Fatigue assessment using an integrated threshold curve method - applications

This paper deals with the analysis and prediction of a high-cycle fatigue behaviour in notched and damaged specimens, as well as butt-welded joints by using a threshold curve for fatigue crack propagation that includes the short crack regime (a function of crack length, a). The approach regards the effective driving force applied to the crack as the difference between the total applied driving force defined by the applied stress distribution corresponding to a given geometrical and loading configuration, ΔK(a), and the threshold for crack propagation, ΔK_th(a). Chapetti’s model is used to estimate the threshold for crack propagation by using the plain fatigue limit, Δσ_eR, the threshold for long cracks, ΔK_thR, and the microstructural characteristic dimension (e.g. grain size). Applications, predictions and results, in good agreement with experimental results from the literature, demonstrate the ability of the method to carry out quantitative analyses of the high cycle fatigue propagation behavior (near threshold) of short cracks in different geometrical, mechanical and microstructural configurations.     

A weight function method for the assessment of partially closed three-dimensional plane cracks

The interference and physical contact between mating fracture surfaces can lead, even under the action of traction loads, to the closure of a crack. A low-cost numerical tool for the assessment of three-dimensional partially closed mode-I cracks is presented in this paper. The devised tool is based on the weight function methodology and it allows computing the geometry of the open part of the crack and the stress intensity factor along the complete crack front. The accuracy and versatility of the proposed procedure is assessed by solving a number of examples and comparing the obtained results with those available in the literature.     

Tunneling radial cracks in layered structures from contact loading

Glass/epoxy laminates glued onto a compliant substrate are indented with a hard ball. The damage is characterized by a set of transverse cracks which pop out from the subsurface of the glass layers due to flexure and propagate stably in the radial direction with load in a bell-shape front under a diminishing stress field. Compliant interlayers, even extremely thin ones, are effective in inhibiting crossover fracture. This leads to crack tunneling and crack multiplication in the hard layers, which enhances energy dissipation and reduces the spread of damage relative to the basic bilayer configuration. The experiments show that the fracture in a given layer is well approximated by a power-law relation of the form c^3/2K_C/P = δ, where P, c, and K_C are the indentation load, crack length and fracture toughness, in that order, and δ an implicit function of the layer position and material and geometric variables, derived with the aid of available tunnel crack solutions.The model specimen studied provides a useful insight into the fracture behavior of natural, biological and synthetic layered structures from concentrated loading. The analysis shows that the crack arrest capability of a thin interlayer increases in proportion to the modulus misfit ratio between the layer and interlayer, and that the spread of radial cracks in a laminate of given thickness reduces in proportion to n^1/3, where n is the number layers in the laminate.     

Crack growth from naturally occurring material discontinuities under constant amplitude and operational loads

This paper discusses how cracks that grow from small naturally occurring material discontinuities under operational load spectra behave. The growth of small cracks under a representative maritime aircraft flight load spectrum is discussed first. The results of this study, when taken in conjunction with the authors previous studies into cracks growing under combat aircraft load spectra, illustrate how for cracks that grow from small naturally occurring material discontinuities under operational load spectra crack growth can often be easily and accurately computed. It is also shown that the Hartman–Schijve variant of the NASGRO crack growth equation is able to accurately represent the growth of small cracks in two different rail steels. It is further shown that the growth of both small and long cracks can be described by a family of da/dN versus ΔK curves and that, for 7050-T7451, the experimental procedures commonly used to determine a closure free da/dN versus ΔK curve produce curves that are consistent with those obtained using the Hartman–Schijve equation and allowing for small variations in the term ΔK_thr.     

The application of asymptotic solutions to a semi-elliptical crack at the root of a notch

This paper presents an approximate method based on asymptotic solutions for estimating the stress intensity factor K for semi-elliptic surface cracks at stress concentrations. The proposed equation for estimating K makes use of the near-notch and remote-notch solution to interpolate over the entire range from shallow to deep cracks. The near-notch solution is obtained by means of the stress concentration factor. For cracks located in the remote stress field, K is obtained by considering the crack to be located in a smooth plate with a crack depth equal to the sum of the notch depth and the actual crack depth. The accuracy of the predictions is assessed using numerical calculations and solutions found in the literature.     

A modified Kachanov method for analysis of solids with multiple cracks

Kachanov proposed an approximate method for the analysis of multiple cracks by assuming that traction in each crack can be represented as a sum of a uniform component and a non-uniform component, and the interaction among the cracks are only due to the uniform components. These assumptions simplify considerably the mathematics and allow ‘closed-form’ solutions to be obtained for some cases. However, it is noted that the assumptions may not be valid when the cracks are very close. Therefore, an improved method of elastic solids with closely spaced multiple cracks is proposed. Unlike the Kachanov method, traction in a crack is decomposed into a linearly varying component and a non-uniform component so that the sum of the two components to be equal to the traction along the crack length. It is further assumed that the interaction effect due to the non-uniform component can be neglected, and therefore, only the effect of the linearly varying component has to be considered. The accuracy of the present method is validated by comparing the results of two and three collinear open cracks obtained by the present method with those of the exact solutions and the original Kachanov method. Applications of the approach in solving non-collinear parallel crack and friction crack problems are also presented to demonstrate the versatility and accuracy of the method.     

The Bauschinger effect’s influence on the SIFs of multiple longitudinal coplanar cracks in autofrettaged pressurized cylinders

The influence of the Bauschinger effect (BE) on the three-dimensional, Mode I, stress intensity factor (SIF) distributions for arrays of longitudinal coplanar, surface cracks emanating from the bore of a fully or partially autofrettaged thick-walled cylinder is investigated. The SIFs for both “realistic” - Bauschinger effect dependent autofrettage (BEDA) and “ideal” - Bauschinger effect independent autofrettage (BEIA) are obtained and compared. The 3D analysis is performed via the finite element (FE) method and the submodeling technique, employing singular elements along the crack front. Both autofrettage residual stress fields, BEDA and BEIA, are simulated using an equivalent temperature field. The Bauschinger effect (BE) is found to significantly lower the beneficial stress intensity factor due to autofrettage, K_IA, by up to 52%, as compared to the “ideal” autofrettage case. The reduction in K_IA varies along the crack front with the maximum determined by the crack ellipticity, crack depth and crack separation distance. The detrimental influence of the BE increases as the crack density decreases and as crack depth decreases. For a partially autofrettaged cylinder, the influence of the BE is considerably reduced as the level of overstrain becomes smaller. Furthermore, the results indicate that in certain situations crack density and crack ellipticity have opposing effects on the autofrettage SIF.     

Multi-crack analysis of hydraulically pumped cone fracture in brittle solids under cyclic spherical contact

The evolution of surface damage in bilayers due to cyclic spherical indentation in the presence of incompressible lubricant is studied using an all-transparent glass/polycarbonate system as a model for more practical applications such as dental crowns and rolling contact fatigue. In situ observations and post-mortem material sectioning reveal that inner cone cracks evolve sequentially from the contact edge inward by slow growth in a process controlled by stress shielding from preceding cracks. The embryonic cracks are then accelerated by the action of fluid pressure into the flexural tensile stress at the lower part of the coating, where crossover fracture leading to delamination between the coating and substrate may ensue. A consistent FEM brittle fracture analysis incorporating multiple cracks, rate-dependent toughness and liquid pressure is used to follow the damage evolution in the coating. Crack trajectories are determined incrementally under the dual constraint K _I = K _II = 0, which maximize the tension at the crack tip upon the application of fluid pressure. The latter, evaluated at each increment with the aid of a fluid entrapment model, helps drive the leading crack past the compression zone beneath the contact via a hydraulic pump like action. In the early stages of fracture, the liquid pressure is reasonably well approximated by the Hertzian radial surface stress at the crack mouth. Fluid trapped in secondary cracks accentuate the compression beneath the contact. This helps squeeze more liquid into the tip of the leading crack in a zipping like action, which further enhance the crack driving force in the far field. The analytic predictions generally collaborate well with the tests.     

Crack growth prediction and non-linear analysis for an elasto-plastic solid

In this paper, a variable radius for the plastic zone is introduced and a maximum principal stress criterion is proposed for the prediction of crack initiation and growth. It is assumed that the direction of crack initiation coincides with the direction of the maximum principal stress. The von Mises yield criterion is applied to define the plastic zone, instead of assuming a plastic zone with a constant distance r from the crack tip. An improvement is made to this fracture criterion, and the criterion is extended to study the crack growth characteristics of mixed mode cracks. Based on the concept of frictional stress intensity factor, k_f, the rate of fatigue crack propagation, db/dN, is postulated to be a function of the effective stress intensity factor range, Δk_eff. Subsequently, this concept is applied to predict crack growth due to fatigue loads. The proposed crack growth model is discussed by comparing the experimental results with those obtained using the maximum principal stress criterion.     

A general weight function approach to compute mode-II stress intensity factors and crack paths for slightly curved or kinked cracks in finite bodies

A simple procedure is proposed that allows computing the stress intensity factors for slightly curved and kinked cracks in finite bodies. Basis of the method is the computation of the stress field around a straight crack under externally applied tractions. Then, this auxiliary crack is replaced by the crack of interest. The stress intensity factors are computed from the stresses caused by the auxiliary crack using the weight function technique. In a practical application of the method, mode-II stress intensity factors are computed for the edge-cracked half-space. From the usual crack path condition, K_II = 0, the paths of propagating cracks under biaxial loading and the critical biaxiality ratio for global directional instability are computed. The results are in very good agreement with finite element computations.     

The fracture mechanics of finite crack extension

This paper describes a modification to the traditional Griffith energy balance as used in linear elastic fracture mechanics (LEFM). The modification involves using a finite amount of crack extension (Δa) instead of an infinitesimal extension (da) when calculating the energy release rate. We propose to call this method finite fracture mechanics (FFM). This leads to a change in the Griffith equation for brittle fracture, introducing a new term Δa/2: we denote this length as L and assume that it is a material constant. This modification is extremely useful because it allows LEFM to be used to make predictions in two situations in which it is normally invalid: short cracks and notches. It is shown that accurate predictions can be made of both brittle fracture and fatigue behaviour for short cracks and notches in a range of different materials. The value of L can be expressed as a function of two other material constants: the fracture toughness K_c (or threshold ΔK_th in the case of fatigue) and an inherent strength parameter σ₀. For the particular cases of fatigue-limit prediction in metals and brittle fracture in ceramics, it is shown that σ₀ coincides directly with the ultimate tensile strength (or, in fatigue, the fatigue limit), as measured on plain, unnotched specimens. For brittle fracture in polymers and metals, in which larger amounts of plasticity precede fracture, the approach can still be used but σ₀ takes on a different value, higher than the plain-specimen strength, which can be found from experimental data. Predictions can be made very easily for any problem in which the stress intensity factor, K is known as a function of crack length. Furthermore, it is shown that the predictions of this method, FFM, are similar to those of a method known as the line method (LM) in which failure is predicted based on the average stress along a line drawn ahead of the crack or notch.     

Evaluation of C* integral for interacting cracks in plates under tension

A closed form solution for C* integral of two interacting cracks in plates under tension is developed on the basis of reference stress method. Comprehensive finite element (FE) creep analyses are carried out to provide the benchmark of the interaction evaluation of multiple cracks. Results indicate that more pronounced interaction is observed between the C* of double cracks and that of a single crack compared to that denoted by stress intensity factor (SIF). Overall good agreement is achieved between the proposed method for C* of multiple crack interaction and the FE results which provides confidence in practical application.     

Validation of stress intensity factors of diametrically opposed corner cracks in a hole

Population of the world’s largest database of stress intensity factor (K) solutions began in 2002 with the calculation of 5.6 million K solutions for diametrically opposed unsymmetric corner cracks at a straight shank hole in a finite width sheet subject to remote tension, remote bending, and bearing loading. Previous work to validate these K solutions was in the form of fatigue life predictions and crack shape development. The current work attempts to build on the previous validation efforts with the addition of comparing the calculated K solutions with K solutions obtained from carefully controlled laboratory experiments. The latter are obtained via fatigue striation measurements at high magnification, up to 40,000×, using a scanning electron microscope and crack growth rate data, in terms of da/dN vs. ΔK at the same test condition. The results show the numerical K solutions are within 20% of the experimentally derived K’s at discrete locations along the crack front. The relatively large error is due to the discontinuous crack extension process of the crack front. Moreover, the entire crack front does not instantaneously extend uniformly in a self similar fashion. The crack extends stepwise over discrete portions of the crack front. Possibly averaging the striation spacing over a specified arc length of the crack front would ameliorate the discontinuous nature of crack propagation resulting in better correlation between the numerical and experimental results. As a result of the current work, we have shown time consuming striation spacing measurements at high magnification are not required to validate K solutions. The best method for such validation efforts is using the fatigue life, crack history, and crack shape which can be obtained at 1/10th the cost of obtaining striation spacing measurements.     

Approximate stress intensity factors for cracked V-notched specimens based on asymptotic solutions with application to T-joints

This paper presents an approximate method based on asymptotic solutions for estimating the stress intensity factor K for semi-elliptic surface cracks at stress concentrations. The proposed equations make use of a reference solution to interpolate over the entire range from shallow to deep cracks. The reference solution is obtained by considering the current crack emanating from the associated specimen with a sharp notch. It is shown that the proposed formulae satisfy the shallow and deep crack asymptotes. The asymptotic solutions are applied to a T-joint with a fillet-weld-shaped transition. The accuracy of the predictions is assessed using numerical calculations.     

Boundary element method for <Emphasis Type="Italic">J</Emphasis>-integral and stress intensity factor computations in three-dimensional interface cracks

A general numerical tool for the analysis of three–dimensional bimaterial interface cracks is presented in this paper. The proposed tool is based on a multidomain formulation of the Boundary Element Method (BEM), with the crack located at the interface of the domain. Mixed mode stress intensity factors are computed along the three-dimensional crack fronts using the Energy Domain Integral (EDI) methodology and decoupled via the Interaction Integral. The capability of the procedure is demonstrated by solving a number of examples. The last of these examples consists in a thick centre cracked panel for which the behaviour of the J-integral and the mixed-mode stress intensity factors along the crack front is studied as a function of the material mismatch.     

A simple model of stress intensity range threshold and crack closure stress

The cyclic stress intensity threshold (Δ$\text{K}{}_{\mathrm{TH}}$) below which cracks will not propagate varies with length for short cracks. A model is proposed which relates Δ$\text{K}{}_{\mathrm{TH}}$ to the crack closure stress arising from fracture surface roughness. This is used to predict a variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length for surface cracks in Ti 6Al-2Sn-4Zn-6Mo alloy, based upon measured values of crack opening displacement arising from roughness. The predicted variation in Δ$\text{K}{}_{\mathrm{TH}}$ with crack length is found to be similar to that obtained from the empirical model of Δ$\text{K}{}_{\mathrm{TH}}$ proposed by El Haddad et al.[5]. The application of the new model to estimate the value of crack closure stress arising from crack tip plasticity for short surface cracks is also discussed.     

Analysis of three-dimensional interface cracks using enriched finite elements

Many important interface crack problems are inherently three-dimensional in nature, e.g., debonding of laminated structures at corners and holes. In an effort to accurately analyze three-dimensional interface fracture problems, an efficient computational technique was developed that utilizes enriched crack tip elements containing the correct interface crack tip asymptotic behavior. In the enriched element formulation, the stress intensity factors K _I, K _II, and K _III are treated as additional degrees of freedom and are obtained directly during the finite element solution phase. In this study, the results that should be of greatest interest are obtained for semi-circular surface and quarter-circular corner cracks. Solutions are generated for uniform remote tension and uniform thermal loading, over a wide range of bimaterial combinations. Of particular interest are the free surface effects, and the influence of Dundurs’ material parameters on the strain energy release rate magnitudes and corresponding phase angles.     

Indentation-induced subsurface tunneling cracks as a means for evaluating fracture toughness of brittle coatings

When a plate glued to a compliant substrate is subject to indentation, cracks may initiate from its subsurface due to flexure. Upon increasing the load, the damage develops into a set of tunnel radial cracks which propagate stably under a diminishing stress field. This phenomenon is utilized here to extract fracture toughness K _C for brittle materials in the form of thin plates or films. Experiments show that the SIF at the tip of the subsurface radial cracks is well approximated as K ~ P/c ^3/2, where P is the indentation load and c the mean length of the crack fragments. Using a transparent substrate, c can be easily determined after unloading, from which K _C is found. This simple and economic concept is applied to a wide variety of thin ceramic coatings, yielding toughness data consistent with literature values. Because the tip of the tunneling cracks are well removed from the contact site, the method circumvents certain complications encountered in common top-surface radial cracking techniques such as the effect of plastic deformation, residual stresses and crack extension after unloading. Although the present tests are limited to coating thicknesses >150 μm, it is believed that thinner coatings may be studied as well provided that the indenter radius is kept sufficiently small to insure that subsurface radial cracking dominates over all other failure modes.     

Shear mode threshold for a small fatigue crack in a bearing steel

The fatigue behaviour of small, semi‐elliptical surface cracks in a bearing steel was investigated under cyclic shear‐mode loading in ambient air. Fully reversed torsion was combined with a static axial compressive stress to obtain a stable shear‐mode crack growth in the longitudinal direction of cylindrical specimens. Non‐propagating cracks less than 1 mm in size were obtained (i) by decreasing the stress amplitude in tests using notched specimens and (ii) by using smooth specimens in constant stress amplitude tests. The threshold stress intensity factor ranges, ΔK_IIth and ΔK_IIIth, were estimated from the shape and dimensions of non‐propagating cracks. Wear on the crack faces was inferred by debris and also by changes in microstructure in the wake of crack tip. These effects resulted in a significant increase in the threshold value. The threshold value decreased with a decrease in crack size. No significant difference was observed between the values of ΔK_IIth and ΔK_IIIth.     

A New Boundary Element for Plane Elastic Problems Involving Cracks and Holes

By applying the new boundary integral formulation proposed recently by Chau and Wang (1997) for two-dimensional elastic bodies containing cracks and holes, a new boundary element method for calculating the interaction between cracks and holes is presented in this paper. Singular interpolation functions of order r^-1/2 (where r is the distance measured from the crack tip) are introduced for the discretization of the crack near the crack tips, such that stress singularity can be modeled appropriately. A nice feature for our implementation is that singular integrands involved at the element level are integrated analytically. For each of the hole boundaries, an additional unknown constant is introduced such that the displacement compatibility condition can be satisfied exactly by the complex boundary function H(t), which is a combination of the traction and displacement density. Another nice feature of the present formulation is that the stress intensity factors (both K_{_I} and K_{_II}) at crack tips are expressed in terms of the nodal unknown of H(t) exactly, and no extrapolation of numerical data is required. To demonstrate the accuracy of the present boundary element method, various crack problems are considered: (i) the Griffith crack problem, (ii) the interaction problem between a circular hole and a straight crack subject to both far field tension and compression, and (iii) the interaction problem between a circular hole and a kinked crack subject to far field uniaxial tension. Excellent agreement with existing results is observed for the first two problems and also for the last problem if the crack-hole interaction is negligible. This revised version was published online in August 2006 with corrections to the Cover Date.