Monotonic subcritical crack growth in T42 high speed steel

Abstract

R-curve behaviour in the microstructurally short crack regime has been reported mainly in ceramics, composites and polymers; this paper describes it for a metallic material: brittle cast and wrought T42 high speed steel. Continuum mechanics has demonstrated the general admissibility of sub-critical growth of cracks with a cohesive zone. Results now reported show that, in a metallic material, growth of microstructurally short cracks under monotonic loading, as in fatigue, is governed by microstructure (texture). Natural cracks, i.e. produced by the hot forging operation, or induced by the application of stress in the range 0.5 to 1.1 GPa in four-point bending experiments, of depths extending to 25µm were always associated with MC carbides. At comparable stress levels cracks were nucleated in compression -- surprisingly some transverse to the compressive axis. Observations of crack nucleation and subsequent studies of subcritical growth of these microcracks were made by surface replica microscopy. Crack extension was easy within the carbide stringers (a characteristic feature of hot-worked high speed steels), but, at higher stresses, took place between these bands to reach up to ∼ 100 µm (surface) length. Dormant cracks were shallow, no more than 6 µm deep; whereas those responsible for failure, at stresses ranging from 0.6 to 1.9 GPa, had a semicircular geomerty -- identified by scanning electron fractography. Step-wise monotonic subcritical crack growth is modelled asR -curves and it is shown that the maximum estimated (microscopic) applied stress intensity factor Ka can vary from 0.5 to 1.0 K1C, the macroscopic fracture toughness independently determined using sharp artificial long cracks.