Crack Growth Process Research Articles

An accelerated corrosion-fatigue testing method for marine high-strength steel based on equivalence principle of fatigue crack growth

The corrosion-fatigue test is widely used to assess marine equipment. However, due to the low-frequency and high-cycle loading of marine equipment in service, conventional test methods require long cycle times and high costs. This makes it challenging to meet the rapid evaluation demands associated with equipment development effectively. In this study, an accelerated corrosion test method was proposed for steel by adjusting the composition, temperature, pH and H2O2 concentration of environment. Fatigue crack growth tests were conducted under various corrosion environments and load frequencies. The matching relationships between corrosion fatigue acceleration multiplier, corrosion environment parameters and load parameters were established. Additionally, a corrosion fatigue acceleration test method was proposed based on the equivalent principle of fatigue crack growth. The results show that effective coupling between corrosion and fatigue can be achieved by gradually reducing the load frequency as the stress intensity factor amplitude increases throughout the crack growth process. It is consistent with the trend of fatigue crack growth rate in the seawater environment. The 4.85% fatigue life deviation and the 15.68 times corrosion fatigue acceleration can be achieved by our method. This work improves the accuracy and reliability of fatigue performance evaluation for offshore equipment.

Prognosis of reflective pavement cracking development with Bayesian updating and surrogate models

ABSTRACT The main objective of this study is to establish an integrated prognostic method for predicting the development of thermal-induced reflective cracking in asphalt overlay on concrete pavement. The integrated prognosis process for crack growth is developed on the modified Paris’ law and includes three steps: (1) calculation of J-integral; (2) Bayesian updating of crack growth parameters and (3) prediction of remaining life. Finite element modelling (FEM) was conducted to calculate J-integrals at different crack depths and cold weather conditions. A surrogate model was built based on the original Kriging method and it shows high accuracy in predicting J-integrals from maximum air temperature, temperature drop and crack depth. The Bayesian updating process starts from the laboratory-measured distribution of fracture model parameters (A and n) in Paris’ Law and converges to the true values to match the measured crack depths at different loading cycles from field inspection. On the other hand, the consideration of material damage in asphalt overlay avoids over-estimation of remaining loading cycles for reflective cracking to reach the pavement surface. Further study is recommended to accurately assess in-situ pavement modulus and detect crack depth over concrete joints for implementation of the proposed prognostics method.

Multiscale modelling strategy for predicting fatigue performance of welded joints

This study predicts the fatigue performance of welded joints through a multiscale modelling strategy accounting for material and structural inhomogeneities. An S-N curve and detailed fracture surfaces with distinct beach marks were first derived by uniaxial fatigue tests utilising the designed cruciform welded joints. Considering the intrinsic features of welded joints, a multiscale modelling strategy was proposed to integrate multiple factors, including microstructural variations, strength distributions within the heat-affected zone (HAZ), and the diversity of three-dimensional weld toe shapes. Significantly, a modelling strategy was presented for the first time to simulate the simultaneous initiation, growth, and coalescence of multiple cracks, and was validated against experimental evidence. The results indicate that the proposed strategy can accurately predict both the fatigue strength and the overall crack growth process. Additionally, comparative assessments of single-crack and multiple-crack modelling strategies revealed notably shorter predicted fatigue lives when considering crack coalescence. Overall, this work establishes a multiscale framework for assessing the fatigue performance of welded joints considering both microscopic and macroscopic factors, offering substantial practical implications for engineering applications.

A multi-scale deep residual network-based guided wave imaging evaluation method for fatigue crack quantification

Abstract As a promising structural health monitoring (SHM) technology, guided wave (GW) imaging is gaining increasing attention for crack monitoring of aircraft structures. However, actual fatigue crack propagation is a complex dynamically evolving process affected by various variabilities. It is still challenging to accurately track and quantify the dynamic fatigue crack propagation with GW imaging methods. Therefore, in order to achieve more accurate fatigue crack quantification, this paper proposes a multi-scale deep residual network-based GW imaging evaluation method. A convolutional neural network (CNN) is utilized to evaluate the entire pixel distribution of GW imaging maps to fuse damage-related information from multiple GW monitoring paths. By designing multi-scale convolutional kernels and deep residual learning, a robust quantitative image feature extraction is ensured with the dynamic evolution process of fatigue crack growth and the performance degradation is avoided as the CNN goes deeper, thereby improving the quantification accuracy. The method is validated on a fatigue test of landing gear beams, which are important load-carrying aircraft structural components. The results demonstrate that the proposed method can extract multi-scale crack length-related features and accurately track fatigue crack propagations. For batch specimens, the maximum quantification error is reduced from the original 6.1mm to 1.6mm, marking a significant improvement.

Predicting fatigue life and crack growth rate of TC4 titanium alloy based on PINN before and after ultrasonic impact treatment

This study conducted fatigue crack growth rate (FCGR) experiments on TC4 titanium alloy specimens under different stress ratios (R=0.06, 0.1, 0.5) before and after ultrasonic impact treatment (UIT) conditions. Based on this, a Physics-Informed Neural Network (PINN) model was employed to predict the FCGR of TC4 titanium alloy. As a control group, the traditional Walker FCGR formula was fitted using experimental data. The results indicate that the stress ratio R does not significantly affect the FCGR of TC4 titanium alloy. Under the same range of stress intensity factor (ΔK), the FCGR (da/dN) decreases with increasing R. The FCGR prediction established by the PINN model can well reflect the nonlinear characteristics of the crack growth process rate. The coefficient of determination R2 for fitting the experimental data reached above 0.9900, generally higher than the 0.9545 of the Walker formula. Although the degree of dispersion increased after UIT, the PINN model demonstrated stable prediction accuracy compared to the Walker formula. In addition, when calculating the fatigue crack growth life using the cycle-by-cycle method, the PINN model also exhibits stable prediction accuracy compared to the Walker formula, and this advantage becomes more apparent with increased data dispersion.

Stochastic Modeling of Crack Growth and Maintenance Optimization for Metallic Components Subjected to Fatigue-Induced Failure

Abstract The degradation of metallic systems under cyclic loading is subject to significant uncertainty, which affects the reliability of residual lifetime predictions and subsequent decisions on optimum maintenance schedules. This paper focuses two main challenges in developing a reliable framework for the lifecycle management of fatigue-critical components: constructing a stochastic model that captures uncertainties in crack growth histories, and presenting a computationally efficient strategy for solving the stochastic optimization associated with maintenance scheduling. Polynomial chaos (PC) representation is proposed to propagate uncertainty in the fatigue-induced crack growth process, using a database from constant amplitude loading experiments. Additionally, an optimization strategy is implemented based on Gaussian process surrogate modeling to solve the stochastic optimization problem under maximum probability of failure constraints. The sensitivity of the optimum solution to different probability of failure thresholds is examined. The proposed framework offers a decision support tool for informed decision-making under uncertainty, aiming to mitigate fatigue failure.

Mechanisms of near-wellbore fracture growth considering the presence of cement sheath microcracks and their implications on wellbore stability

Placement of intended perforations is usually extensive enough into the reservoir to minimize any near wellbore influence on the expected fracture growth. However, some unplanned fractures do not necessarily originate from the intended shot holes. A sufficient volume of published work exists on the processes of crack growth from the near wellbore regions such as from the cement sheath or from fractures observed on the formation wall surrounding the wellbore. A robust quantification of wellbore stability issues should not detach such fracture development, which can potentially result into issues such as cement sheath damage and unnecessary formation damage in the near-wellbore regions. Such fractures may become fluid injection points during stimulation related wellbore pressurization, leading to pronounced development. In such scenarios, fracture development may become a nuisance if it jeopardises the intended structural support and zonal isolation integrity of the cement sheath around the wellbore, leading to wellbore failure, and a potential abandonment. The pressure transmission across this structural seal affects the zonal isolation integrity and its intended structural support leading to wellbore instability. Understanding crack growth behaviour in such cement-rock structural framework is still illusional yet it poses the wellbore to a risky state of instability. Our study provides insight into mechanical and elastic behavior of a tightly bonded cement-rock framework with presence of initial cracks. It also provides insight into how the acting far-field stresses, applied wellbore pressures, crack length, and orientation angle influence the crack growth morphologies including planar fractures, curved and cyclic fractures. The study is important not only for a proper selection of the cement slurry but also for the definition of allowable pressures during the wellbore lifespan. Inappropriately selected parameters might lead to the loss of wellbore integrity to a point as early as the start of a well’s life.

The effect of constant electric field on the crack growth process of aluminum nanosheet using molecular dynamics simulation

Aluminum nanosheets are a form of Al nanoparticle that have been recently manufactured on an industrial scale and have a variety of uses. Al nanoparticles are extensively used in a variety of sectors, including aerospace, construction, medical, chemistry, and marine industries. Crack propagation in various constructions must be investigated thoroughly for structural design purposes. Cracks in nanoparticles may occur during the production of nanosheets (NSs) or when different mechanical or thermal pressures were applied. In this work, the effect of a continuous electric field on the fracture formation process of aluminum nanosheets was investigated. For this study, molecular dynamics simulation and LAMMPS software were used. The effects of various electric fields on several parameters, including as stress, velocity (Velo), and fracture length, were explored, and numerical data were retrieved using software. The results show that the amplitude of the electric field parameter affected the atomic development of modeled Al nanosheets throughout the fracture operation. This effect resulted in atomic resonance (amplitude) fluctuations, which affected the mean interatomic forces and led the temporal evolution of atoms to converge to certain specified initial conditions. The crack length in our modeled samples ranged from 22.88 to 32.63 Å, depending on the electric field parameter (0.1–1 V/Å). Finally, it was determined that the crack growth of modeled Al nanosheets may be controlled using CEF parameters in real-world situations.

Experimental study on fractal dimension of energy dissipation and crack growth in saturated tuff at different strain rates

In order to investigate the effects of strain rate and water saturation on the energy dissipation and crack growth of tuff, uniaxial compression tests were carried out on dry and water saturated tuff with different strain rates using an electro-hydraulic servo press and a 50 mm diameter split Hopkinson pressure rod (SHPB) device. High-speed camera and Image J image analysis software were used to obtain the crack growth process of the specimen under impact load, and fractal dimension was introduced to quantitatively study the crack growth degree. The results show that more than 90% of the energy is stored in the specimen as elastic energy when it reaches the peak stress under static load. The average total energy of water-saturated specimens is 67.55% of that of dry specimens. The average energy dissipation density of water-saturated specimens under 0.3 MPa, 0.4 MPa and 0.5 MPa air pressure is 0.79, 0.91 and 0.92 times of that of dry specimens, respectively. Water-saturated specimens will deteriorate and thus reduce their energy storage and energy absorption effects. The reflected energy, transmitted energy, absorbed energy and incident energy are linear, logarithmic and linear functions, respectively, and the energy absorptivity and specific energy absorptivity of water-saturated specimens are lower than those of dry specimens. Due to the existence of “stefan” effect, the increase of energy dissipation density of water-saturated specimen at high strain rate is greater than that of dry specimen. The mean fractal dimension of water-saturated specimens under 0.3 MPa, 0.4 MPa and 0.5 MPa is 1.09, 1.05 and 1.16 times that of dry specimens. At the same strain rate, the number and width of cracks in water-saturated specimens are larger than that in dry specimens. Water-saturated behavior reduces the energy absorption capacity of tuff, increases the fractal dimension of crack growth, and significantly reduces the resistance of water-saturated rock to external loads.

Non-equilibrium nature of fracture determines the crack paths

Local kinetic processes during crack growth are non-equilibrium and discrete and thus cannot be resolved in the framework of continuum thermodynamics. Atomistic modeling using existing empirical or machine-learning force fields also fails to offer satisfactory solutions for the lack of sufficient accuracy in predicting the energetics of strong lattice distortion and edge cleavage during fracture. The problem is addressed here by using a high-fidelity neural network-based force field for fracture (NN-F3) that covers the space of strain states up to material failure and the non-equilibrium, intermediate states at the crack tip. Atomistic simulations using NN-F3 reveal spatial complexities from lattice-scale kinks to sample-scale crack patterns in 2D crystals such as graphene, which evolve along the process of crack growth. The non-uniform lattice distortion and undercoordination of cleaved edges at the crack front play critical roles in the fracture process. The fracture toughness by cleaving specific edges thus cannot be quantified by their energy densities with relaxed atomic-level structures, which, however, have been widely used in the literature. Instead, the fracture patterns, the critical stress intensity factors corresponding to the kinking events, and the energy densities of edges in the intermediate, unrelaxed states offer reasonable measures for the fracture resistance and its anisotropy, which can be determined from experimental or simulation data with the atomic-level resolution. The findings conform well with recent experimental observations.

Experimental study on slow tensile, fatigue, and impact on X42 steel and #20 carburizing steel

Hydrogen embrittlement is a common phenomenon in high-strength steels and presents a significant challenge in the research and development process. This study aims to analyze the mechanism of hydrogen embrittlement, investigate the causes of crack growth in steel, and conduct experiments at mesoscopic and microscopic scales to gain a deep understanding of the relationship between hydrogen embrittlement and defects in high-strength steels. The research includes a slow tensile test to study the shrinkage and ductility of X42 steel and 20# carburizing steel under air and hydrogen environments. Furthermore, fatigue testing is conducted to comparatively investigate the crack growth of CT specimens in nitrogen and hydrogen environments at different pressures. Additionally, impact testing is performed to examine the fracture of V-notched specimens in air and hydrogen at different pressures. The findings reveal that 20# carburizing steel exhibits better fracture toughness than X42 steel during the slow tensile process, and its hydrogen embrittlement sensitivity is lower. Moreover, the fatigue crack growth process of 20# carburizing steel is less affected by hydrogen embrittlement, resulting in better fatigue rupture resistance compared to X42 steel. Furthermore, the impact toughness value of 20# carburizing steel is higher than that of X42 steel in the impact toughness test. Both steels show varying effects on crack growth under different hydrogenation pressures. Importantly, the impact toughness of both steels is less affected by different hydrogenation pressures.

Study on the multi‐scale online fatigue crack deformation and growth behaviors under overload in Q&P steel

AbstractThe multi‐scale online fatigue crack deformation and growth behaviors under single overload (SOL) and periodic overload (POL) case in Quenching and Partitioning (Q&P) steel were studied using two micro cameras and sub‐image stitching and matching digital image correlation (DIC) method. Firstly, the microscopic crack tip speckle images and crack images on both sides of the compact tension (CT) specimen during the fatigue crack growth (FCG) process were collected under different overload parameters. Then, the FCG overload retardation, crack tip closing and blunting behaviors, and the crack tip strain distribution and evolution, overload retardation mechanism were analyzed. In addition, the corresponding multi‐scale FCG morphological characteristics and material microstructure under overload case were observed. The results indicate that the overload ratio and interval affect the overload retardation effect of Q&P steel seriously; the overload crack tip blunting and plastic zone are the major factors inducing the overload retardation effect in Q&P steel.

Investigating the effect of external heat flux on the crack growth process in an aluminum nanoplate using molecular dynamics simulation

The effect of heat flux (HF) is crucial for understanding the behavior of materials, particularly in terms of crack propagation. HF can induce thermal stresses that accelerate crack growth, which can compromise the structural integrity and safety of materials. However, by studying the effect of HF, we can gain insights into the mechanisms that lead to crack initiation and growth. The importance of this study lies in its contribution to understanding the impact of external HF (EHF) on the cracking behavior of Aluminum nanoplates. For this purpose, EHF with 0.01, 0.02, 0.03, 0.05, and 0.1 W/m2 are added to the initial structure. By inserting EHF into the modeled samples, the atomic evolution of them is investigated. This study was performed using LAMMPS software and molecular dynamics (MD) simulation. Numerically, the maximum velocity of atoms increased from 4.81187 Å/ps to 4.81236 Å/ps as the EHF rose from 0.01 W/m2 to 0.1 W/m2. The maximum stress of samples increases from 151.689 GPa to 151.712 GPa by the EHF ratio enlarging. Finally, the crack length reaches to the maximum value (33.492 Å) by the EHF ratio set to 0.03 W/m2.By investigating the atomic evolution and crack growth process under different EHF values, the study provides valuable insights into the underlying mechanisms and thermal effects that influence crack propagation in these materials. This knowledge can be utilized to optimize the design and performance of aluminum nanoplates in practical applications, such as in the development of more robust and reliable structural components or devices.

Hot cracks in camshaft casting: initiation and propagation

ABSTRACT In this paper, a numerical simulation method based on the camshaft casting process and crack expansion was proposed to study the propagation characteristics of casting hot cracks. The dynamic visualisation process of hot crack growth indicates that the formation of hot tear is dominated by opening mode cracks. And during the propagation process, the equivalent stress intensity factor at the crack front first decreases and then increases. Furthermore, the propagation characteristics of the crack under different hot tear initiation conditions were studied by this method. The results reveal that the expansion ability of a hot crack is affected by the equilibrium solidification scale, solidification sequence, and solidification path of the casting. Finally, using the microscopic morphology of the cracks, the semi-quantitative analysis of the elements illustrates that the carbon content decreases sharply at the crack formation site, while manganese and sulphur are relatively rich.

A fatigue crack growth prediction method on small datasets based on optimized deep neural network and Delaunay data augmentation

The neural network-based prediction method has shown great potential in the field of fatigue crack growth prediction due to its powerful nonlinear processing and generalization capabilities. However, traditional deep neural network-based methods often encounter problems such as overfitting, underfitting, and instability when predicting FCG rates on small datasets. To address these issues, this study proposes a SA-DNN prediction method for metal fatigue crack growth by introducing Delaunay data augmentation and simulated annealing algorithm into the basic DNN framework. The proposed SA-DNN model is then used to predict the fatigue crack growth process of AM60B magnesium alloy and 7055 Al alloy, and the intrinsic and extrinsic generalization abilities of the model are evaluated. In both the evaluation of intrinsic and extrinsic generalization abilities, the mean squared errors of the training, validation, and testing sets rapidly converge to the target error in various epochs. The lowest mean squared errors achieved are 1.07 e-5 and 1.241 e-5, respectively. Moreover, the results also indicate that the proposed model can accurately predict the fatigue crack growth process of metal materials with varying degrees of nonlinearity.

Effects of thermal aging level on the morphological structures, rheological properties and fatigue characteristics of high-viscosity asphalts

High-viscosity asphalt (HVA) provides excellent cracking and rutting resistance for ecological permeable pavement. However, HVA suffers from severe aging due to higher construction temperatures and rich porous structures, which limited its applications for urban sustainability. Currently there is still a lack of knowledge about the thermal aging effects and mechanisms of HVA. In this study, the effects of thermal aging on the morphological structures, rheological and fatigue properties of two HVAs (i.e. HVA-1 and HVA-2) at five aging levels via Simple Aging Test (SAT) are systematically investigated. HVA-1, characterized by loosen and coarse reticulated structures, undergoes significant structural changes during aging, whereas HVA-2, characterized by dense and fine reticulated structures, experiences fewer alterations. The changes in the modulus master curves of HVAs become more gradual after aging, indicating the reduced temperature sensitivity. Multiple stress creep recovery results reflect that two types of HVAs exhibit totally different dominance of oxidation or polymer degradation depending on aging level. Liner amplitude sweep (LAS) results based on damage mechanics analysis reveal that aging leads to an increase in the accumulated strain energy observed in stress-strain curves for both HVAs. As aging progresses, the proportion of elastic energy decreases due to polymer degradation, resulting in a reduction in fatigue life. Especially, the fatigue life of aged HVAs significantly decreases after SAT40. LAS results based on fracture mechanics analysis show that the crack length increases with aging due to polymer degradation and asphalt phase hardening. Aging effect on crack length was limited at initial stage but becomes more significant as crack extends. As aging deepens, the crack initial stage of HVAs tends to lengthen while the crack extension stage tends to shorten. Moreover, the crack growth process of HVAs follows a two-stage behavior of crack initiation and propagation under certain aging levels from the relationship between energy release rate and crack propagation rate. Overall, the thermal aging kinetics of various HVAs differ significantly in the structures, rheological and fatigue properties as aging deepens. HVA-2 with loosen and coarse structures exhibits greater aging resistance and lower temperature sensitivity than HVA-1 with dense and fine structures.

Phase field study of crack growth in t′ yttria stabilized zirconia with initial domain structures

In this paper, the fracture behavior of t′ yttria stabilized zirconia (YSZ) with initial domain structures is studied with the phase field (PF) method. Firstly, a PF model is proposed to characterize the initial domain structure and the subsequent domain switching in YSZ. After that, the PF model for domain structure evolution is coupled with the variational PF fracture model to simulate crack growth in the multi domain YSZ. The toughening effect induced by the ferroelastic domain switching is evaluated by computing the energy dissipation rate (EDR) along with the crack growth. It is shown that the internal stress field of the initial domain structure has very trivial influence on the crack growth resistance. However, the domain switching in the crack growth process can have significant influences on the fracture resistance. The domain structure evolution can bring about a local toughening or deshielding effect on the crack growth, depending on the crystal orientation. The underlying mechanisms are analyzed in detail. The proposed PF approach is efficient to study the mesoscale fracture behavior of multi domain YSZ and is helpful to assess the integrity of thermal barrier coatings.

High-Cycle Fatigue Crack Growth in T-Shaped Tubular Joints Based on Extended Finite Element Method

High fatigue load, which exists widely in steel building structures, likely leads to brittle failure at the joints, supports, and so on. This can lead to the partial or total damage of the structure and even to cause the collapse of the whole structure. This article aims to provide a method to simulate high-cycle crack propagation in tubular joints, which is one of the most common types occurring in steel structures. Firstly, sixteen T-shaped tubular joint models under different load conditions and initial crack dimensions were built through the coordinate mapping method. Secondly, based on the extended finite element method (XFEM), an algorithm was developed by combining the secondary development in Abaqus and a quasistatic simulation method to simulate high-cycle crack growth in tubular joints under a constant amplitude. The results of the simulations were compared with experimental data. The study found that the surface stress calculated from the tubular joint models using the coordinate mapping method was close to the experimental data. Through the comparison of the crack propagation rate and the crack growth process between the simulation and experiment results, the simulation method was validated. When a crack penetrated the tube wall, the difference in the load cycles between the simulations and the experiment was 9.5%. The initial crack dimension had an impact on the crack propagation, with the decrease in the a/c and KII generally becoming the dominant factor with respect to the crack growth, while the fatigue life of the joints tended to increase.

Fatigue crack growth prediction for shot-peened steel considering residual stress relaxation

The compressive residual stress field (CRSF) relaxes during the fatigue crack growth (FCG) process, and the pattern of this relaxation remains unclear. Residual stress (RS) relaxation leads to a change in residual stress intensity factor (RSIF), which significantly affects the fatigue crack growth rate (FCGR) and thus affects the assessment of fatigue crack growth rate. To this end, this work designed a series of experiments to explore the FCG behaviour in compressive residual stress fields (CRSFs) by considering RS relaxation. Firstly, shot peening(SP) treatments were conducted on the specimens. Then, residual stress fields (RSFs) at different crack propagation stages were measured to analyse the relationship between surface RS and inner RSF distribution. The derived weight function and the real-time RSF are combined to calculate the RSIF with/without considering RS relaxation. Finally, the effect of RS relaxation on the accuracy of FCGR assessment was investigated. The results show that the positive effect of CRS on the fatigue performance of the peened specimens is primarily embodied in the early stage of the FCG process. With the continuous relaxation of the CRSF, the difference in FCGR between the peened and unpeened specimens gradually decreases and tends to disappear. When the applied SIFs are large enough, the CRS would completely relax, and the inhibiting effect of CRSF on FCGR would fail. The proposed method in this work can effectively predict the FCGR of the peened specimen when considering the RS relaxation. This work could provide some meaningful insights for the assessment method of FCGR prediction in CRSF induced by surface strengthening treatment.

Nanoscale ductile fracture and associated atomistic mechanisms in a body-centered cubic refractory metal

Understanding the competing modes of brittle versus ductile fracture is critical for preventing the failure of body-centered cubic (BCC) refractory metals. Despite decades of intensive investigations, the nanoscale fracture processes and associated atomistic mechanisms in BCC metals remain elusive due to insufficient atomic-scale experimental evidence. Here, we perform in situ atomic-resolution observations of nanoscale fracture in single crystals of BCC Mo. The crack growth process involves the nucleation, motion, and interaction of dislocations on multiple 1/2 < 111 > {110} slip systems at the crack tip. These dislocation activities give rise to an alternating sequence of crack-tip plastic shearing, resulting in crack blunting, and local separation normal to the crack plane, leading to crack extension and sharpening. Atomistic simulations reveal the effects of temperature and strain rate on these alternating processes of crack growth, providing insights into the dislocation-mediated mechanisms of the ductile to brittle transition in BCC refractory metals.