Calibration of cohesive parameters for a castable refractory using 4D tomographic data and realistic crack path from in-situ wedge splitting test

Abstract

Crack propagation in an alumina castable refractory with mullite-zirconia aggregates was investigated in-situ using a wedge splitting test performed inside a laboratory tomograph. Four-dimensional (i.e., 3D space and time) data from digital volume correlation were used to investigate the influence of a realistic crack path on the simulation of the fracture process. A cohesive law was chosen, since toughening mechanisms were present, and calibrated via finite element model updating. When a straight crack path was assumed instead of the experimental crack path, a 10% higher fracture energy and a 35% higher cohesive strength were calibrated. Although the force alone could be used in the minimized cost function, the kinematic information gives valuable insight into the trustworthiness of the geometrical hypotheses assumed in the finite element model. Such framework can be applied to study nonlinear fracture processes for different materials with complex toughening mechanisms such as crack deflection or branching.