct annealing heat treatment in the temperature ranges of (−67 to +70), (−70 to +60), (−70 to +29), respectively, were accomplished. The ductile–brittle transition temperature (DBTT) and the fracture modes of the samples were obtained, and the fracture surface of the steel was observed through scanning electron microscopy (SEM). The results revealed that the best mechanical properties in dual-phase steels, like impact toughness and flexibility, appear at the inter-critical temperature of 725 °C for both continuous and direct annealing cycles. The (DBTT) for the specimens obtained from direct and continuous annealing and the initial sample were −49 °C, −6 °C, and −34 °C, respectively. The dual-phase specimen achieved through the direct annealing method had better toughness and impact properties than the initial specimen or the one obtained through continuous annealing.     

Cracking in a multiple gas-nitrided H13 aluminum extrusion mandrel

A failure analysis was carried out to investigate the root cause of cracking in a mandrel used in a local aluminum extrusion plant. The tool was made of AISI H13 and received multiple gas-nitriding case hardening during its service life. The scraped mandrel showed several microcracks in the filleted bridges. Izod impact tests were conducted over a range of temperatures (23–550 °C) for un-nitrided and single nitrided H13 specimens to examine the possible susceptibility of the tool steel to temper embrittlement. The effect of single and multiple nitriding cycles on the surface fracture resistance of H13 specimens was characterized using Vickers indentation test. The impact test results showed a low impact-energy regime at temperatures at or below 350 °C and a high impact-energy regime at higher temperatures. Temper embrittlement was ruled out as a likely cause of cracking since the extrusion temperature of 425 °C is within the high impact-energy regime. Vickers indentations typically showed sharp cracks initiated from the corners of the indentation for a sample taken from the mandrel. No cracks emanated from indentations applied on un-nitrided and single-nitrided specimens. Crack initiation in the mandrel is primarily attributed to multiple gas-nitriding and the subsequent thickening of the brittle nitrided layer which promoted brittle crack initiation in the mandrel bridges under the applied extrusion pressure.     

Comparison of tensile and impact behavior of carbon steel in H2S environments

The present research reports the effect of hydrogen sulfide pressure on the tensile and impact behavior of carbon steel. Hydrogen content measurement was conducted due to the relationship between hydrogen and mechanical behavior. A remarkable increase in the relative tensile strength and plasticity loss was observed as hydrogen sulfide pressure increased. However, the Charpy absorbed energy showed no obvious change with increase of H₂S pressure from 0.1 MPa to 1.6 MPa, even though a significant decrease compared to that of as-received steel. Combined with the results of hydrogen content measurement, it was found that hydrogen has a profound effect on the tensile and impact behavior of steel. Fractography of the corroded tensile and impact specimens exhibited mixed ductile–brittle rupture. In addition, the brittle zone on the fracture surface increased for corroded tensile specimens and showed nearly similar area fraction for corroded impact specimens as H₂S pressure increased. A probable mechanism is proposed to interpret the difference in the tensile and impact results.     

Fatigue crack growth and damage characteristics of high-speed rail at low ambient temperature

Low temperature can be a significant problem affecting safety and maintenance of railway. In this study, the fatigue crack growth rate and rolling contact fatigue damage behaviors of high-speed rail material under different temperature conditions were investigated by a series of experiments. The results indicate that the stress and strength of rail material increase with the decrease of ambient temperature. The crack growth rate at 0 °C and − 20 °C is similar with that at 20 °C. While, when the temperature decreases to − 60 °C, the growth rate of crack increases sharply. The promotion of rail embrittlement at low temperature accompanied with the action of high stress causes the rapid failure and increase of surface crack length and subsurface crack damage. Meanwhile, three crack growth mechanism models at different temperatures can be inferred. The brittle fracture mode is increasingly apparent with the temperature decreasing.     

Behavior and failure of uniformly hydrided Zircaloy-4 fuel claddings between 25 °C and 480 °C under various stress states,including RIA loading conditions

The anisotropic plastic behavior and the fracture of as-received and hydrided Cold-Worked Stress Relieved Zircaloy-4 cladding tubes are investigated under thermal–mechanical loading conditions representative of Pellet–Clad Mechanical Interaction during Reactivity Initiated Accidents in Pressurized Water Reactors. In order to study the combined effects of temperature, hydrogen content, loading direction and stress state, Axial Tensile, Hoop Tensile, Expansion Due to Compression and hoop Plane Strain Tensile tests are performed at room temperature, 350 °C and 480 °C on the material containing various hydrogen contents up to 1200 wt. ppm (hydrides are circumferential and homogeneously distributed). These tests are combined with digital image correlation and metallographic and fractographic observations at different scales. The flow stress of the material decreases with increasing temperature. The material is either strengthened or softened by hydrogen depending on temperature and hydrogen content. Plastic anisotropy depends on temperature but not on hydrogen content. The ductility of the material decreases with increasing hydrogen content at room temperature due to damage nucleation by hydride cracking. The plastic strain that leads to hydride fracture at room temperature decreases with increasing hydrogen content. The influence of stress triaxiality on hydride cracking is negligible in the studied range. The influence of hydrogen on material ductility is negligible at 350 °C and 480 °C since hydrides do not crack at these temperatures. The ductility of the material increases with increasing temperature. The evolution of material ductility is associated with a change in both the macroscopic fracture mode of the specimens and the microscopic failure mechanisms.     

Impact behavior of entangled steel wire material

Entangled steel wire (Q195F) with total porosity of 36.3 ± 1.3 to 61.8 ± 2.4% and pore sizes of 15–825 µm have been investigated in terms of the porous morphologies, impact deformation and failure behavior. The results reveal that the impact toughness increases with the decrease of the porosity. The sintered entangled steel wire materials with 61.8 ± 2.4% porosity exhibit an average of 11.8 J/cm² impact toughness. With 36.3 ± 1.3% porosity, the sintered materials have an average of 45.5 J/cm² impact toughness. Impact absorbing energy and impact toughness have been obtained by Charpy impact testing. Essential impact deformation and failure mechanisms such as pore edges (i.e. fibers) bending, bulking, rotating, yielding, densification and fracture, as well as break (or avulsion) of sintering points in the steel wire framework contribute to the excellent energy-absorbing characteristics under impact loading condition.     

Fracture toughness characterization of austempered ductile iron produced using both conventional and two-step austempering processes

The aim of the present study is to characterize mainly fracture toughness as well as the other mechanical properties of austempered ductile iron produced using both single-step and two-step austempering processes. The effect of alloying with Ni and Mo has been investigated. Austempering heat treatment was conducted at temperatures between 260 °C and 390 °C. Plane strain fracture toughness was evaluated for each material and heat treatment condition. It was found that two-step austempering process resulted in improving the fracture toughness of the material, while maintaining reasonable levels of strength. Alloyed samples showed higher fracture toughness than un-alloyed ones.     

Impact of thick PMMA plates by long projectiles at low velocities. Part II: Effect of confinement

A hybrid experimental–numerical investigation of the penetration process in unconfined and confined thick polymethylmethacrylate (PMMA) plates was carried out. The confinement was applied by insertion of the polymeric plate into a conical steel ring. The response of such plates to the impact of long hard steel projectiles having an ogive-head shape in the range of velocities of 165 < V₀ < 260 (m/s), was investigated experimentally. The results show that unconfined targets were perforated and broken due to combined effect of penetration and cracking. By contrast, the confined targets were not perforated and could withstand repeated impacts due to suppression of the brittle damage mechanism by the confinement. The tests were modeled using 3D explicit finite element analyses. A good agreement regarding the trajectory of the projectile and the depths of penetration was obtained. The numerical results show that the confinement introduces a negative triaxiality and even some plasticity within the confined plates prior to impact. The increase of plastic failure strain of the PMMA at negative triaxiality reduces the ductile damage during penetration, while the hydrostatic pressure reduces significantly the brittle fracture mechanism. The resisting force to the penetration depends on the failure strain–triaxality relationship, and does not necessarily increase with higher confinement levels.     

Taylor impact of polyether ether ketone

Right cylinders of the thermoplastic polyether ether ketone have been impacted onto a hardened steel anvil at velocities from 152 to 408 m s⁻¹. The resultant deformation showed the expected ‘mushrooming’ behaviour up to impact velocities of 303 m s⁻¹, before the impact face began to fracture. No evidence of brittle failure was observed, but rather a ductile process was noted. Discolouration behind the impact face gave evidence of high temperatures in this region, believed to be due to adiabatic heating as the material flowed across the impact face. The concave nature of the impact face after recovery showed that the material had relaxed after the loading had been removed, mostly likely due to the viscoplastic nature of the material.     

Thickness-dependence of the translaminar fracture toughness: Experimental study using thin-ply composites

The concept of translaminar fracture toughness of 0° plies has enabled the development of a considerable number of ply-level numerical models for structural failure of laminated composites. Using thin-ply pre-pregs, this paper demonstrates that this translaminar toughness is not an absolute, but rather in-situ, property and depends strongly on the 0° ply-block thickness, even in situations where delamination and diffuse damage are inhibited. We used two different grades of a thin-ply carbon-epoxy system to produce four different 0° ply-block thicknesses ranging from 0.03 mm to 0.12 mm, and measured the respective translaminar fracture toughness using compact tension tests. SEM and X-ray analysis showed no delamination nor diffuse damage. Yet, the translaminar fracture toughness increased from 46 to 104 kJ/m² (initiation), and from 49 to 160 kJ/m² (propagation), for the thickness range above. This finding has significant implications for the development and use of ply-level numerical failure models, for structural design with thin-ply composites, and for the development of thin-ply material systems.     

Failure analysis of Grade-80 alloy steel towing chain links

An experimental investigation of the causes of failure of chain links that occurred during towing operation of heavy-weight army vehicles is reported in this study. All failures took place at the weld area of the links after a short service life. Tensile tests on both base metal and the weld samples indicated high tensile strength of 800 MPa for both materials. However, the weld exhibited brittle fracture at relatively small strains of ε ≈ 0.05, while the base metal failed at strains ε ≈ 0.20, indicating moderate ductility. Optical metallography and scanning electron microscopy (SEM) analysis revealed that fatigue was initiated due to inherited cracks at the outer circumference of the weld. Fatigue crack propagation was evident by progressive marks and intervening striations. Their distribution was not rotationally symmetric, indicating a possibility of combined cyclic loading on the links. The large area of final rupture indicated a ductile rupture in the weld center and brittle fracture in the outer region of the weld due to overloading. The results suggest that the major causes of chain failure are as follows: high cyclic loading, weld defects, improper post-weld heat treatment, and decrease in material hardness and corrosion resistance due to insufficiency of some alloying elements.     

Processing of a new high strength high toughness steel with duplex microstructure (Ferrite + Austenite)

In this investigation a new third generation advanced high strength steel (AHSS) has been developed. This steel was synthesized by austempering of a low carbon and low alloy steel with high silicon content. The influence of austempering temperature on the microstructure and the mechanical properties including the fracture toughness of this steel was also examined. Compact tension and cylindrical tensile specimens were prepared from a low carbon low alloy steel and were initially austenitized at 927 °C for 2 h and then austempered in the temperature range between 371 °C and 399 °C to produce different microstructures. The microstructures were characterized by X-ray diffraction, scanning electron microscopy and optical metallography. Test results show that the austempering heat treatment has resulted in a microstructure consisting of very fine scale bainitic ferrite and austenite. A combination of very high tensile strength of 1388 MPa and fracture toughness of 105 MPa √m was obtained after austempering at 371 °C.     

Analyses of the failures on shear cutting blades after trimming of ultra high-strength steel

Damages on shear cutting blades were analyzed after 50,000 strokes of trimming on an ultra high-strength steel sheet. Traditional D2 alloy and an advanced one (Cr08H) based on the composition of 1C-8Cr were quenched from 1030 °C, tempered at 180 °C and submitted to the shear cutting test. Cr08H had lower hardness, a smaller volume fraction of M₇C₃ carbides while it contained a larger volume fraction of retained austenite. And these resulted in more scratches and rounded edges because of degraded resistance to wear and local plastic deformation. In spite of higher impact toughness, Cr08H exhibited inferior resistance to chipping which was the consequence of localized brittle fracture. It could be concluded that this was caused by more transformation of austenite as well as by insufficiently hardened matrix, both of which were attributed to inappropriate conditions of the heat treatment.