Crack Propagation Analysis Research Articles

Failure analysis of fatigue crack propagation in specimens of AlSi10Mg aluminum alloy produced by L-PBF: Effect of different heat treatments

Fatigue crack growth behavior of AlSi10Mg aluminum alloy processed by laser powder bed fusion (L-PBF) was studied for three material conditions: as-built, stress relieved and hot isostatic pressed. An improvement in the fatigue crack growth resistance was found for the heat-treated conditions which was attributed to the residual stress relief induced by the heat treatments. The stress ratio did not affect the fatigue crack growth in regime II which was explained by the absence of crack closure. Fatigue crack growth rates were predicted using a model based on the cyclic plasticity of the tested aluminum alloy. The proposed model agreed well with the experimental results.

Strength and Crack Propagation Analysis of Layered Backfill Based on Energy Theory

The strength of backfill is greatly influenced by its inclination angle and interlayer concentration. In order to study the influence of inclination angle and interlayer mass concentration on the strength of backfill, a group of layered cemented backfill with cement-sand ratio of 1:4, interlayer mass concentration of 66%, 67% and 68% and inclination angles of 0°, 10°, 20° and 30° were prepared by using tailings as aggregate. The uniaxial compression test was carried out to analyse the effect of interlayer mass concentration and inclination angle on layered cemented backfill. The crack propagation and energy change law of the specimen during compression were analysed by J-integral and energy conservation law. The relationship between the crack initiation and propagation and strain energy of two representative three-layer backfill specimens was analysed by numerical modelling. The results show that the increase in the layer number and the inclination angle of the backfill can weaken the strength of the backfill. In a certain range of inclination angles, the weakening coefficient of the backfill caused by the inclination angle is very consistent with the cosine value of the corresponding angle. Due to the release of crack energy and the existence of interface J integral, the uniaxial compressive strength of different mass concentration backfill is different at various positions. When the displacement reaches a certain value, the crack and strain energy no longer increase.

Development of Strength Evaluation Methodology for Independent IMO TYPE C Tank with LH2 Carriers

Given the inadequate regulatory framework for liquefied hydrogen gas storage tanks on ships and the limitations of the IGC Code, designed for liquefied natural gas, this study introduces a critical assessment procedure to ensure the safety and suitability of such tank designs. This study performed a heat transfer analysis for boil-off gas (BOG) calculations and established separate design load cases to evaluate the yielding and buckling strength. In addition, the study assessed methodologies for both high-cycle and low-cycle fatigue assessments, complemented by comprehensive structural integrity evaluations using finite element analysis. A comprehensive approach was developed to assess the structural integrity of Type C tanks by conducting crack propagation analysis and comparing these results with the IGC Code criteria. The practicality and efficacy of these methods were validated through their application on a 23K-class liquefied hydrogen carrier at the concept design stage. These findings may have important implications for enhancing safety standards and regulatory policies.

Analysis of crack propagation and life estimation of spiral bevel gears with root cracks

Abstract In order to study the effect of tooth root cracks on the fatigue life of spiral bevel gears, a certain spiral bevel gear was taken as the research object, and the mechanism of tooth root fatigue cracks was analyzed based on crack propagation theory; By combining the extended finite element method and the level set method, an initial crack propagation finite element model is established. The crack location of the gear teeth is determined through static analysis of the gear pair, and the influence of alternating loads on the initiation and propagation life of tooth surface cracks is studied. The analysis results indicate that the number of load cycles required for each crack propagation after its first occurrence gradually decreases; The crack propagation path of gear cracks under fatigue load is consistent with the actual tooth surface fracture surface; Realize life estimation from crack propagation to fracture failure.

Analysis of crack propagation of annular butt weld and distribution of weld-induced residual stress

The circumferential surface crack propagation and the effect of weld-induced residual stress were analyzed to comprehensively understand the mechanical behavior and fracture resistance of dissimilar girth welded joints of steel castings. The evaluation of stress intensity factors is conducted for circumferential cracks on internal surfaces, aiming to predict the fracture toughness of dissimilar welded joints. The distribution of weld-induced residual stress is obtained by thermal elastic-plastic finite element methods. The impact of residual stress on the propagation of cracks is investigated through the application of extended finite element theory. The high-stress intensity factors were found in such dissimilar welded joints due to the local bending and distortion caused by the asymmetrical weld geometry. The tensile residual stress and distortion were applied to the weld root area and its vicinity. Both the asymmetrical weld geometry and tensile residual stress contribute to the tensile distortion of the inner surface around the weld root, and enable the growth of internal surface cracks in the circumferential direction and radially from inside out of the welded joint. The fracture resistance decreases with the simultaneous influence of residual stress and welds’ asymmetry.

Digital fatigue cracking test and fatigue life assessment of rib-deck joints in orthotropic steel decks

The orthotropic steel decks (OSDs) are vulnerable to fatigue fractures, which will inevitably impair the normal service of the steel bridge panels. To determine the impact of the initial cracks on the fatigue life, this study constructed an evaluation model of the OSD rib-to-deck joints crack based on the fracture mechanics principle. And combined it with the multi-scale finite element analysis model, the digital fatigue test model of the whole bridge was established. Research shows: A typical I-II-III composite crack with the supremacy of type I crack can be seen in the OSD rib-to-deck joints. Fatigue cracks developed at the deck weld toe dominate the fatigue failure mode. Further research revealed that as the depth of cracks increased, the stress on the cross-section was redistributed. The intensity factor then displayed a trend of growing and then gradually flattening or even dropping. Based on the relationship between cracks of different depths and the remaining life of the OSDs, recommendations are given for bridge maintenance. The multi-scale digital fatigue test can provide analysis and simulation methods for the fatigue crack propagation in the steel bridge deck of the bridge in operation.

Progressive Damage and Crack Propagation Analysis of Composite-Patched Aluminum Plate with 3D Inclined Crack under Fatigue Loading

Progressive Damage and Crack Propagation Analysis of Composite-Patched Aluminum Plate with 3D Inclined Crack under Fatigue Loading

Interfacial stress and crack propagation experimental study in mini-LED chip debonding

The ultra-miniaturization trend of chips presents new challenges for non-destructive peeling-off techniques. This study models the mini-LED chip-UV film adhesive system as a micro laminated structure and conducts the interfacial stresses and crack propagation analysis of the structure using theoretical, finite element and experimental methods. The innovations of this paper are the illustration of the negligible effect of size effect on 125 μm x 75 μm x 60 μm chips, and the determination of the technology parameter tuning method to promote chip peeling-off. Firstly, applying the first-order shear deformation theory, and considering the UV-curable acrylic adhesive layer and the UV film as elastic materials, Lamé coefficients are introduced to explore the free vibration of the micro laminated structure. The analyses indicate that the scale effect has an extremely small impact, within 0.5%, on natural frequencies of the 100-micron scale laminated structure with a small length-to-thickness ratio. Thereafter, a three parameter elastic foundation (3-PEF) model of the chip-UV film adhesive structure is established and the interfacial stresses distributions are parametrically analyzed. Additionally, an experimental platform for needle-ejecting chip peeling-off is designed and constructed. Finite element simulation, experimental observations, and image recognition of crack generation and propagation during the peeling process were performed. Results show that cracks are generated at both free ends of the adhesive layer and progressively extended inwards. This is consistent with the 3-PEF analytical solution, in which the stress concentration also occurs at free ends of the adhesive layer. The agreement between theoretical, simulation and experimental results regarding interfacial stresses provides a solid foundation for further analysis of chip peeling-off mechanism.

Analysis of crack propagation and hydraulic fracturing behavior of coral reef limestone

Analysis of crack propagation and hydraulic fracturing behavior of coral reef limestone

A Physics-Based Tweedie Exponential Dispersion Process Model for Metal Fatigue Crack Propagation and Prognostics

Most structural faults in metal parts can be attributed to fatigue crack propagation. The analysis and prognostics of fatigue crack propagation play essential roles in the health management of mechanical systems. Due to the impacts of different uncertainty factors, the crack propagation process exhibits significant randomness, which causes difficulties in fatigue life prediction. To improve prognostic accuracy, a physics-based Tweedie exponential dispersion process (TEDP) model is proposed via integrating Paris Law and the stochastic process. This TEDP model can capture both the crack growth mechanism and uncertainty. Compared with other existing models, the TEDP taking Wiener process, Gamma process, and inverse process as special cases is more general and flexible in modeling complex degradation paths. The probability density function of the model is derived based on saddle-joint approximation. The unknown parameters are calculated via maximum likelihood estimation. Then, the analytic expressions of the distributions of lifetime and product reliability are presented. Significant findings include that the proposed TEDP model substantially enhances predictive accuracy in lifetime estimations of mechanical systems under varying operational conditions, as demonstrated in a practical case study on fatigue crack data. This model not only provides highly accurate lifetime predictions, but also offers deep insights into the reliability assessments of mechanically stressed components.

Crack generation and propagation mechanism of Mo[sbnd]14Re alloy laser welding

This paper investigates the mechanism of crack generation and propagation in laser-welded joints of Mo14Re alloy plates. The study utilized optical microscopy (OM) and scanning electron microscopy (SEM) to examine the microstructure and morphology of the crack area in the Mo14Re laser-welded joint. Additionally, energy dispersive spectroscopy (EDS) was employed to characterize the elements at the crack defect, while electron backscatter diffraction (EBSD) was utilized to analyze the grain boundary and crystal orientation at the crack defect.The analysis of crack formation and propagation considered various factors, including grain boundary segregation, characteristics of grain boundaries and crystal orientation, and the Schmidt factor. The findings revealed that cracks formed in the weld area exhibited distinct characteristics of brittle fracture along the grain. Notably, these cracks displayed evident carbon and oxygen segregation attributed to the presence of a low melting point eutectic liquid film. The segregation, along with high-temperature compounds on the fracture surface, emerged as the primary factors contributing to crack formation.In the proximity of the crack, there exists a concentration of strain, inducing plastic deformation and thereby facilitating crack initiation. Cracks exhibit a tendency to originate along large-angle grain boundaries and deflect along these boundaries. Owing to the difference in atomic slip characteristics on both sides of the crack, the direction of crack propagation is more inclined to deflect towards grains with a smaller Schmidt factor.

Numerical Analysis of Crack Propagation in an Aluminum Alloy under Random Load Spectra

This study develops a rapid algorithm coupled with the finite element method to predict the fatigue crack propagation process and select the enhancement factor for the equivalent random load spectrum of accelerated fatigue tests. The proposed algorithm is validated by several fatigue tests of an aluminum alloy under the accelerated random load spectra. In the validation process, two kinds of panels with different geometries and sizes are used to calculate the stress intensity factor, critical crack length, and crack propagation life. The simulated and experimental findings indicate that when the aluminum alloy is in a low plasticity state, the crack propagation life exhibits a linear relationship with the acceleration factor. When the aluminum alloy is in a high plasticity state, this study proposes an empirical formula to calculate the equivalent stress intensity factor and crack propagation life. The normalized empirical formula is independent of the geometry and size of different samples, although the fracture processes are different in the two kinds of panels used in our study. Overall, the numerical method proposed in this paper can be applied to predict the fatigue crack propagation life for the random spectrum of large samples based on the results of the simulated accelerated crack propagation process and the accelerated fatigue tests of small samples to reduce the cost and time of the testing.

First and second law analysis of crack propagation in canvas painting

The knowledge of how the craquelures happen and their pattern on historical objects, especially paintings, is interested in the field of cultural heritage. Entropy generation and thermal analysis of crack growth are calculated numerically for the canvas painting. The painting is modeled as a three-layer composite with isotropic material properties. An in-house code is developed to model the plane strain elasto-static structural mechanics with hybrid-Trefftz finite element formulation. The results are benchmarked with numerical and analytical solutions. Entropy generation and temperature fields are simulated throughout stacking in mode I of a delamination process. The parameter study shows that the parameter of entropy has a great influence on the process of expectation of break proliferation in fast and low areas. It is likewise demonstrated that the use of the corruption entropy age hypothesis gives a technique for assessing the steady in the law of crack growth regarding the rate of entropy production.

First and second law analysis of crack propagation in canvas painting

The knowledge of how the craquelures happen and their pattern on historical objects, especially paintings, is interested in the field of cultural heritage. Entropy generation and thermal analysis of crack growth are calculated numerically for the canvas painting. The painting is modeled as a three-layer composite with isotropic material properties. An in-house code is developed to model the plane strain elasto-static structural mechanics with hybrid-Trefftz finite element formulation. The results are benchmarked with numerical and analytical solutions. Entropy generation and temperature fields are simulated throughout stacking in mode I of a delamination process. The parameter study shows that the parameter of entropy has a great influence on the process of expectation of break proliferation in fast and low areas. It is likewise demonstrated that the use of the corruption entropy age hypothesis gives a technique for assessing the steady in the law of crack growth regarding the rate of entropy production.

Thermal corrosion fatigue crack growth behavior and life prediction of 304SS pipeline structures in high temperature pressurized water

The influence of transient water temperature changes on the fatigue crack growth behavior of 304SS pipeline structures was studied based on high-throughput testing method through the modification of dual loop circulating water equipment. Results demonstrated that the fatigue crack growth rate gradually decreased with the decrease of cooling rate, and the crack growth rate was exponentially related to the cooling rate. Both the base material and weld of the stepped pipe showed a transgranular cracking mode, and propagated continuously by slip-oxidation mechanism. Compared with the fine equiaxed grain of the base material, the grain in the weld was coarse and the residual strain was large, and the crack growth rate of the weld was obviously higher. Then, the thermal fatigue crack growth rate model for stepped pipes was established by combining finite element thermo-mechanical coupling simulation and three-dimensional crack propagation analysis software, and the model was modified based on the experimental results.

Accelerating SPH-Fatigue Computation by Using Single Precision Program on GPU

The fatigue crack propagation analysis based on the SPH framework “SPH-Fatigue” is accelerated by using the single precision program on GPU. It is found that the single precision program slightly disorders the stress wave but doubles the computational speed. In addition, the computational results of the fatigue crack propagation by the single precision program show almost the same crack shapes as the experimental ones. Accordingly, it is concluded that the use of the single precision program is one of the choices to accelerate the SPH-Fatigue computation.

Analysis method useful for calculating various interface stress intensity factors efficiently by using a proportional stress field of a single reference solution modeling

This paper has proposed an efficient analysis method to calculate interface stress intensity factors (SIFs) based on a proportional stress field of a reference problem whose exact solution is available. In the previous proportional methods, the same crack length and the same element size were applied to both reference and unknown problems so that the same FEM error can be produced. Therefore, when analyzing many unknown problems, the conventional method needs to analyze many reference problems at the same time. Since this approach is time-consuming, this paper considers how to calculate many crack lengths efficiently by using only one single reference solution modeling. For this purpose, several general relations of SIFs are derived for the unknown and the reference problems when both crack length and element size are different. To analyze many unknown problems accurately by using a single reference solution modeling, how to choose the most suitable element dimension of the reference model is clarified. The proposed method is especially useful for crack propagation analysis.

An adaptive extended finite element based crack propagation analysis method

In this paper, a method of crack propagation analysis based on adaptive extension finite element is proposed. This method combines adaptive mesh reconstruction technology with extended finite element method (XFEM). Firstly, the model of engineering structure is discretized with the help of mesh generation software, and the initial mesh is divided. Secondly, Construction of XFEM model, and the tip of crack strengthening function is introduced to describe the physical field properties of the crack tip. The integral equation is solved to obtain the crack tip parameters. Then, the adaptive mesh reconstruction technology is built to refine the mesh of crack tip area through the error estimation of crack tip. Finally, the SIFs at the crack tip were calculated using the interaction integral, and the path direction of crack growth was determined using the maximum circumferential tensile stress criterion. Thus, the propagation path can be well traced.

Methodology for Studying Brittle Fracture of HTHP Diamond Single Crystals by Crack Propagation Analysis under Shock Load

Methodology for Studying Brittle Fracture of HTHP Diamond Single Crystals by Crack Propagation Analysis under Shock Load

Analysis of electrode crack propagation in solid oxide fuel cell with pre-crack

The mechanical performance of solid oxide fuel cell is one of the main factors limiting its commercialization process. In order to reduce the degree of crack propagation during the cooling process and improve the stability and durability of the cell, the finite element analysis is conducted on a three-dimensional model of solid oxide fuel cell containing pre-cracks. Utilizing the extended finite element method (XFEM) and fracture theory, considering the stress distribution, length and maximum width after crack propagation and deflection angle of crack as criteria, this paper investigates the influence of various parameters, including working temperature, material properties, pre-crack angle and pre-crack location, on pre-crack propagation behavior and proposes a solution to improve the stability of the cell based on material optimization and structural optimization. Set a pre-crack at the left boundary of the anode to analyze the influence of different operating conditions on the propagation of anode cracks in the cell. The correctness of finite element simulation is verified by comparing the simulation results and theoretical results of crack stress intensity factors in the same model. From the comprehensive analysis of the thermal stress of the cell, the crack length and maximum width after pre-crack propagation, and the two deflection angles of crack propagation, it can be seen that within the selected parameters, in order to ensure the stability of the cell and inhibit the degree of crack propagation, the operating temperature of the cell should not be lower than 1023 K, and the coefficient of thermal expansion of anode should be less than 12.50×10<sup>-6</sup> K<sup>-1</sup>. In addition, when the pre-crack angle is 45° or the pre-crack is 0.45mm away from the bottom of anode, the maximum width after crack propagation is the smallest, and the propagation path is the most predictable. In this case, the cell is affected by the smallest crack range and the highest stability. This research provides a guidance for suppressing crack propagation in solid oxide fuel cell, improving the lifetime and promoting the commercialization process of fuel cell.