Fractography: Determining the sites of fracture initiation

Abstract

Fractography is the analysis of fracture surfaces. Here, it refers to quantitative fracture surface analysis (FSA) in the context of applying the principles of fracture mechanics to the topography observed on the fracture surface of brittle materials. The application of FSA is based on the principle that encoded on the fracture surface of brittle materials is the entire history of the fracture process. It is our task to develop the skills and knowledge to decode this information. There are several motivating factors for applying our knowledge of FSA. The first and foremost is that there is specific, quantitative information to be obtained from the fracture surface. This information includes the identification of the size and location of the fracture initiating crack or defect, the stress state at failure, the existence, or not, of local or global residual stress, the existence, or not, of stress corrosion and a knowledge of local processing anomalies which affect the fracture process. The second motivating factor is that the information is free. Once a material is tested to failure, the encoded information becomes available. If we decide to observe the features produced during fracture then we are rewarded with much information. If we decide to ignore the fracture surface, then we are left to guess and/or reason as to the cause of the failure without the benefit of all of the possible information available. This paper addresses the application of quantitative fracture surface analysis to basic research, material and product development, and “trouble-shooting” of in-service failures. First, the basic principles involved will be presented. Next, the methodology necessary to apply the principles will be presented. Finally, a summary of the presentation will be made showing the applicability to design and reliability.