The Microscopic Mechanism of Crack Evolution in Brittle Material Containing 3-D Embedded Flaw
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The present study deals with the experimental characterization of short crack propagation in SLM (selective-laser-melting) manufactured stainless steel. More specifically, the determination of cyclic R-curves is discussed. This describes the dependency of the crack propagation threshold on crack growth during the short crack propagation stage. For metals, the threshold, starting at a material-intrinsic value, increases until it reaches a value independent of the crack length due to crack closure phenomena which build up at that stage. The cyclic R-curve, when used in the frame of a cyclic R curve analysis, characterizes the resistance of a material to fatigue crack growth and the ability to arrest a physically short crack. Thus, it is the link between classical fatigue and fracture mechanics. In the high-cycle-fatigue range, the short crack propagation stage dominates the overall lifetime, i.e., the number of cycles until failure. Below the fatigue limit crack arrest of hitherto propagable micro-cracks will occur. The effort for the experimental characterization of the short fatigue crack propagation behavior and the cyclic R-curve is very high compared to experiments on long crack propagation. A very exact measurement of crack extension is required, since small increments need to be depicted. Pre-cracking must leave a closure free initial crack, since closure must be build up only by the cyclic R-curve. The closure-free status is achieved by compression pre-cracking. The aim of the present study is an insight into the influence of an AM process on the short crack propagation threshold. Cyclic R-curves are experimentally determined at different load-ratios for 316L austenitic steel specimens produced by SLM and conventional manufacturing. Residual stresses are measured in the crack plane and their influence on the cyclic R-curve is discussed.
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In recent years, it has been revealed that in high strength steel, fracture occurs from non-metallic inclusions inside of the material in the very high cycle region. However, because of the difficulty in directly observing the internal fatigue process, its mechanism is largely unknown. In this study, we try to clarify the internal fatigue process on the basis that the environment around an internal crack is like a vacuum environment. Also, it has been reported that the effect of vacuum environment is more prominent in the initial stages of crack propagation. This suggests that targeting the crack propagation process of small cracks, like that with the same size as a small defect, would shed light on the controlling factors in the internal fatigue process. Thus, we conducted ΔK-increasing tests in air and in vacuum using specimens with a small artificial defect on its surface. As a result, fatigue crack propagation rates in vacuum were lower than that in air. Also, when compared with the results of long cracks, the crack propagation rates in both environments were much higher. However, after eliminating the effect of crack closure for the results of long crack, the crack propagation rates in both environments matched.
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Titanium alloy
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This chapter contains sections titled: Special Features of the Propagation of Microstructurally Short Fatigue Cracks Definition of Short and Long Cracks Transgranular Crack Propagation Crystallographic Crack Propagation: Interactions with Grain Boundaries Mode I Crack Propagation Governed by Cyclic Crack-Tip Blunting Influence of Grain Size, Second Phases and Precipitates on the Propagation Behavior of Microstructurally Short Fatigue Cracks Significance of Crack-Closure Effects and Overloads General Idea of Crack Closure During Fatigue-Crack Propagation Plasticity-Induced Crack Closure Influence of Overloads in Plasticity-Induced Crack Closure Roughness-Induced Crack Closure Oxide- and Transformation-Induced Crack Closure ΔK*/K*max Thresholds: An Alternative to the Crack-Closure Concept Development of Crack Closure in the Short Crack Regime Short and Long Fatigue Cracks: The Transition from Mode II to Mode I Crack Propagation Development of the Crack Aspect Ratio a/c Coalescence of Short Cracks Intercrystalline Crack Propagation at Elevated Temperatures: The Mechanism of Dynamic Embrittlement Environmentally Assisted Intercrystalline Crack Propagation in Nickel-Based Superalloys: Possible Mechanisms Mechanism of Dynamic Embrittlement as a Generic Phenomenon: Examples Oxygen-Induced Intercrystalline Crack Propagation: Dynamic Embrittlement of Alloy 718 Increasing the Resistance to Intercrystalline Crack Propagation by Dynamic Embrittlement: Grain-Boundary Engineering
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In this study, the crack initiation and propagation behavior of interfacial crack in bimaterial are discussed. Normal crack opening displacements(NCOD) and stresses are analyzed by finite element method using ANSYS and used for extracting fracture parameters. The energy release rates can not explained the initiation and crack propagation velocity of interfacial crack. Initial velocity of crack propagation is dependent upon the normal and shear stress behind of crack tip. The crack propagation velocity of interfacial crack is very dependent upon the normal and shear stress behind of crack tip. In case of negative shear displacements increase in interfacial crack, initiation delay of crack propagation is dependent upon the negative shear stress ahead of crack tip due to the suppressing of crack opening. In case of positive shear displacements increase in interfacial crack, initiation delay of crack propagation is dependent upon the stress behind of crack tip due to the stress decrease. The fracture toughness increase is due to the initiation delay of crack propagation.
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Lüders band
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In past studies, we showed that cracks synthesized under carefully controlled conditions will propagate when subjected to sonic IR testing. The extent or severity of the propagation observed depended on several parameters including the stress intensity factor (which corresponds to crack growth rate) under which the crack was synthesized, the tightness of the crack closure, and the initial crack length. Furthermore, we showed that crack propagation during sonic IR testing occurs for 2024 aluminum, titanium and 304 stainless steel specimens. In this study, we extend the range of experimental conditions for synthesizing cracks to further elucidate their effect on the crack propagation, and we focus more specifically on the stress intensity factor. The stress intensity factor not only determines the rate of crack growth, but it has two profound effects on crack characteristics: the establishment of plastic zones around the crack tip and the variation of the topography of the mating crack surfaces. These two factors strongly affect crack propagation.
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Fracture mechanics is a key to fatigue assessment in AM metal components. Short fatigue cracks are initiated at defects and pronounced surface roughness intrinsic to AM. The subsequent crack-propagation is strongly influenced by microstructural interactions and the build-up of crack-closure. The aim of the present study is to give an insight into short-crack propagation in AM-metals. Fatigue crack propagation resistance curves were determined experimentally for AISI 316L manufactured by Laser Powder Bed Fusion (L-PBF) which was heat treated at three different temperatures. Differences in the build-up of the fatigue-crack propagation threshold in between the L-PBF specimens and compared to wrought material are due to the residual stress states, a pronounced roughness of the crack-faces in the L-PBF specimens and phase transformation in the vicinity of the crack-tip, resulting in increased crack-closure. This, together with crack-branching found along the crack path, enhances the resistance to the propagation of fatigue cracks.
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Abstract Analytical and experimental studies were performed to investigate the effect of gear rim thickness on crack propagation life. The FRANC (FRacture Analysis Code) computer program was used to simulate crack propagation. The FRANC program used principles of linear elastic fracture mechanics, finite element modelling, and a unique re‐meshing scheme to determine crack tip stress distributions, estimate stress intensity factors, and model crack propagation. Various fatigue crack growth models were used to estimate crack propagation life, based on the calculated stress intensity factors. Experimental tests were performed in a gear fatigue rig to validate predicted crack propagation results. Test gears were installed with special crack propagation gauges in the tooth fillet region to measure bending fatigue crack growth. Good correlation between predicted and measured crack growth was achieved when the fatigue crack closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear tooth fillet region increased. This retarded crack growth and increased the number of crack propagation cycles to failure.
Fillet (mechanics)
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