Crack Propagation Zone Research Articles

Effect of multi-pass overlapping friction stir processing on fatigue behavior of Al-Cu alloy

More than half of mechanical breakdowns stem from fatigue failure, often occurring suddenly and without warning. Friction stir processing (FSP) enhances the material's toughness and resilience to fatigue by refining its grain structure. This study investigates how multi-pass overlapping technique impacts the fatigue crack growth rate of FSPed Al-Cu alloy. Microstructural analysis revealed that the stir region exhibited uniformly dispersed and fragmented precipitates and finely recrystallized ultrafine grains. The hardness and strength were reduced, and ductility was enhanced after FSP due to high thermal cycling. Fatigue testing demonstrated a significant increase in fatigue life and reduced fatigue crack growth rate attributable to the combined effects of precipitation and grain refinement during cooling-assisted FSP. SEM examination of fatigue fracture surfaces revealed dimples indicative of ductile failure in the rapid crack propagation zone, while the steady-state propagation region displayed striation markings and secondary fractures.

Modeling the effect of material heterogeneity on the thermo-mechanical behavior of concrete using mesoscale and stochastic field approaches

The adverse impact of high temperatures on concrete is a well-recognized issue that can lead to significant mechanical deterioration and structural integrity loss. Factors such as aggregate type, cement composition, temperature, duration of exposure, and moisture content can substantially influence the fire resistance of concrete. To simulate and better understand the effects arising from the heterogeneity of concrete in a fire situation, a mesoscale approach is proposed, using the Mesh Fragmentation Technique (MFT) to assess the complex thermo-mechanical behavior of concrete. The MFT introduces high aspect ratio interface elements to model crack propagation and interfacial transition zones by means of an appropriated tensile damage constitutive law. In this extended framework, a fully-coupled thermo-mechanical model is proposed. The modeling approach includes considerations of both macroscopic and mesoscopic scales, in which the coarse aggregate, mortar matrix and interfacial transition zones are represented. Besides, a stochastic distribution is assumed for the material properties to account for the lower scale heterogeneity. The main novelty proposed in this study consists in the synergy of mesoscale and stochastic approaches that are herein combined to model the effect of heterogeneity on the concurrent macro-mesoscale thermo-mechanical behavior of concrete. To validate the numerical model’s capabilities in capturing thermally induced cracks, benchmark cases and a simulation of a bending beam exposed to elevated temperatures are presented. The results demonstrate the potential of the proposed approach in predicting the behavior of concrete subjected to thermal loading and the role played by heterogeneity in the thermally induced cracking.

High-temperature low-cycle fatigue characteristics of the 12Cr10Co3MoWVNbNB turbine rotor steel

Low-cycle fatigue (LCF) experiments of the 12Cr10Co3MoWVNbNB steel at 598 °C and a strain amplitude ranging from 0.27 % to 0.55 % were executed to reveal the fatigue characteristics, fatigue fracture mechanism, and further to predict the high-temperature fatigue life of the new-style turbine rotor steel. The results indicate that the steel exhibits a high-temperature fatigue softening characteristic. During the high-temperature LCF, the cracks are generated at surface or subsurface defects of the specimens, and the fatigue striations and dimples are apparent on the fracture surfaces of the crack propagation zone and the final fracture zone, respectively. The Smith-Watson-Topper (SWT) and Manson-Coffin models are suitable to predict the high temperature fatigue life of the steel at high/low strain amplitudes, respectively. In terms of finite element analysis of the turbine set rotor, it is determined that the steady state strain of the rotor steel is approximately 0.2 %. And thus, the fatigue life of the steel rotor is estimated as 172,500 cycles at the strain amplitude, based on the Eq. (6) in this work. After 100,000 cycles at the strain amplitude, the yield and tensile strengths of the steel specimens are only reduced by 1 % and 3 %, respectively, indicating a long residual life, which is consistent with the above predicting result.

Microstructure and fatigue properties of laser-MIG hybrid welding of medium-thickness 6005A aluminum alloy

Light alloys represented by aluminum alloys have a wide range of applications in railway transportation, the key load-bearing parts of high-speed train bodies are welded with a large number of medium-thickness plates, so the study of the welding performance of medium-thickness aluminum alloy plates is significant. In this study, laser-MIG hybrid welding technology is used to realize the single-layer, single-pass welding of 6005A aluminum alloy plate with a thickness of 10 mm. The grains in the weld zone (WZ) are coarsened by welding heat, and the average diameter is about 1.6 times that of the base metal (BM), while the average grain diameter in the heat-affected zone (HAZ) is similar to that of the BM. A softening phenomenon is observed in the welded joint, with a minimum hardness of 72.6 HV in the HAZ. TEM analysis shows that the softening phenomenon is caused by the coarsening of precipitate phases in the HAZ. In terms of tensile properties, the ultimate tensile strength (UTS) of the welded joint is approximately 237 MPa, which is 70.1 % of the BM. The fatigue strength (Nf = 2 × 106 cycles) of the welded joints is predicted to be 83 MPa, which is 64 % of the yield strength (YS), from the S-N curve obtained by fitting the tension–compression fatigue test data. Different morphologies of secondary phase particles are observed in the fatigue crack propagation zone, and their formation and effects on secondary crack are described. The fracture location indicates that softening behavior in the HAZ is the main factor influencing tensile performance, while defects in the WZ are the primary factors affecting fatigue fracture. The experimental results can enrich the tensile and compressive fatigue data of 6005A aluminum alloy.

Influence of confining pressure on rock fracture propagation under particle impact

Revealing the influence of confining pressure on the propagation and formation mechanism of rock cracks under particle impact is significant to deep rock excavation. In this study, the three-dimensional fracture reconstruction of the rock after particle impact was carried out by CT scanning, and the stress and crack field evolution of the rock under particle impact were analyzed by PFC2D discrete element numerical simulation. The results demonstrate that after particles impact, a fracture zone and intergranular main crack propagation zone are formed in the rock. The shear stress and tensile stress caused by compressive stress are the main reasons for the formation of the fracture zone, while the formation of the intergranular main crack propagation zone is mainly due to tangential derived tensile stress. The confining pressure induces prestress between rock particles such that the derived tensile stress needs to overcome the initial compressive stress between the particles to form tensile fractures. And the increase in the confining pressure leads to increases in the proportion of shear cracks and friction effects between rock particles, resulting in an increase in energy consumption for the same number of cracks. From a macroscopic perspective, the confining pressure can effectively inhibit the generation of cracks.

In vitro corrosion-fatigue behaviour of rare-earth containing magnesium WE43 in sterile complex cell culture medium

Rare-earth containing magnesium alloys are promising biomedical materials for a new generation of biodegradable orthopaedic implant systems due to their excellent biocompatibility, mechanical and biodegradation properties. However, chemo-mechanical interactions in aggressive physiological corrosion environments result in rapid degradation and early loss of mechanical integrity, limiting its broader application for orthopaedic implants. To date, only few studies have assessed the corrosion-fatigue behaviour of medical-grade magnesium alloys in an organic physiological corrosion environment, especially under sterile test conditions. In the present work, the corrosion-fatigue behaviour of fine-grained medical-grade magnesium alloy WE43MEO was systematically analysed under in vitro conditions using an organic physiological fluid DMEM. The experimental results showed that the fatigue strength of the alloy is nearly unaffected by a 1-day precorrosion, while a 7-day precorrosion resulted in a significant deterioration of mechanical integrity. In corrosion-fatigue experiments, the fatigue life was considerably reduced by interactions between corrosion and fatigue damages. The SEM analysis revealed that the mixed mode of intergranular and transgranular fracture in the crack propagation zone transits to intergranular cracking dominant mode under the corrosion-fatigue conditions due to hydrogen embrittlement.

Evolution of fracture process zone and variation of crack propagation velocity in sandstone

To solve the safe containment and recovery efficiencies of gas in rock masses, a study on fracture process zone (FPZ) and crack propagation is conducted. By using digital image correlation technology, the displacement of three-point bending specimens was measured. By analyzing the distributions of displacement at different loading stages, a specific region between the pre-crack tip and the loading point was divided into three zones: the intact zone, the crack propagation zone, and the FPZ. The length and the migration velocity of FPZ were determined, and the crack propagation velocity was also measured. The microstructures in FPZ were investigated through optical microscopy, x-ray diffraction analysis, and x-ray photoelectron spectroscopy. The results show that (1) FPZ length slightly varies during crack propagation and the FPZ is fully formed at the peak load; (2) the average value of the bond energy (446.7 eV) in the grains is greater than that (296.7 eV) in the matrix, thus the microdamage appears in the matrix around grain boundaries in FPZ; (3) the mean FPZ length varies from 4.09 to 8.42 mm for all tested specimens during crack propagation; (4) the propagation of the crack and the migration of FPZ proceed simultaneously in the loading process, and both velocities of crack propagation and FPZ migration are almost the same and with the same trend; (5) the peak velocity of crack propagation appears after the peak load, and the crack propagation progress was intermittent due to fracture energy accumulation, fracture energy release, and FPZ's shielding effect.

Failure Behavior and Fracture Evolution Mechanism of Coal with Fissures around Holes.

The fracture of coal is the main channel of gas flow and an important factor affecting the stability and efficiency of gas drainage boreholes. The coal structure, the development of hole cracks, and the degree of deformation are different. It affects the strength and mechanical deformation characteristics of coal to a great extent. In order to investigate the law of fracture evolution around the borehole of fractured coal, uniaxial and triaxial compression tests of raw coal samples have been carried out. The stress field evolution characteristics of fractured coal under compression were analyzed by Particle Flow Code (PFC2D). The strength, deformation, and fracture evolution behavior of fractured coal around boreholes under different confining pressures were studied. The results show that the compressive strength and fracture morphology evolution characteristics of coal around the hole are obviously related to the confining pressure and fracture occurrence of raw coal. The borehole structure itself has an important influence on the distribution location of the shear failure zone of the fracture around the hole, and its influence degree increases with the decrease of borehole confining pressure. During the deformation of coal with cracks around the hole, the initiation, propagation, and union behavior of cracks are related to the crack angle β. The cracks with β 0 and 180° are most easily closed during compression and the cracks with β 90° have little effect on the crack propagation zone. When the crack angle β is 45°, it is most easy to sprout and expand at the end; when the coal is compressed to the ultimate strength, the increase rate of the tensile crack increases, and the polymerization and combination behavior of the crack is more obvious. The evolution cloud map of the stress field can better reflect the evolution characteristics of fracture development, expansion, and fracture in the process of coal loading. Studying the failure behavior and fracture evolution mechanism of the coal around the hole can better predict and control the gas migration and extraction effect, which is of great significance to prevent the occurrence of gas accidents.

Mechanical Response of Zr51.9Cu23.3Ni10.5Al14.3 Metallic Glass Ribbon under Varying Strain Rates

In this work, we investigated the mechanical behavior of a low-cost Zr51.9Cu23.3Ni10.5Al14.3 (at. %) metallic glass ribbon prepared with industrial-grade material through the melt-spinning method. The ribbons have good appearances and almost no defects. The mechanical behavior associated with the corresponding microstructure of the ribbon was tested at different strain rates. Striation and veining patterns were observed in the crack propagation zone and the fast fracture zone. The results show that the tensile strength of the ribbons exceeds 1 GPa. Therefore, they are considered to have good potential for industrial applications. This study could contribute to the preparation of low-cost bulk metallic glass.

Ultrasonic fatigue tests on maraging 300 steel: Under solution annealed, after aging heat treatment and under pre-corrosion attack

Ultrasonic fatigue tests were carried out under continuous cycling on the maraging 300 steel for the following conditions: (A) solution annealed (as received from supplier), (B) after aging heat treatment of 490 °C for 6 h, (C) after pre-corrosion attack, and (D) specimens loaded at 293 MPa at room temperature without failure until 1.0E+10 cycles. The ultrasonic fatigue strength of the four modalities were compared and discussed in regard the crack initiation inclusion, the heat treatment and the testing conditions. Crack initiation and propagation under this fatigue testing modality was analyzed; revealing that ultrasonic fatigue strength is related to internal TiN-inclusions and its parameters of shape and orientation, in regard the uniaxial applied load. Numerical simulations were carried out to investigate the stress concentration of an ellipsoidal void of 150 mm (longer radius), and a TiN ellipsoidal inclusion of same dimensions. In addition, SEM (Scanning Electron Microscope) analysis was carried out on the fracture surfaces to determine the crack initiation and propagation zones.

Low-Cycle Fatigue Behavior of Hydrostatic Extruded AZ80 Mg Alloy

The fatigue properties of conventional and hydrostatic extruded AZ80 Mg alloy were fully studied under strain-controlled mode. The hydrostatic extrusion can effectively increase the tensile strength, but decrease the elongation. Consequently, the low cycle fatigue lifespan of the hydrostatic extruded specimens was shorter than that of the conventional extruded ones. The Manson-Coffin-Basquin relationship was adopted to describe the fatigue lifespan of the extruded AZ80 alloys. Finally, the fracture surfaces were observed by scanning electron microscope. The fatigue crack stable propagation zone of the hydrostatic extruded sample has decreased significantly compared with that of the conventional extruded sample. The hydrostatic extruded specimen has small reverse plastic zone size, which leads to microscopically rough fatigue crack propagation zone.

Fracture Mechanics Induced by Drilling and Blasting in Underground Openings: Prevailing Practices and Studies

This article presents the prevailing practices and literature review on the study of fracture mechanics of rock mass, during the construction of underground openings, by drill and blast method (DBM). The paper makes an introductory discussion on basic fracture and failure mechanics on the rock, followed by a review due to the blast-induced failure mechanism. The damage zone in drill and blast openings is discussed which is followed by the conclusions of the literature. DBM is a widely acceptable and broadly applicable approach in the underground construction method. The blasting damaged zones are classified as the borehole expansion zone, crushed zone, nonlinear fracture zone, and radial crack propagation zone. Blasting activities create stress waves in construction work, which fundamentally influence the fracture and failure mechanics of rock with pre-existing discontinuities, in-situ stress, and groundwater conditions. On the other hand, the cumulative action of subsequent explosion gas and stress waves defines the final damage limit and crack pattern map. Thus, it is of utmost importance to investigate the blast-induced fracture and failure mechanism to mitigate the instability in the underground openings.

Study on Fatigue Performance of Pulsed Tungsten Inert Gas Welding Joint of Duplex Stainless Steel Thin Tube.

To solve the shortage of austenite phase precipitation caused by nitrogen loss in the welding process of UNS S2205 duplex stainless steel (DSS), shielding gas nitriding was investigated by adding different N2 contents in Ar shielding gas during the welding process. A good thin-walled pipe butt joint was formed using the pulsed tungsten inert gas (P-TIG) welding method with Ar-N2 shielding gas. High cycle fatigue tests of the weld joints were conducted to study the effect of shielding gas nitriding on the fatigue properties. Fatigue tests at three stress levels of 225 MPa, 270 MPa, and 360 MPa were carried out on the weld joints with different N2 contents, and the fatigue samples were all fractured in the high temperature heat-affected zone (H-HAZ). Within the current process parameters, the fatigue life of the 4 vol.% N2 welded joints was optimal. Fatigue striations appeared in the fatigue crack propagation zone, and the transient fracture zone was similar to the tensile fracture. Under the low-stress level, the area of the crack propagation zone under 4 vol.% N2 was the highest, the tear ridges all expanded around the crack source area, and the fatigue crack propagation zone presented a radial distribution. The proliferation and expansion of dislocations were mainly carried out in the austenite grains, and the dislocation density of the fatigue specimens under 4 vol.% N2 was smaller than that of the Ar specimens. Shielding gas nitriding effectively improved the balance of the two-phase ratio and the hardness of austenite phase, optimized the internal slip system, inhibited the proliferation of dislocations in the austenite phase, and improved the fatigue life of weld joints.

Microstructure analysis and life prediction of DD6 superalloy under 760 °C combined high and low cycle fatigue conditions

The impact of high and low cycle combined loads on the fatigue performance of DD6 alloy was investigated in this work. Specifically, the combined high- and low-cycle fatigue response of DD6 alloy was examined at a temperature of 760 °C under different low cycle stress amplitudes (960, 1000, and 1040 MPa). The findings revealed that higher low cycle stress amplitudes result in shorter combined high and low cycle fatigue life and less dispersion in life. Correlations between the microstructural features (crystal plane distribution, fracture elevation difference, and the area proportion of crack propagation zone) and fatigue performance were accurately established, demonstrating a linear relationship between these microstructural features and the logarithm of fatigue life. The study also uncovered the evolution rule of microstructural features in high- and low-cycle combined fatigue. Furthermore, the fracture mechanism was analyzed and the distribution of high and low cycle combined fatigue life of DD6 alloy at 760 °C was statistically validated using the dual-parameter Weibull distribution theory. Building upon the crystal plasticity theory, a fatigue life prediction model was developed, and the combined cycle fatigue lifespan under various low cycle stress amplitudes was compared. The comparison between the predicted life and actual fatigue life indicated that the predicted lifespan falls in three times the scatter band.

Research on mode-I fracture characteristics of basalt fiber reactive powder concrete

Basalt fiber reactive powder concrete (BFRPC) has strong potential application value because of its green environmental protection and good comprehensive properties. However, basalt fiber content is the important factor affecting the mode-I fracture characteristics of reactive powder concrete (RPC). Through the three-point bending fracture experiments, the effect of different basalt fiber content (0 %∼2.0 %) on the fracture parameters of RPC was studied. Based on DIC technology, the crack propagation and fracture process zone (FPZ) evolution of BFRPC were deeply studied, and the deformation and failure ability of BFRPC was evaluated by horizontal displacement standard deviation. The results showed that the double-K fracture toughness of RPC reaches the maximum (0.71 and 1.78 MPa mm1/2) under the action of 1.5 % basalt fiber content. However, the interfacial fracture energy is positively correlated with the basalt fiber content. Due to the bridging and restraint effect of basalt fiber on RPC, an appropriate amount of basalt fiber (0.5%–1.5 %) can effectively reduce the length of FPZ. The basalt fiber content has a positive effect on the growth of horizontal displacement standard deviation of BFRPC, which further highlights the excellent ability of BFRPC to resist deformation and failure.

Experimental study on crack propagation pattern and fracture process zone evolution based on far-field displacement by using DIC

This study utilizes digital image correlation (DIC) technology to measure the far-field displacements and strains of rock specimens during the entire loading and unloading. Through analyzing the distributions of strain, displacement and their variations per unit length at different stages, the variations of both length and migration velocity of the fracture process zone (FPZ) were studied, and the crack propagation was also investigated. In addition, the entire path of crack propagation was observed by scanning electron microscope (SEM). The results reveal that (1) the fractured ligament can be divided into three zones based on the displacement variation per unit length: intact zone, crack propagation zone, and FPZ. (2) The FPZ length reaches its maximum at the peak load and then decreases, and the minimum length even is only 1/3–1/2 of the maximum length. The FPZ migration velocity is − 48 to 1460 m/s. FPZ’s microscale features are intergranular microcracks, transgranular microcracks, cleavage, and debris on fracture surface and around main crack propagation path. (3) The crack propagation length during peak load to peak-post 90% accounts for more than 1/3–1/4 of the entire post-peak length. Crack propagation is alternating fast and slow, i.e., the velocity of crack propagation varies regularly in the range of 24–700 m/s. The region of crack initial propagation is more severely damaged compared to other propagation regions.

Microstructure, mechanical and fracture properties of friction stir welded 2195 Al-Li alloy joints

The 8 mm-thick 2195 Al-Li alloy joints were achieved by Friction Stir Welding (FSW). The microstructural evolution, temperature-dependent mechanical properties, and fracture properties were studied. The T1, δ′/β′ and θ′ precipitates were observed in the Base Metal (BM) and the Heat Affected Zone (HAZ). Most of the precipitates, except for re-precipitated δ′/β′ phases, were dissolved in the Nugget Zone (NZ). The tensile specimens that failed at cryogenic temperatures (–196 °C) had the maximum Ultimate Tensile Strength (UTS), and the fracture surface showed the inter-granular fracture characteristics. Compared to those at room temperature (25 °C), the decreasing tensile properties at high temperature (180 °C) were related to microstructure and strain hardening effects. The NZ presented the optimal fracture toughness, and the Crack Tip Opening Displacement (CTOD) was mutually dominated by microhardness and grain size. Analysis on Fatigue Crack Growth (FCG) rates indicates that the Thermal-Mechanically Affected Zone (TMAZ) exhibited the most superior fatigue resistance performance at stress intensity range below 17 MPa·m1/2 due to compressive residual stress and the crack closure effect. The fatigue fracture surfaces reveal that the crack propagation zone was characterized by the striations and secondary cracks. Also, inter-granular fracture behavior was responsible for the fastest FCG rates in the NZ.

Developing Mixed-Mode (I/II) Fracture Resistance Curves for Asphalt Concrete Mixtures at Low Temperatures

Mixed mode (I/II) loading conditions occur frequently in the asphalt layers of pavements. Therefore, a low-temperature fracture analysis based on mixed mode loading turns out to be of utmost importance. In this research, asphalt concrete (AC) mixtures were prepared using two aggregate gradations and PG58-22 bitumen. AC beams were produced by the mixtures and notch offset values of 48 mm, 75.2 mm, and 107.2 mm were fabricated in the beams in order to be tested in a modified single-edge notched beam (SE(B)) setup. The tests were carried out at two temperature levels of-5 °C and-15 °C. Using the modified SE(B) setup and capturing and processing digital imaged from the growing crack during the tests, fracture resistance curves (R-curves) in mixed mode (I/II) conditions could be constructed for each mixture. The results revealed that increasing the mode mixity and impairing the tensile mechanism in the fracture of asphalt beams could significantly contribute to higher fracture resistance of the mixtures. Mixtures with the highest mode mixity exhibited greater crack tip blunting energy by up to 25%. Similarly, energy dissipation in the unstable crack propagation zone is also increased being a desirable characteristic in post-peak performance of the mixtures.

Numerical simulation and experimental verification of fatigue crack propagation in high-strength bolts based on fracture mechanics.

To investigate the fatigue crack propagation behavior of high-strength bolts for high-speed train brake discs, the fatigue crack propagation of high-strength bolts with initial defects under various load ratios was numerically simulated and experimentally verified based on fracture mechanics in this paper. Firstly, the fracture mechanics model of a three-dimensional hexahedral mesh with initial root defects was established using ABAQUS-FRANC3D interactive technology. Then the stress intensity factor (SIF) of the crack front was calculated by the stress superposition of the crack surface to simulate the coupling effect of preload and axial cyclic load. Based on it, fatigue crack propagation was simulated. Finally, the corresponding fatigue experiments on prefabricated crack bolts were carried out. The results show that mode I cracks dominate in the process of crack propagation. The stable crack propagation zones of the fractured high-strength bolts all show a semi-elliptical cross-section. The SIF of the crack front decreases with the increase of the load ratio, thus making the crack propagation life increase with the increase of the load ratio. The experimental outcomes are in great agreement with the simulation results, which verify that the numerical simulation method can effectively and accurately evaluate the fatigue life of high-strength bolts with initial defects and provides an effective means for predicting the fatigue crack propagation life of the same type high-strength bolts in engineering applications.

Effect of rolling on crack behavior of FeCrAl alloys in ultra-long life

PurposeThe purpose of this paper is to determine (1) the relationship between microstructure and fatigue cracking behavior and (2) effect of rolling on the process of crack initiation and propagation in FeCrAl alloys.Design/methodology/approachThe qualitative and quantitative fracture studies were performed using scanning electron microscopy and the non-contact optical measurement system (IFMG5).FindingsThe results show that the formation of facets, rough facets and parallel stripes in the crack initiation and early crack propagation zones are closely related to the sensitivity of crack behavior to the microstructure of the material. Besides, the rolling process has a significant influence on the small crack initiation and propagation behavior. Quantitative analysis demonstrates that the size of the stress intensity factor and plastic zone size in the rough zone is associated with the rolling process.Originality/valueThe findings of this study have the potential to enhance the understanding of the microstructural crack formation mechanisms in FeCrAl alloys and shed light on the impact of rolling on the long-term and ultra-long fatigue behavior of these alloys. This new knowledge is vital for improving manufacturing processes and ensuring the safety and reliability of FeCrAl alloys used in nuclear industry applications.