CRACK NUCLEATION AND PROPAGATION IN BLADE STEEL MATERIAL

Stress corrosion cracking and corrosion fatigue of 12 Cr steel in sodium chloride solution has been investigated. Tests have been performed in air at room temperature and in aqueous solution with 22% NaCl at 80°C. The influence of corrosion pits on crack nucleation has been investigated. On fracture surfaces tested in environment (22% NaCl solution), crack initiation was observed in correspondence with corrosion pits; in this case fatigue life can be described using a fracture mechanics approach. The ΔK value for crack nucleation from a pit in rotating bending fatigue tests is very low in air (about 3 MPa√m). The results of slow strain rate tests on smooth specimens show that there is a threshold stress intensity, K_ISCC, of about 15 MPa√m and a plateau in stress corrosion crack growth rate of about 10^-5mm/s.     

Development of an ultrahigh strength low alloy steel for armour applications

Abstract

The present paper describes a steel with yield strength exceeding 1900 MPa and fracture toughness in the range of 40–50 MPa?m^1/2, in its optimum heat treated condition. Its strength is similar to that of 18 Ni (300) grade of maraging steel with good fracture toughness. When tempered at 300°C, it shows tempered martensite along with a small amount of retained austenite phase. The steel shows nearly 25% reduction in weight over typical rolled homogeneous armour (RHA) steel against high velocity hard steel core projectiles. The processing, microstructure, mechanical and ballistic properties of the steel are demonstrated.     

Investigation on the Fatigue Behaviors of Maraging Steel at Different Stress Ratios

Herein, the high-cycle fatigue behaviors of 18Ni maraging steel with different tensile strength in the stress ratio range from 0.1 to 0.5 are investigated, and compared with those at the stress ratio of −1. It is found that the relationship between the fatigue strength at the stress ratios of −1 and 0.1 and tensile strength is nonmonotonic, while the fatigue strength at the stress ratio of 0.5 improves as the tensile strength heightens. The tensile strength corresponding to the optimal fatigue strength state would change with the variation of the stress ratio, which is related to the alteration of key factors affecting the fatigue damage. Moreover, it is found that the Walker equation: σ_aR = σ₋₁ ⋅ [(1 − R)/2]^β gives reasonable results for the influence of stress ratio on the fatigue strength of 18Ni maraging steel.     

Threshold stress intensity factor and crack growth rate for stress corrosion cracking of simulated heat affected zone in caustic solution

The threshold stress intensity factor for stress corrosion cracking (K_Iscc) of the simulated heat affected zone (HAZ) of mild steel in caustic solution has been determined using circumferential notch tensile (CNT) technique. The HAZ microstructure produced upon manual metal arc welding of grade 250 steel was simulated over a length of 35 mm of CNT specimens, using a thermo-mechanical simulator. Inter- and trans-granular stress corrosion cracking has been confirmed using a scanning electron microscope. The results presented here validate the ability of CNT technique for the determination of K_Iscc of HAZ and Base metal. Crack growth rates have also been determined using CNT technique. Further, the effect of microstructures on K_Iscc and crack growth rate is discussed in the present study. The determined K_Iscc of Base metal and simulated heat affected zone in 30% caustic solution is 24 and 45 MPa m^1/2, respectively.     

Stress corrosion cracking of maraging steel weldments

Abstract

The stress corrosion characteristics of 18 wt-%Ni (MDN-250) maraging steel and its weldments made under different welding conditions have been investigated. The threshold stress intensity factor K _ISCC in stress corrosion conditions has been determined in 3.5 wt-%NaCl environment for the base metal and weldments. The fractured surfaces were analysed to study the types of fracture during stress corrosion cracking in base and weld metals. Fracture toughness tests were carried out and the results obtained from these tests have been compared with K _ISCC values.     

High-temperature hydrogen resistance of stainless steels

At elevated temperatures, the influence of hydrogen on various mechanical characteristics of martensitic and disperse-hardened austenitic steels is different. The maraging steel has better characteristics of durability and plasticity and the critical values of static and cyclic crack resistance at temperatures of 450–600°K than the austenitic steel with intermetallic hardening. As a result of the intense temperature softening, its ultimate and yield strengths are much lower than for the austenitic steel. The austenitic steel has higher resistance in terms of the threshold value ∆K _th. At room temperature, the low-cycle fatigue limit proves to be most sensitive to the action of hydrogen, whereas at 673°K, the parameter K _fc for the maraging steel decreases.     

Fracture toughness of maraging steel from Charpy “V” notch specimens

Compact tension (CT) and Charpy V notch (CVN) (impact and three-point bend) specimens of 18 Ni 1800 MPa maraging steel (parent metal and weldment) were used to determine plane strain fracture toughness (K _IC) and CVN impact energy (CVNIE), respectively. Using an empirical equation,K _IC-CVNIE correlation is attempted which could be advantageously utilized for routine quality control of inward material to effect savings in cost and time. Investigations reveal betterK _IC-CVNIE correlation for tests using the precracked CVN specimens. Scanning electron microscopic (SEM) observations reveal good correlation between fractographic features and fracture toughness.     

Crack resistance of 15Kh2MFA steel after combined warm-prestressing

We have studied the influence of parameters of combined warm-prestressing under eccentric tension of compact cracked specimens (temperature, maximum stress intensity factor K ₁, and its range ΔK) on the critical J-integral J _f, critical opening of the crack tip, and critical stress intensity factor of 15Kh2MFA steel at 293 K. The essence of combined warm-prestressing consists of the fact that, at the stage of overstressing of a cracked specimen in the course of its tensile deformation, one imposes a cyclic load of small amplitude. At a temperature of preliminary overstressing of 423 K, which is close to the critical temperature of brittleness of steel (T _k0 = 393 K), combined warm-prestressing decreases the J _f value for steel by a factor of up to 1.5 as compared with static warm-prestressing. At a temperature of 623 K, which exceeds substantially the critical temperature of brittleness of steel, combined warm-prestressing increases the critical J-integral J _f by up to 30% and critical crack opening δ _f ^ep by up to 14% as compared with warm-prestressing. Irrespective of the temperature (T ₁ = 423 and 623 K) and scheme of warm-prestressing (combined or static), all experimental values of the critical stress intensity factor K _f depending on δ _f ^ep are concentrated in a common scatter band and can be described well by a single relation. __________ Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 43, No. 6, pp. 67–73, November–December, 2007.     

Überlebensrate und Sicherheit von keramischen Kugelköpfen für Hüftendoprothesen

Survival Rate and Reliability of Ceramic Femoral Heads for Total Hip Arthroplasty Femoral heads and sockets made of alumina ceramics are successfully used in total hip replacement. The in vivo fracture rate of Biolox heads is lower than 0.02%. An extremely high load (e. g. accident) can initiate subcritical crack growth causing fracturing. 107 retrieved Biolox heads were investigated. When measuring their fracture load no fatigue was detected. This result can be explained by the relation between crack velocity and stress intensity (v-K-diagram). The stress intensity of ceramic heads when loaded with standard conditions (e. g. walking, max. load 3 kN) is in the order of 0.6 MPa m^1/2. Stress intensities like that are below alumina's fatigue limit K_Io which is in the order on 1 MPa m^1/2. Biolox alumina heads are examples for engineering ceramics that are reliable despite tensile stress over very long periods of time.     

Effects of active chitosan-flaxseed mucilage-based films on the preservation of minced trout fillets: A comparison among aerobic,vacuum, and modified atmosphere packaging

The objectives of the current study were to examine physical–mechanical, structural, and morphological characteristics of chitosan-flaxseed mucilage films enriched with Ziziphora clinopodioides essential oil (ZEO; 0%, 0.25%, and 0.5%) and sesame oil (SO; 0% and 0.75%) and to provide useful information for the preservation of minced trout fillet's using antimicrobial films under aerobic, vacuum, and modified atmosphere conditions for 16 days. The films showed thickness, tensile strength, puncture force, puncture deformation, water vapor transmission rate, water vapor permeability, swelling index, and oxygen permeability values ranging 0.082–0.86 mm, 33.34–46.83 MPa, 25.69–53.08 N, 11.45–28.45 mm, 17.48–26.73 g/m² h, 8.57–12.49 × 10⁻⁴ g mm/m² h Pa, 12.45–38.43%, and 3.02–13.32 × 10⁻¹² cm³/m² s Pa, respectively. The following order of effect on the microbial spoilage population of treated samples was found in the applied packaging methods: modified atmosphere packaging > vacuum packaging > aerobic packaging. The final microbial population of treated samples was 0.35–4.91 log CFU/g lower than the controls after 16 days of refrigerated storage. At the end of the storage, the total volatile base nitrogen, peroxide value, and thiobarbituric acid reactive substances of untreated samples were 34.02–48.6 mg of N/100 g, 1.43–2.32 meq of peroxide/1000 g, and 3.33–4.24 mg of malondialdehyde/kg, respectively. The lowest corresponding values were recorded for the treated samples with ZEO 0.5% + SO 0.75% films by 14.26–17.73 mg of N/100 g, 0.48–0.86 meq of peroxide/1000 g, and 1.08–1.48 mg of malondialdehyde/kg, respectively.     

Experimental investigation of critical heat flux under boiling in subcooled swirling flow under conditions of one-sided heating

Results are given of an experimental investigation of critical heat flux in a turbulent swirling flow of subcooled water under one-sided heating. The parameters of flow are varied in the following ranges: the pressure of water at the inlet, 0.7 and 1.0 MPa; mass velocity ρw, 1100 to 9900 kg/(m² s); flow swirl coefficient k = 0.19 and 0.37; the temperature of water at the inlet—20, 40, and 60°C; and the hydraulic diameter of the channel, 2.16 mm.     

Subcritical crack growth in partially stabilized ZrO2(MgO)

The room temperature slow crack growth resistance in air ( 50% relative humidity) and in water for large cracks in MgO-partially stabilized zircoba (PSZ) improves with increase in critical fracture toughness,K _lc. Ageing the as-fired PSZ at 1400° C for 8 h results in decreasing K_lc from 8.5 MPa m^1/2 to 6 M Pa M^1/2. The ageing treatment also promotes the growth of eutectoid decomposition products on grain boundaries that is accompanied by a decrease in the dependence (A the change in Region I crack velocity with a change in the applied stress intensity. Calculated times to failures are markedly decreased in the aged as compared to the as-fired PSZ ceramic.     

Single Pass Laser-Arc Hybrid Welding of Maraging Steel Thick Sections

Maraging steel 250 grade plates of 10 mm thickness were welded in single pass using a laser-arc hybrid welding (LHW) setup comprising 3.5 kW CO₂ laser and synergic pulse metal inert gas (MIG) welding power source at a welding speed of 1 m/min. The influence of single-pass welding on the bead characteristics, microstructure, and mechanical properties was investigated. The size and volume fraction of reverted austenite was effectively reduced in the fusion zone. Moreover, the width of the heat-affected zones (HAZ) was reduced and the microhardness results did not show significant softening in the HAZ after post weld aging. Tensile testing of the welds in transverse direction showed 97.3% weld efficiency. The fusion zone exhibited K_Ic fracture toughness of 77.4 MPa√m which was affected by the distribution pattern of reverted austenite. The study vividly brings out the process advantages of LHW for accomplishing thick section welds of maraging steel in single pass with narrow groove and lesser filler wire consumption.     

Corrosion fatigue crack initiation and growth in 18 Ni maraging steel

Nucleation of fatigue cracks in air and 3.5 wt% NaCl solution has been studied in an 18 wt% Ni maraging steel. Specimens tested on reverse bending fatigue machine showed a marked decrease in fatigue strength of the steel in NaCl solution reducing the 10⁷ cycles endurance limit from 410 MPa in air to 120 MPa. Microscopic studies revealed crack initiation to be predominantly associated with non-metallic silicate inclusions in both cases. In air, initiation is caused by decohesion of the inclusion/matrix interface, while in NaCl solution complete detachment of inclusions from the matrix results due to the dissolution of the interface. 70% more inclusions are quantitatively shown to be associated with cracks in NaCl solution than in air at the same stress levels. Experimental and theoreticalS-N curves and inclusion cracking sensitivity data are consistent with the mechanism suggested. The final fracture occurs by the main crack consuming the inclusions ahead of it by the “unzipping” of the shear band produced between the crack tip and the inclusion ahead.     

VHCF properties of nitrided 18Ni maraging steel thin sheets with different Co and Ti content

High cycle fatigue (HCF) and very high cycle fatigue (VHCF) properties of two 18Ni maraging steels with different cobalt and titanium content and similar static strength are investigated. Ultrasonic fatigue tests are performed with thin sheets with nitrided surfaces at load ratio R = 0.1. The specimens are mounted on a carrier and are forced to joint vibrations at approximately 20 kHz. The increase of Co content and the elimination of Ti improved the HCF and VHCF strength of 18Ni maraging steel. TiN inclusions if Ti is present and Al₂O₃ inclusions in the Ti free material with sizes (area_INC)^1/2 smaller than 10 µm were preferential crack initiation locations. Considering inclusions as initial cracks, the minimum stress intensity range for VHCF failure is 1.2 MPam^1/2 for TiN inclusions and 1.8 MPam^1/2 for Al₂O₃ inclusions. Data scatter may be slightly reduced if lifetimes are presented versus stress amplitudes multiplied by (area_INC)^1/12 rather than in an S–N diagram.     

Strain rate effects on tensile deformation behavior of Fe-3.5Mn-0.3C-5Al ferritic based lightweight steel

Tensile deformation behavior of Fe-3.5Mn-0.3C-5Al ferritic based lightweight steel was studied in a large range of strain rate (0.001 s⁻¹–1200 s⁻¹). Microstructures of the steel before and after tension were observed. The results show that Fe-3.5Mn-0.3C-5Al lightweight steel has a good strength (820 MPa) and plasticity (40 %) and exhibits excellent combinations of specific strength and ductility (>32000 MPa %) at the strain-rate of 0.001 s⁻¹ after annealing at 850 °C for 5 minutes then directly quenching into water. The austenite in the steel tested was transformed into α′-martensite during the tensile deformation process. With an increase in strain rate from 0.001 s⁻¹ to 1200 s⁻¹, tensile strength of the steel investigated increased from 820 MPa to 932 MPa, while its elongation first decreased from 40 % to 15 %, and then increased from 15 % to 29 %. At the strain rate of 1200 s⁻¹, adiabatic heating resulted in temperature rising in matrix, suppressed the transformation of austenite to α′-martensite. Comparing with transformation induced plasticity steel, the austenite in 3.5Mn lightweight steel is obviously unstable and cannot provide progressive phase transition.     

Fatigue crack growth rates of API X70 pipeline steel in a pressurized hydrogen gas environment

Hydrogen is known to have a deleterious effect on most engineering alloys. It has been shown repeatedly that the strength of steels is inversely related to the ductility of the material in hydrogen gas. However, the fatigue properties with respect to strength are not as well documented or understood. Here, we present the results of tests of the fatigue crack growth rate (FCGR) on API X70 from two sources. The two materials were tested in air, 5.5 and 34 MPa pressurized hydrogen gas, and at both 1 and 0.1 Hz. At these hydrogen pressures, the FCGR increases above that of air for all values of the stress intensity factor range (ΔK) greater than ~7 MPa · m^1/2. The effect of hydrogen is particularly sensitive at values of ΔK below ~15 MPa · m^1/2. That is, for values of ΔK between 7 and 15 MPa · m^1/2, the FCGR rapidly increases from approximately that found in air to as much as two orders of magnitude above that in air. Above 15 MPa · m^1/2, the FCGR remains approximately one to two orders of magnitude higher than that of air.     

Correlations of the craze profile in PMMA with Dugdale's plastic zone profile

The craze opening profile in PMMA has been determined as a function of stress intensity using interference optics and a special wedge loading device. An attempt was made to correlate the craze profile with the corresponding parameters (crack opening displacement and plastic zone length) predicted by the Dugdale model. Over the mid-range of stress intensities (K _I=0.4 to 1.0 MPa m^1/2), samples which were annealed after precracking were found to exhibit a profile similar in shape but smaller than that predicted by the Dugdale model. The lower limit of this range marks the critical stress intensity for crazing in PMMA. Both the craze length and the opening at the craze-crack interface increase with increasing stress intensity and, due to strain-hardening of the craze material, reach maximum values of about 40m and 3m respectively atK _I=1.0 MPa m^1/2. Experimental uncertainties cannot account for the profile difference and it is therefore concluded that the Dugdale model is not fully adequate to describe craze geometries in PMMA. The discrepency between the Dugdale model and the experimental data is suggested to be due to either fibril strain-hardening and/or the formation of a plane strain plastic zone ahead of the craze.     

Fracture characteristics of a burst tested maraging steel rocket motor case

A 0.3 m diameter, 2 m long and 0.0015 m thick, 18 nickel 1800 MNm^–2 grade maraging steel motor case was designed, fabricated and burst tested to gain experience for using the steel as booster case material in satellite launch vehicles. The bursting occurred at 15.2 MPa for which the effective hoop stress worked out to be 1754 MNm^–2 almost equal to the ultimate tensile strength (1764 MNm^–2) of the material in the solution treated and aged condition. The failure analysis revealed that the material failed due to normal tensile overload fracture. The burst test data was used to arrive at fracture mechanics parameters like crack size, gross section area stress and the stress for leak before bursting.     

A fractographic criterion for subcritical crack-growth boundaries in hot-pressed alumina

The percent intergranular fracture (PIF) was measured along radii extending from fracture origins in hot-pressed alumina specimens, fractured at various loading rates and temperatures, and plotted versus estimates of stress intensity factors (K _I) at the various crack lengths. Minima in PIF occur at values ofK _I that are close to the critical stress intensity factors (K _IC) for cleavage on various crystal lattice planes in sapphire. The subcritical crack-growth boundary (K _I=K _IC of the polycrystalline material) occurs near the primary minimum in PIF suggesting that this minimum can be used as a criterion for locating this boundary. In addition, it was noted that the polycrystallineK _IC (4.2 MPa m^1/2) is very close to theK _IC for fracture on {¯1 ¯1 2 6} planes which is 4.3 MPa m^1/2. These observations suggest that critical crack growth begins when increased fracture energy can no longer be absorbed by cleavage on these planes. There is a secondary minimum atK _I>K _IC that appears to be associated with theK _IC necessary for fracture on combinations of planes selected by the fracture as alternatives to the high fracture-toughness basal plane.