DYNAMIC CRACK PROPAGATION AND CRACK ARREST INVESTIGATED WITH A NEW SPECIMEN GEOMETRY: PART II: EXPERIMENTAL STUDY ON A LOW-ALLOY FERRITIC STEEL

The novel experiment developed in our Institute to investigate crack initiation, rapid crack propagation and crack arrest with one specimen, the ring test, was applied to a ferritic HSLA pipeline steel. The maximum crack speed achieved in these experiments was between 230 m/s and 1165 m/s. The fracture toughness at crack arrest, K_Ia, was determined by a static analysis of this specific test. In all cases, it was found that K_Ia was much lower than K_Ic. The values of K_Ia decrease when the maximum crack speed increases, the results being largely scattered. The fracture toughness at crack arrest is therefore not an intrinsic parameter of the material for a given temperature. Cleavage fracture obtained under these conditions is characterized by the existence of numerous cleavage microcracks, mechanical twins and unbroken ligaments. The decrease in fracture toughness when crack speed increases is related, using the Beremin or the RKR model, to the high strain rates at the tip of a rapid propagating crack. A model which takes into account the effect of unbroken ligaments left in the wake of a propagating crack is developed to account for the large values of K_Ia which were occasionally measured.     

Brittle crack-arrest fracture toughness in a high heat-input thick steel weld

Brittle crack-arrest fracture toughness (K_Ia) was determined as a function of the temperature in a large-scale (1 x 1 m) 50-mm thick steel base metal and its high heat-input (32 kJ/mm) weld. An impact initiates crack propagation from a notch at low temperature toward a higher temperature region where the crack stopped due to the improved fracture toughness. The relationship between the toughness and crack-arrest temperature provides the K_Ia at ?10 °C of about 100 MPa√m in the weld specimen, which is a significant decrease compared to that of the base metal (240 MPa√m). Furthermore, the path of the crack propagation was discussed in terms of the grain size, hardness, and Charpy impact energy of the localized crack region.     

Anwendung des instrumentierten Kerbschlagbiegeversuchs zur Ermittlung von Referenztemperaturen nach dem Master‐Curve‐Konzept

Application of the Instrumented Impact Test for the Determination of Reference Temperatures Using the Master Curve Concept The instrumented impact test is suitable for the determination of fracture mechanical parameters. In this paper the determination of the dynamic fracture toughness values in the lower ductile‐to‐brittle transition region is presented. The fracture toughness is determined at the onset of cleavage fracture and evaluated by the Master Curve (MC) concept. The MC concept allows to quantify the variation of fracture toughness with the temperature within the lower ductile‐to‐brittle transition region. Limit curves of fracture toughness for defined failure probabilities and a reference temperature can be determined using this method. This paper presents the application of the master curve concept to the reference temperature determination through the thickness of reactor pressure vessel (RPV) steel plate. The reference temperatures determined dynamic fracture toughness values (T₀^dy) are compared with quasi‐static reference temperatures (T₀^st) and Charpy‐V transition temperatures (TT). T₀^dy, T₀^st and TT increase from the surface to the middle of the RPV steel plate. Compared with T₀^st, the T₀^dy values are higher approximately 70 to 90 K.     

An engineering interpretation of pop-in arrest and tearing arrest in terms of static crack arrest, KIa

When fracture toughness specimens are tested under displacement controlled conditions, they are often observed to exhibit unstable cleavage fracture followed by arrest of the cleavage mode wherein a significant load remains on the specimen (pop-in arrest). This behavior carries over into the ductile tearing regime wherein tearing may occur rapidly identified by load reduction and then proceeds at a discernible less rate (tearing arrest). Both these behaviors represent an initiation condition followed by an arrest condition. In this paper it is demonstrated that from either of the arrest conditions an arrest value may be determined which, for available experimental data, is shown to be an engineering estimate for the static crack arrest toughness, K_Ia. A general lower bound property for the arrest value is postulated based on referenced information.A data analysis procedure is outlined and K_Ic and K_Ia estimates from sixty-eight 1/2, 1 and 2 in. thick compact specimens from two steels (A533 Grade B Class 1 and AISI 1018) tested between -40°F and 200°F are summarized. The crack arrest estimates are seen to compare favorably with K_Ia results obtained by other investigators using 2 in. thick specimens. Also it is demonstrated that when failure is by fully ductile tearing, the crack arrest toughness is at least equal to the estimate for K_Ia for the specimen.It is judged that an engineering procedure has been demonstrated for obtaining reasonable estimates of K_Ia throughout the transition region and onto the upper shelf. Based on referenced work, shelf values are most likely specimen size dependent.     

Comparison of ASME K IR curve and dynamic master curve in determining ductile–brittle transition temperature of A48P2 steel

Abstract

The ductile–brittle transition temperature (DBTT) of grade A48P2 steel is characterised based on the American Society of Mechanical Engineers (ASME) fracture toughness K _IR curve and dynamic master curve approaches. The indexing parameter for the K _IR curve, reference temperature RT_NDT, is determined from drop weight and Charpy tests to be ?45°C. The dynamic master curve is constructed following ASTM standard E1921 guidelines; however, instead of precracked tests, the dynamic fracture toughness K _Jd is determined from Charpy V notch tests using a modified Schindler's procedure. A Weibull plot is constructed using the K _Jd data, and it is found that the points comply reasonably with the forced fit line of slope 4. The reference temperature for constructing the dynamic master curve, termed T^dy,Sch₀, thus determined is ?56°C. The ASME K _IR curve is shown to be conservative compared with the dynamic master curve constructed using T^dy,Sch₀.     

POP-IN AND CRACK ARREST IN AN HY80 WELD

It is generally thought that, when a material is in its brittle to ductile transition, it is more difficult to design for crack arrest than to prevent crack initiation (cleavage). This report shows that this is not always true for weldments. Comparison is made between compact crack arrest (CCA), K_a, and crack tip opening displacement (CTOD), K_Jc, toughness for the same HY80 weld. The value of K_a is shown to be much higher than the minimum K_Jc for pop-in fracture initiation. It is considered that the results support the conclusion of Japanese research workers (Arimochi and Isaka) that small pop-ins (in the CTOD test) propagate and arrest without load drop. It follows that prediction of structural failure for weldments need not be based on minimum pop-in toughness from CTOD tests.     

Determination of the Fracture Toughness of a Low Alloy Steel by the Instrumented Charpy Impact Test

An attempt to establish a non-empirical relationship between the Charpy V-notch energy CVN and the fracture toughness K _Ic is presented. We focus our study on the lower shelf of fracture toughness and on the onset of the ductile-to-brittle transition of a A508 Cl.3 low alloy structural steel. The methodology employed is based on the `local approach'. Brittle cleavage fracture is modelled in terms of the Beremin (1983) model, whereas the ductile crack advance preceding cleavage in the transition region is accounted for with the GTN model (Gurson, 1977; Tvergaard, 1982; Tvergaard and Needleman, 1984. Mechanical testing at different strain rates and temperatures allowed the establishment of the constitutive equations of the material in a rate dependent formulation. Numerous fracture tests on different specimen geometries provided the large data set necessary for statistical evaluation. All specimen types were modelled with finite element analysis. Special consideration was taken in order to handle the dynamic effects in the Charpy impact test in an appropriate way. The fracture toughness could be predicted from Charpy impact test results, on the lower shelf, by applying the `local approach'. In the transition region the parameters of the Beremin model were found to deviate from those established on the lower shelf. Detailed fractographic investigations showed that the nature of `weak spots' inducing cleavage fracture changes with temperature. It is concluded that the Beremin model must be refined in order to be applicable in the ductile-to-brittle transition region.     

Abschätzung von Bruchzähigkeitskennwerten aus der Bruch‐ oder Kerbschlagarbeit

Estimation of Fracture Toughness from the Charpy Fracture Energy By means of a simplistic mechanical model a mathematical relation between the total fracture energy of an edge‐cracked beam under bending and the fracture toughness was derived. Inserting the parameters of the standard Charpy specimens and accounting for the finite root radius and the shallowness of the notch, an equation to calculate fracture toughness from the Charpy fracture energy was obtained. Unlike the commonly used empirical correlation formulas, the presented equation is applicable to any elastic‐plastic material. From its theoretical basis and the underlying assumptions it is expected to be conservative in any case. Although the derivation only holds for the upper‐shelf regime, it also is applicable to the brittle‐to‐ductile transition regime as a lower bound. In this range, the degree of conservatism can be reduced by accounting for the well‐known shift of the transition temperature. Comparison with experimental data confirm these features of the presented formula.     

Effect of thermal treatment on the mechanical and toughness properties of extruded SiCw/aluminium 6061 metal matrix composite

Mechanical, instrumented Charpy V-notch (CVN) energy and plane strain fracture toughness properties of SiC whisker reinforced-6061 aluminium metal matrix composite material from an extruded tube have been determined. The effect of thermal treatment and orientation have been studied. The mechanical strength properties are higher than wrought Al 6061 in the T6 condition. CVN energy values, however, were reduced by an order of magnitude.K _lc fracture toughness of the as-received, T6 and degassed + T6 thermal treatments were 50% of the wrought Al 6061 alloy. The effect of orientation showed that the orientation with the least amount of SiC whisker in the crack plane (i.e. greatest mean free path between reinforcements) yields the highest toughness value.     

Interaction between tensile strength failure and mixed mode crack propagation in concrete

Crack size and structure size transitions are illustrated which connect the two limit-cases of ultimate tensile strength failure (small cracks and small structures) and mixed-mode crack propagation (large cracks and large structures). The problem of mixed-mode crack propagation in concrete is then faced. By increasing the size-scale of the element the influences of heterogeneity and cohesive crack tip forces disappear and crack branching is governed only by the linear elastic stress-singularity in the crack tip region. It is proved in this way that the fracture toughness of the material is measured by a unique parameter (G_IF, G_IC or K_IC) even for the mixed-mode condition. The ratio of the sliding or Mode II fracture toughness (G_IIF, G_IIC or K_IIC) to the opening or Mode I fracture toughness depends only on the crack branching criterion adopted and not on the material features. Eventually, very controversial experimental results recently obtained on the shear fracture of concrete are explained on the basis of the above-mentioned size-scale transition.     

Experimental analysis of the practical LBZ effects on the brittle fracture performance of cryogenic steel HAZs with respect to crack arrest toughness near fusion line

Focusing on crack arrest behavior, this study investigates the practical influence of local brittle zones (LBZs) on the brittle fracture resistance of heat-affected zones (HAZs) in advanced 9% Ni cryogenic steel welds, and discusses whether the LBZs of this steel in practice have potentially deleterious effects as previously thought, or not. By analyzing the variations in brittle crack arrest toughness (K_a) and brittle crack initiation toughness (K_c) within actual HAZ, it is found that LBZs of this steel may not be harmful in consideration of crack arrest toughness near fusion line.     

The restraining effect of ductile ligaments on plane strain crack propagation and arrest in ferritic steels

In the transition regime plain strain crack propagation in ferritic steels proceeds by a combination of cleavage and ductile rupture processes, the latter being confined to ligaments that are parallel to the direction of macroscopic crack propagation. These ligaments rupture as the crack propagates, and it is generally accepted that they have a restraining effect on crack propagation, and also provide a major contribution to the arrest fracture toughness $\text{K}{}_{\mathrm{Ia}}$. In modelling the propagation and arrest phenomena, and in quantifying this restraining effect, it is tempting to average the effect of the discrete ligaments over a region behind the crack tip. The results of this paper's theoretical analysis justify the use of the averaging procedure.     

Bruchmechanische Charakterisierung des Vergütungsstahls 30 CrNiMo 8 nach verschiedenen Anlaßbehandlungen

Fracture Mechanics Characterisation of the Q & T Steel 30 CrNiMo 8 after Different Heat Treatments The investigations show that the fracture toughness K_Ic of the Q & T steel 30 CrNiMo 8 for large structural members is more sensitive to a change of the tempering treatment than the Charpy energy A_v. For tempering temperatures between 200 and 250°C the fracture toughness K_Ic shows maximum values with K_Ic ? 87 MN/m^3/2, R_m = 1800 MN/m² and R_p0,2 = 1400 MN/m² at room temperature. With these values this steel may be an inexpensive alternative to the maraging steels, for example to 18 Ni 300 (X 2 NiCoMo 18 9 5) with K_Ic = 76 MN/m^3/2 at R_m = 2100 MN/m² and R_p0.2 = 2000 MN/m² (aged 4 h 480°C). Elastic-plastic fracture toughness values K_Ji were determined at onset of stable crack growth with specimens that fail after more or less large plastic deformations because the thickness of specimen is too small or test temperature and tempering temperature, respectively are too high. These values are essentially independent of specimen size, if some minimum size conditions are fulfilled, and they are in agreement with the linear elastic fracture toughness K_Ic. But the test of more especially large linear elastic failing specimens may clarify the uncertainty whether this procedure delivers conservative results in all cases.     

The use of master curve method for statistical re-evaluation of surveillance test data for WWER-1000 reactor pressure vessels

The surveillance fracture toughness test data for WWER-1000 reactor pressure vessel materials from Ukrainian nuclear power plants were re-evaluated using the Master curve methodology. It has been shown that experimental temperature dependence of fracture toughness parameters and a scatter of K_Jc values are in a good agreement with a Master curve shape and 5 and 95% tolerance bounds for materials in unirradiated condition and after neutron irradiation up to fluence 41. 2·10²² n/m² (E > 0.5 MeV). For the Khmelnitsky nuclear power plant unit 1 reactor pressure vessel an analysis has shown that normative approach PNAé G-7-002-86 underestimates essentially the measured fracture toughness of unirradiated weld metal. The reference temperature T₀ calculated according to the Master curve method was compared with a critical brittleness temperature T_K0 for reactor pressure vessel materials in unirradiated condition. It has been found that temperature T₀ is much lower than T_K0 . Furthermore a difference between T₀ and T_K0 values varies essentially from one material to another. A correlation between temperatures T_{28 J} defined from Charpy energy curve and T₀ values calculated from precracked Charpy specimens test was obtained. The analysis has shown that the results based on precracked Charpy specimens can provide nonconservative assessment of fracture toughness for WWER-1000 reactor pressure vessel materials.     

Three‐dimensional analyses of in‐plane and out‐of‐plane crack‐tip constraint characterization for fracture specimens

Three‐dimensional elastic–plastic finite element analyses have been conducted for 21 experimental specimens with different in‐plane and out‐of‐plane constraints in the literature. The distributions of five constraint parameters (namely T‐stress, Q, h, T_z and A_p) along crack fronts (specimen thickness) for the specimens were calculated. The capability and applicability of the parameters for characterizing in‐plane and out‐of‐plane crack‐tip constraints and establishing unified correlation with fracture toughness of a steel were investigated. The results show that the four constraint parameters (T‐stress, Q, h and T_z) based on crack‐tip stress fields are only sensitive to in‐plane or out‐of‐plane constraints. Therefore, the monotonic unified correlation curves with fracture toughness (toughness loci) cannot obtained by using them. The parameter A_p based on crack‐tip equivalent plastic strain is sensitive to both in‐plane and out‐of‐plane constraints, and may effectively characterize both of them. The monotonic unified correlation curves with fracture toughness can be obtained by using A_p. In structural integrity assessments, the correlation curves may be used in the failure assessment diagram (FAD) methodology for incorporating both in‐plane and out‐of‐plane constraint effects in structures for improving accuracy.     

Crack arrest in steels

This paper examines 3 theories that have been used to characterize the arrest capabilities of steels and structures: (1) The static analysis, arrest toughness ($\text{K}{}_{\mathrm{Ia}}$) theory; (2) The dynamically loaded/stationary crack toughness ($\text{K}{}_{\mathrm{Id}}$) theory, and (3) The dynamic analysis, propagating crack energy or toughness ($\text{R}{}_{\mathrm{ID}}$ or $\text{K}{}_{\mathrm{ID}}$) theory. These three concepts are examined in the light of measurements of unstable fracture and crack arrest in wedge-loaded DCB test pieces together with a fully dynamic analysis of the experiments.     

Long-term service effect on the toughness of pipeline steel 17GS

A transit oil pipeline, 720 mm in diameter, 334 km in length, and made of steel 17GS, after 30 years of service was twice non-destructively tested with intelligent Pipeline Inspection Gauges (PIGs). Two segments of this pipeline were cut in order to investigate the steel structure, composition, and mechanical properties and to compare these properties with those of `archive' material. Metallographic and microprobe analyses revealed no significant difference between the `archive' and `aged' materials. Specimens for testing tensile mechanical properties, for fatigue-crack growth rate measurements, and for a Charpy test were used. All those specimens were fabricated from both the base and weld metal in longitudinal and circumferential directions. At room temperature, the ultimate strength of the aged steel was found to be 5% higher than that of the `archive' material, whereas the yield point was 18% higher for the aged material. Charpy energy changed more significantly; decreasing by approximately 40% at room temperature. In addition to conventional mechanical properties, new characteristics such as `microcleavage stress' R _MC (minimum brittle fracture stress) and the toughness index K _T were determined. It has been found that a long period of operation does not affect the values of the steel microcleavage stress R _MC and does not influence the hardening exponent significantly. The use of the local approach to fracture has shown that an increase in yield stress is the main cause of the decrease in its toughness after long-term service. It is shown that a minor (15%) increase in the yield stress results in a rise (by 40°) in the Charpy transition temperature and may cause a twofold reduction in the fracture toughness K _IC.     

Long-term service effect on the toughness of pipeline steel 17GS

A transit oil pipeline, 720 mm in diameter, 334 km in length, and made of steel 17GS, after 30 years of service was twice non-destructively tested with intelligent Pipeline Inspection Gauges (PIGs). Two segments of this pipeline were cut in order to investigate the steel structure, composition, and mechanical properties and to compare these properties with those of `archive' material. Metallographic and microprobe analyses revealed no significant difference between the `archive' and `aged' materials. Specimens for testing tensile mechanical properties, for fatigue-crack growth rate measurements, and for a Charpy test were used. All those specimens were fabricated from both the base and weld metal in longitudinal and circumferential directions. At room temperature, the ultimate strength of the aged steel was found to be 5% higher than that of the `archive' material, whereas the yield point was 18% higher for the aged material. Charpy energy changed more significantly; decreasing by approximately 40% at room temperature. In addition to conventional mechanical properties, new characteristics such as `microcleavage stress' R _MC (minimum brittle fracture stress) and the toughness index K _T were determined. It has been found that a long period of operation does not affect the values of the steel microcleavage stress R _MC and does not influence the hardening exponent significantly. The use of the local approach to fracture has shown that an increase in yield stress is the main cause of the decrease in its toughness after long-term service. It is shown that a minor (15%) increase in the yield stress results in a rise (by 40°) in the Charpy transition temperature and may cause a twofold reduction in the fracture toughness K _IC.     

Untersuchungen zum Einfluß des Gefügezustandes auf das Rißausbreitungs-Verhalten bei einsinniger Belastung von TiAl6V4

Investigations on the Effect of Microstructure on Crack Propagation during Unidirectional Loading of TiAl6V4 Fracture mechanics tests were performed with the titanium alloy Ti-6 Al-4 V between ?196°C and room temperatur. Crack propagation behaviour was characterized by the K-Δa-curve, K_Io at the onset of stable crack extension and by K_Q, determined with the 5% secant method. K_Q is strongly dependent on the microstructure, whereas there is a less effect on K_Io. For a material with a microstructure with a low fracture toughness the value K_Q can be increased considerably by vaccum annealing at 750°C. There is only a small decrease of the yield strength.     

Residual strength of unidirectional fibre-metal laminates based on JC toughness of C(T) and SE(B) specimens: comparison with M(T) test results

Fibre‐metal laminates (FMLs) are structural composites designed with the aim of producing very low fatigue crack‐propagation rate, damage‐tolerant and high‐strength materials, if compared to aeronautical Al alloys. Their application in aeronautical structures demands a deep knowledge of a wide set of mechanical properties and technological values, including both fracture toughness and residual strength. The residual strength of FMLs have been traditionally determined by using wide centre‐cracked tension panels M(T). The use of this geometry requires large quantities of material and heavy laboratory facilities. In this work, fracture toughness ( J_C) of some unidirectional FMLs laminates was measured using a recently proposed methodology for critical fracture toughness evaluation on compact tension C(T) and single‐edge bend SE(B) specimens. Additionally, residual strength values of wider M(T) specimens with different widths (W from 150 to 200 mm) and several crack to width ratios (2a/W) were experimentally obtained. Some experimental residual strength values of M(T) specimens (W from 150 to 400 mm and different 2a/W ratios) of Arall were also obtained from the bibliography. Based on J_C results from C(T) and SE(B) specimens, and either using or not using crack‐tip plasticity corrections, the residual strengths of the M(T) specimens were predicted and compared to the experimental ones. The results showed good agreement, especially when crack‐tip plasticity corrections were applied.