Weibull stress model for cleavage fracture under high-rate loading

This paper examines the effects of loading rate on the Weibull stress model for prediction of cleavage fracture in a low-strength, A515-70 pressure vessel steel. Interest focuses on low-to-moderate loading rates ( K˙ _I < 2500  MPa √m  s⁻¹ ). Shallow cracked SE(B) specimens were tested at four different loading rates for comparison with previous quasi-static tests on shallow notch SE(B)s and standard C(T)s. To utilize these dynamic experimental data, we assume that the Weibull modulus ( m ) previously calibrated using quasi-static data remains invariant over the loading rates of interest. The effects of dynamic loading on the Weibull stress model enter through the rate-sensitive material flow properties, the scale parameter ( σ _u ) and the threshold Weibull stress ( σ _w-min ). Rate-sensitive flow properties are modelled using a viscoplastic constitutive model with uniaxial, tension stress–plastic strain curves specified at varying plastic strain rates. The analyses examine dependencies of σ _w-min and σ _u on K˙ _I . Present results indicate that σ _w-min and σ _u are weak functions of loading rate K˙ _I for this pressure vessel steel. However, the predicted cumulative probability for cleavage exhibits a strong sensitivity to σ _u and, consequently, the dependency of σ _u on K˙ _I is sufficient to preclude use of the static σ _u value for high loading rates.     

PROBABILISTIC ASPECTS OF CLEAVAGE CRACK INITIATION SITES AND FRACTURE TOUGHNESS

Abstract— Fracture toughness tests were performed in the ductile-brittle transition temperature range using 110 specimens of the three-point bend and CT types. Probabilistic characteristics of fracture toughness and cleavage crack initiation sites were analysed in detail, together with the fibrous crack shape, from which the plane strain region in the specimen was deduced. The criterion for obtaining plane strain at the mid plane of the specimen was established as: B ≤ 0.004{ K _c( J )/σ _y }²+ 0.01. The thickness effect of cleavage fracture toughness for the specimen satisfying this equation is mainly caused by the statistical distribution of the weakest points ahead of the crack front (the Weibull volume effect).     

Influence of threshold parameters on cleavage fracture predictions using the Weibull stress model

This study explores applications of three-parameter Weibull stress models to predict cleavage fracture behavior in ferritic structural steels tested in the transition region. The work emphasizes the role of the threshold parameters (_th and _{w – min}) in cleavage fracture predictions of a surface crack specimen loaded predominantly in tension for an A515-70 pressure vessel steel. A recently proposed procedure based upon a toughness scaling methodology using a modified Weibull stress (^* _w) extends the calibration scheme for the Weibull modulus, m, to include the threshold parameters. The methodology is applied to calibrate the Weibull stress parameter for the tested material and then to predict the toughness distribution for the surface crack specimen. While the functional relationship between ^* _w and m suggests a strong effect of the threshold stress, _th, on the calibrated m-parameter, the results show a remarkably weak dependence of fracture predictions on _th as does the dependence of fracture predictions on _w–min for this specimen.     

Analysis of ductile to cleavage transition in part-through cracks using a cell model incorporating statistics

This paper describes an approach to study ductile/cleavage transition in ferritic steels using the methodology of a cell model for ductile tearing incorporating weakest link statistics. The model takes into account the constraint effects and puts no restriction on the extent of plastic deformation or amount of ductile tearing preceding cleavage failure. The parameters associated with the statistical model are calibrated using experimental cleavage fracture toughness data, and the effect of threshold stress on predicted cleavage fracture probability is investigated. The issue of two approaches to compute Weibull stress, the 'history approach' and the 'current approach', is also addressed. The numerical approach is finally applied to surface-cracked thick plates subject to different histories of bending and tension, and a new parameter, ψ, is introduced to predict the location of cleavage initiation.     

MODE I STRESS INTENSITY FACTOR EQUATIONS FOR CRACKS AT NOTCHES AND CAVITIES

Abstract— In this paper, the notch-crack problem is treated in two different ways: if the non-dimensional crack length l /ρ ( l = crack length; ρ= notch root radius) is smaller than the transition crack length l _T/ρ, it is treated as an edge crack lying within the local stress field around the notch tip; if l/ ρ is larger than l _T/ρ, the notch-crack is considered as a simple flat crack problem subjected to remote loading, the flat crack size being the sum of notch depth and the real crack length. Based on currently available numerical data, expressions for the transition crack length, l _T, and for the geometric factor F = K _I/(1.1215K_tσ√π l ) are developed for various notch problems for the crack length range l ≦ l _T. It is found that the stress (σ_yy) normalized by the peak stress (σ_peak), σ_yy/σ_peak, for the pre-cracked component is very similar to the geometric factor for short cracks.     

Effects of notch geometry on the local cleavage fracture stress σf

An elastic–plastic finite element method (FEM) is used to analyse the stress and strain distributions ahead of notches with various depths and flank angles in four-point bending (4PB) specimens of a C–Mn steel. By accurately measuring the distances of the cleavage initiation sites from the notch roots, the local cleavage fracture stress σ _f is measured. By increasing the notch depth and notch flank angle from 2.25 to 8.25 mm and 10 to 90°, respectively, the distributions of high stress and strain at the moment of fracture show considerable variations. However, the value of σ _f stays relatively constant. The critical fracture event is thus shown to be identical, i.e. the propagation of a ferrite grain-sized crack into the neighbouring matrix. It is concluded that σ _f is mainly determined by the length of the critical microcrack, while the notch geometry and its associated stress volume have little effect on the value of σ _f . The cleavage site ahead of a notch is determined by the stress distributions and the positions of the weakest grains.     

Constraint effects on the ductile-to-brittle transition temperature of ferritic steels: a Weibull stress model

This study examines crack front length and constraint loss effects on cleavage fracture toughness in ferritic steels at temperatures in the ductile-to-brittle transition region. A local approach for fracture at the micro-scale of the material based on the Weibull stress is coupled with very detailed three-dimensional models of deep-notch bend specimens. A new non-dimensional function g(M) derived from the Weibull stress density describes the overall constraint level in a specimen. This function remains identical for all geometrically similar specimens regardless of their absolute sizes, and thus provides a computationally simple approach to construct (three-dimensional) fracture driving force curves _w vs. J, for each absolute size of interest. Proposed modifications of the conventional, two-parameter Weibull stress expression for cumulative failure probability introduce a new threshold parameter _w–min. This parameter has a simple calibration procedure requiring no additional experimental data. The use of a toughness scaling model including _w–min>0 increases the deformation level at which the CVN size specimen loses constraint compared to a 1TSE(B) specimen, which improves the agreement of computational predictions and experimental estimations. Finally the effects of specimen size and constraint loss on the cleavage fracture reference temperature T ₀ as determined using the new standard ASTM E1921 are investigated using Monte Carlo simulation together with the new toughness scaling model.     

A K0‐based calibration procedure for the Weibull stress cleavage model

This paper presents a simplified calibration procedure for the microscopic Weibull stress model to estimate the cumulative probability of cleavage fracture for ferritic steels. The proposed method requires two discrete values of the macroscopic Weibull scale parameter (K₀) in contrast to the two sets of statistically significant fracture toughness data mandated in previous calibration schemes. The proposed approach predicates on the fundamental assumption that the macroscopic toughness, for specimens dominated by cleavage mechanisms, follow the three‐parameter Weibull model outlined in the testing standards. The calibration procedure thus generates two sets of fictitious toughness data corresponding to two sets of specimens with marked differences in crack‐front constraints. The calibrated Weibull parameters agree closely with the calibration results based on the conventional approach for the Euro steels. The proposed calibration also leads to an improved method to determine a limiting load level, beyond which extensive plastic deformation propagates in the specimen.     

Loading rate effects on parameters of the Weibull stress model for ferritic steels

This study investigates the effects of loading rate on parameters of the Weibull stress model for prediction of cleavage fracture in a low strength, strongly rate-sensitive A515-70 pressure vessel steel. Based on measured, dynamic fracture toughness data from deep- and shallow-cracked SE(B) specimens, the calibrated Weibull modulus (m) at shows little difference from the value calibrated previously using static toughness data. This newly obtained result supports the hypothesis in an earlier study [Gao X, Dodds RH, Tregoning RL, Joyce JA. Weibull stress model for cleavage fracture under high-rate loading. Fatigue Fract Engng Mater Struct 2001;24:551-64] that the Weibull modulus likely remains rate independent for this material over the range of low-to-moderate loading rates. Additional experimental and computational results for higher rates show that a constant m-value remains applicable up to the maximum loading rate imposed in the testing program . Rate dependencies of the scale parameter (σ_u) and the threshold parameter (σ_w-min) are computed using the calibrated m, and the results indicate that σ_u decreases and σ_w-min increases with higher loading rates. The predicted cumulative probability for cleavage fracture exhibits a strong sensitivity to small changes in σ_u. Consequently, σ_u must be calibrated using dynamic fracture toughness data at each loading rate of interest in an application or selected to make the Weibull stress model predict a dynamic master curve of macroscopic toughness for the material.     

The role of T-stress in brittle fracture for linear elastic materials under mixed-mode loading

The purpose of this paper is to revisit the maximum tensile stress (MTS) criterion to predict brittle fracture for mixed mode conditions. Earlier experimental results for brittle fracture of polymethylmethacrylate (PMMA) using angled cracked plates are also re-examined. The role of the T -stress in brittle fracture for linear elastic materials is emphasized. The generalized MTS criterion is described in terms of mode I and II stress intensity factors, K _I and K _II and the T- stress (the stress parallel to the crack), and a fracture process zone, r _c . The generalized MTS criterion is then compared with the earlier experimental results for PMMA subjected to mixed mode conditions. It is shown that brittle fracture can be controlled by a combination of singular stresses (characterized by K ) or non-singular stress ( T -stress). The T -stress is also shown to have an influence on brittle fracture when the singular stress field is a result of mode II loading.     

A transferability model for brittle fracture including constraint and ductile tearing effects: a probabilistic approach

This study describes a computational framework to quantify the influence of constraint loss and ductile tearing on the cleavage fracture process, as reflected by the pronounced effects on macroscopic toughness (J _c , _c). Our approach adopts the Weibull stress _w as a suitable near-tip parameter to describe the coupling of remote loading with a micromechanics model incorporating the statistics of microcracks (weakest link philosophy). Unstable crack propagation (cleavage) occurs at a critical value of _w which may be attained prior to, or following, some amount of stable, ductile crack extension. A central feature of our framework focuses on the realistic numerical modeling of ductile crack growth using the computational cell methodology to define the evolution of near-tip stress fields during crack extension. Under increased remote loading (J), development of the Weibull stress reflects the potentially strong variations of near-tip stress fields due to the interacting effects of constraint loss and ductile crack extension. Computational results are discussed for well-contained plasticity, where the near-tip fields for a stationary and a growing crack are generated with a modified boundary layer (MBL) formulation (in the form of different levels of applied T-stress). These analyses demonstrate clearly the dependence of _w on crack-tip stress triaxiality and crack growth. The paper concludes with an application of the micromechanics model to predict the measured geometry and ductile tearing effects on the cleavage fracture toughness J _c of an HSLA steel. Here, we employ the concept of the Dodds-Anderson scaling model, but replace their original local criterion based on the equivalence of near-tip stressed volumes by attainment of a critical value of the Weibull stress. For this application, the proposed approach successfully predicts the combined effects of loss of constraint and crack growth on measured J _c -values.     

FATIGUE LIFE PREDICTION OF HEAT-TREATED CARBON STEELS AND LOW ALLOY STEELS BASED ON A SMALL CRACK GROWTH LAW

Abstract— Since heat-treated high strength steels are often used as materials for machines and structures that operate under severe service conditions, it is important to evaluate their fatigue life. Hence the growth law of a small fatigue crack must be known in order to estimate the fatigue life of machines and structures since the life of such members is controlled mainly by the behaviour of a small crack. The growth rate of a small crack can not be predicted usually by linear elastic fracture mechanics, but can be determined uniquely by the term σⁿ_a l , where σ_a is stress amplitude, l is crack length and n is a material constant. In this paper, the small-crack growth law of heat-treated carbon steels and low alloy steels was studied. An effective and convenient method based on a small-crack growth law, d l /d N = C ₃(σ_a/σ_a)ⁿ l is proposed, where σ_u is the ultimate tensile strength, for predicting the small crack propagation life of heat- treated steels with different tensile strength levels, together with a method for determining the fatigue life of plain members.     

FINITE ELEMENT ANALYSIS OF SPECIMEN GEOMETRY EFFECTS ON FATIGUE CRACK CLOSURE

Abstract— Elastic-plastic finite element analysis is used to study fatigue crack closure at three different crack length to width ratios for three plane stress specimen geometries: center-cracked plate, single-edge-cracked plate (tension), and single-edge-cracked plate (bend). The maximum stress to flow stress ratio, S_max/σ_O, which successfully describes closure results in many center-cracked plate configurations, does not correlate the effect of different geometries on the normalized opening stress, S _open/ S _max. Crack opening stresses for different geometries and crack lengths are successfully correlated by a normalized stress intensity parameter, K _max/ K ₀, where K ₀=σ₀φa. The quality of the correlation is very high at small K _max/ K ₀, and gradually deteriorates as K _max/ K ₀ increases beyond the small-scale yielding regime.     

MECHANISMS OF CYCLIC FATIGUE-CRACK PROPAGATION IN A FINE-GRAINED ALUMINA CERAMIC: THE ROLE OF CRACK CLOSURE

Abstract— Cyclic fatigue-crack growth and resistance-curve behavior have been studied in a fine-grained (∼ 1 μm), high-purity alumina. Specific emphasis is given to the mechanisms associated with crack growth that are controlled by the maximum ( K _max) and the alternating (Δ K ), stress intensities and to the role of crack-face interference (crack closure), which is known to be an important crack-tip shielding mechanism in metal fatigue. Significant levels of subcritical crack growth were detected above a threshold stress intensity of ∼60% of the fracture toughness ( K _c) in the alumina, with growth rates displaying a far larger dependence on K _max compared to Δ K. The role of crack closure was examined using constant- K _max experiments, where the minimum stress intensity ( K _min) was maintained either above or below the stress intensity for crack closure ( K _cl). Where K _min< K _cl, growth rates were found to exhibit a lower dependence on Δ K , which was rationalized in terms of the frictional wear model for crack growth in grain-bridging ceramics. It is concluded that crack closure, as conventionally defined, has little relevance as a crack-tip shielding mechanism during fatigue-crack growth in grain-bridging ceramics, due to the low dependence of growth rates on Δ K compared to K _max.     

FATIGUE CRACK GROWTH FROM A CIRCULAR NOTCH UNDER HIGH LEVELS OF BIAXIAL STRESS

Abstract— A series of experiments have been conducted on cruciform specimens to investigate fatigue crack growth from circular notches under high levels of biaxial stress. Two stress levels (Δσ₁= 380 and 560 MPa) and five stress biaxialities (λ=+1.0, +0.5, 0, −0.5 and −1.0; where λ=σ₂/σ₁ were adopted in the fatigue tests in type 316 stainless steel having a monotonic yield strength of 243 MPa. The results reveal that fatigue crack growth rates are markedly influenced by both the stress amplitude and the stress biaxiality. A modified model has been developed to describe fatigue crack growth under high levels of biaxial stress.     

The analysis of thermoelastic isopachic data from crack tip stress fields

A computer program—FACTUS (fracture analysis of crack tips using SPATE)—has been developed for the efficient analysis of thermoelastic data obtained from around a crack tip. The program is based on earlier work for the determination of stress intensity factors (SIFs), and also includes a novel solution procedure for the derivation of the non-singular stress term σ _{0 x} . The program has been used in the analysis of a series of large plate specimens with central or edge slots/cracks. The derived SIFs are compared with independent values. Issues, e.g. crack closure and the extent and effect of the plastic zone, are discussed.     

Stability analysis and experimental verification for optimum notch configuration in chevron-notched round bar specimens

In some earlier communications [Ray and Poddar, FFEMS, 27 (2004), Sarkar and Ray, FFEMS, 31 (2008)], a methodology to estimate the minimum normalized stress intensity factor for chevron-notched round bar (CVNRB) specimens has been outlined. The primary aim of this report is to theoretically analyse stable crack propagation in CVNRB specimens in order to estimate conservative fracture toughness value associated with this specimen geometry. The theoretical analyses have been substantiated using fracture toughness tests on CVNRB specimens of steel having initial normalized notch lengths (α₀) between 0.2 and 0.5. The major inferences drawn from this investigation are: (1) the optimum notch geometry in CVNRB specimens corresponds to 0.2 < α₀ < 0.3 for the maximum stable crack extension, and (2) the estimated fracture toughness of the steel using CVNRB specimens indicates minimum K_ICV at α₀= 0.29 in good agreement with the theoretical analyses.     

Probabilistic treatment of fracture using two failure models

A probabilistic methodology for brittle fracture based on two local failure models is presented. Probabilistic fracture parameters are obtained using a weakest link and a chain-of-bundles formulation. Both models define limiting distributions for the fracture stress described by a two-parameter Weibull distribution. Numerical procedures employing measured toughness data and finite element solutions are also described to calibrate the Weibull parameters. An application of the methodology then follows to predict geometry and stable crack growth effects on the distribution of macroscopic fracture toughness (J_c) for a high-strength steel. Measured fracture toughness values for a high-constraint geometry that exhibit no prior ductile tearing are effectively ‘transferred' to a different geometry having much lower constraint and in which tearing precedes cleavage. The inherent difficulty in predicting the scatter of experimental fracture toughness, as well as constraint and ductile tearing effects, within the scope of conventional procedures appears greatly reduced in the framework presented in this work.     

AN EXPERIMENTAL PARAMETER Jmax IN ELASTIC-PLASTIC FATIGUE CRACK GROWTH

Abstract— Imitating Garwood's 3-parameter technique, an experimental parameter J _max was introduced to predict fatigue crack growth rate (d a /d N ) over a wide range including small scale yielding and large scale yielding. It was found that for a Δ K -increasing fatigue test condition, J _max is a valid parameter. A significant crack growth acceleration, caused by a transition of fracture mechanism, occurs when J _max= J _IC The fracture mechanism involving striation formation when J _max < J _IC becomes ductile tearing when J _max > J _IC Equations to predict the effect of stress-ratio on J _max as well as on d a /d N are given.     

考虑骨料体积含量影响的混凝土准脆性断裂预测模型及应用

基于对准脆性断裂边界影响模型参数的分析,该文将平均骨料粒径d_ave引入模型中,得到了考虑骨料体积含量及尺寸影响的混凝土准脆性断裂预测模型。模型中的有效裂缝与特征裂纹的比值,明确表征了三分点加载单边切口梁(SENB)试件的尺寸及初始缝长度变化时服从的断裂失效准则;模型中d_ave及分散系数β_ave将影响最大荷载P_max作用下临界微裂纹扩展区的平均虚拟裂纹长度Δa_fic。通过SENB试件在P_max时的受力分析,得到了临界正应力σ_n、有效裂缝长度a_e、拉伸强度f_t及断裂韧度K_IC之间的关系式。通过Amparano的试验结果,当a_fic为0.8~1.4倍d_ave时,采用混凝土准脆性断裂模型能较好预测混凝土拉伸强度及断裂韧度。通过对Δa_fic=1.2d_ave时模型得到的预测曲线与试验结果的对比,证明了模型计算结果的可靠性。考虑骨料体积含量影响的混凝土准脆性断裂模型能基于RILEM规范中三分点加载SENB试验预测混凝土断裂韧度与拉伸强度。