Some experimental observations of crack-tip mechanics with displacement data

Estudio de la mecánica en el vértice de la grieta mediante datos de desplazamiento.In the past two decades, crack-tip mechanics has been increasingly studied with full-field techniques. Within these techniques, Digital Image Correlation (DIC) has been most widely used due to its many advantages, to extract important crack-tip information, including Stress Intensity Factor (SIF), Crack Opening Displacement, J-integral, T-stress, closure level, plastic zone size, etc. However, little information is given in the literature about the experimental setup that provides best estimations for the different parameters. The current work aims at understanding how the experimental conditions used in DIC influence the crack-tip information extracted experimentally. The influence of parameters such as magnification factor, size of the images, position of the images with respect the crack-tip and size of the subset used in the correlation is studied. The influence is studied in terms of SIF and T-stress by using Williams’ model. The concept of determination of the K-dominance zone from experimental data has also explored. In this regard, cyclic loading on a fatigue crack in a compact tension (CT) specimen, made of aluminium 2024-T351 alloy, has been applied and the surface deformation ahead of the crack tip has been examined. The comparison between theoretical and experimental values of KI showed that the effect of subset size on the measured KI is negligible compared to the effect of size of the image.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Crack paths under mixed mode loading

Long fatigue cracks that initially experience mixed mode displacements usually change direction in response to cyclic elastic stresses. Eventually the cracks tend to orient themselves into a pure mode I condition, but the path that they take can be complex and chaotic. In this paper, we report on recent developments in techniques for tracking the crack path as it grows and evaluating the strength of the mixed mode crack tip stress field

NDE: An effective approach to improved reliability and safety. A technology survey

Technical abstracts are presented for about 100 significant documents relating to nondestructive testing of aircraft structures or related structural testing and the reliability of the more commonly used evaluation methods. Particular attention is directed toward acoustic emission; liquid penetrant; magnetic particle; ultrasonics; eddy current; and radiography. The introduction of the report includes an overview of the state-of-the-art represented in the documents that have been abstracted

Comparison of alternatives to amplitude thresholding for onset detection of acoustic emission signals

Acoustic Emission (AE) monitoring can be used to detect the presence of damage as well as determine its location in Structural Health Monitoring (SHM) applications. Information on the time difference of the signal generated by the damage event arriving at different sensors in an array is essential in performing localisation. Currently, this is determined using a fixed threshold which is particularly prone to errors when not set to optimal values. This paper presents three new methods for determining the onset of AE signals without the need for a predetermined threshold. The performance of the techniques is evaluated using AE signals generated during fatigue crack growth and compared to the established Akaike Information Criterion (AIC) and fixed threshold methods. It was found that the 1D location accuracy of the new methods was within the range of <1–7.1%<1–7.1% of the monitored region compared to 2.7% for the AIC method and a range of 1.8–9.4% for the conventional Fixed Threshold method at different threshold levels

High-resolution 3D weld toe stress analysis and ACPD method for weld toe fatigue crack initiation

Weld toe fatigue crack initiation is highly dependent on the local weld toe stress-concentrating geometry including any inherent flaws. These flaws are responsible for premature fatigue crack initiation (FCI) and must be minimised to maximise the fatigue life of a welded joint. In this work, a data-rich methodology has been developed to capture the true weld toe geometry and resulting local weld toe stress-field and relate this to the FCI life of a steel arc-welded joint. To obtain FCI lives, interrupted fatigue test was performed on the welded joint monitored by a novel multi-probe array of alternating current potential drop (ACPD) probes across the weld toe. This setup enabled the FCI sites to be located and the FCI life to be determined and gave an indication of early fatigue crack propagation rates. To understand fully the local weld toe stress-field, high-resolution (5 mu m) 3D linear-elastic finite element (FE) models were generated from X-ray micro-computed tomography (mu-CT) of each weld toe after fatigue testing. From these models, approximately 202 stress concentration factors (SCFs) were computed for every 1 mm of weld toe. These two novel methodologies successfully link to provide an assessment of the weld quality and this is correlated with the fatigue performance

Damage analysis and fracture toughness evaluation in a thin woven composite laminate under static tension using infrared thermography

This work deals with the issue of damage growth in thin woven composite laminates subjected to tensile loading. The conducted tensile tests were monitored on-line with an infrared camera, and tested specimens were analysed using Scanning Electron Microscopy (SEM). Combined with SEM micrographs, observation of heat source fields enabled us to assess the damage sequence. Transverse weft cracking was confirmed to be the main damage mode and fiber breakage was the final damage leading to failure. For cracks which induce little variation of specimen stiffness, the classic “Compliance method” could not be used to compute energy release rate. Hence, we present here a new procedure based on the estimation of heat source fields to calculate the energy release rate associated with transverse weft cracking. The results are then compared to those computed with a simple 3D inverse model of the heat diffusion problem and those presented in the literature

Deformation compatibility in a single crystalline Ni superalloy

Deformation in materials is often complex and requires rigorous understanding to predict engineering component lifetime. Experimental understanding of deformation requires utilization of advanced characterization techniques, such as high spatial resolution digital image correlation (HR-DIC) and high angular resolution electron backscatter diffraction (HR-EBSD), combined with clear interpretation of their results to understand how a material has deformed. In this study, we use HR-DIC and HR-EBSD to explore the mechanical behaviour of a single-crystal nickel alloy and to highlight opportunities to understand the complete deformations state in materials. Coupling of HR-DIC and HR-EBSD enables us to precisely focus on the extent which we can access the deformation gradient, F, in its entirety and uncouple contributions from elastic deformation gradients, slip and rigid body rotations. Our results show a clear demonstration of the capabilities of these techniques, found within our experimental toolbox, to underpin fundamental mechanistic studies of deformation in polycrystalline materials and the role of microstructure

Temperature and load-ratio dependent fatigue-crack growth in the CrMnFeCoNi high-entropy alloy

Multiple-principal element alloys known as high-entropy alloys have rapidly been gaining attention for the vast variety of compositions and potential combinations of properties that remain to be explored. Of these alloys, one of the earliest, the ‘Cantor alloy’ CrMnFeCoNi, displays excellent damage-tolerance with tensile strengths of ∼1 GPa and fracture toughness values in excess of 200 MPa√m; moreover, these mechanical properties tend to further improve at cryogenic temperatures. However, few studies have explored its corresponding fatigue properties. Here we expand on our previous study to examine the mechanics and mechanisms of fatigue-crack propagation in the CrMnFeCoNi alloy (∼7 μm grain size), with emphasis on long-life, near-threshold fatigue behavior, specifically as a function of load ratio at temperatures between ambient and liquid-nitrogen temperatures (293 K–77 K). We find that ΔKth fatigue thresholds are decreased with increasing positive load ratios, R between 0.1 and 0.7, but are increased at decreasing temperature. These effects can be attributed to the role of roughness-induced crack closure, which was estimated using compliance measurements. Evidence of deformation twinning at the crack tip during fatigue-crack advance was not apparent at ambient temperatures but seen at higher stress intensities (ΔK ∼ 20 MPa√m) at 77 K by post mortem microstructural analysis for tests at R = 0.1 and particularly at 0.7. Overall, the fatigue behavior of this alloy was found to be superior, or at least comparable, to conventional cryogenic and TWIP steels such as 304 L or 316 L steels and Fe-Mn steels; these results coupled with the remarkable strength and fracture toughness of the Cantor alloy at low temperatures indicate significant promise for the utility of this material for applications at cryogenic environments

Thermoelastic investigations for fatigue life assessment

An investigation is presented on the suitability and accuracy of a thermoelastic technique for the analysis of fatigue cracks. The stress intensity factor ranges ΔKI and ΔKII are determined from thermoelastic data recorded from around the tip of a sharp slot in a steel specimen under biaxial load, in order to assess the accuracy of the technique. ΔKI and ΔK II are determined to within 4% and 9% of a theoretical prediction, respectively. The results from a similar test on a fatigue crack under biaxial load are also presented. These show that thermoelastic stress analysis is a rapid and accurate way of analyzing mixed-mode fatigue cracks. A discussion is given on the potential of thermoelastic stress analysis of propagating cracks