Cracks In Metals Research Articles

An RFID smart structure using inkjet-printed additive manufacturing technology for metal crack characterization

Abstract Developing an indicator for metal materials to characterize cracks is urgent. However, traditional sensor-based technology has drawbacks such as high costs for installation and maintenance when using wired connections. In this paper, we studied the Radio Frequency Identification (RFID) sensors created through 3D printing technology to characterize surface cracks in metals, this approach simplifies the manufacturing process, silver nanoparticles are printed layer by layer on substrate to form the sensor pattern. The functionality of the sensor is verified through simulations and experiments involving samples with various crack sizes. Our findings demonstrate that when cracks pass over the sensor, there is a distinct response in terms of a shift in resonant frequency, moreover, the sensor offers a reading range greater than 0.7 m at resonance frequency without requiring power supply or wired connection for data transmission purposes. This research showcases the design of a smart structure that is compact, easy-to-fabricate, and potential for applications related to structural health monitoring (SHM) and crack sensing.

Effects of irradiation plus thermal aging on the phase boundary microstructure of austenitic stainless steel welds

Irradiation damage and thermal aging greatly affect the phase boundary microstructure and stress corrosion cracking of austenitic stainless steel weld metals (ASSWMs) in water-cooled nuclear reactors. However, the effects of irradiation plus thermal aging (I + A) on the phase boundary segregation and phase changes remain unclear. Phase changes and elemental segregation at the carbide and carbide-free phase boundaries of 308 L ASSWMs after I + A treatment were investigated using atom probe tomography and transmission electron microscopy. The I + A treatment induced Si depletion at the phase interfaces of δ-ferrite/austenite (δ/γ) and δ-ferrite/carbide (δ/C) and also induced Ni enrichment and Cr depletion with concentrations having the order Ni/Cr(δ/γ) > Ni/Cr(δ/C) > Ni/Cr(γ/C). The solute-defect binding model and the vacancy mechanism were applied to explain the phase boundary segregation. Furthermore, the I + A treatment affected microstructural evolution near the phase boundaries; this reduced spinodal decomposition and inhibited G-phase and Ni/Si-rich-cluster formation. The phase separation of δ-ferrite near δ/γ and δ/C phase boundaries differed with the distance from the boundary, forming a gradient microstructure from phase boundaries to δ-ferrite internally. The gradual precipitation of the G-phase was observed beyond about 15 and 10 nm from the δ/γ and δ/C interfaces, respectively; moreover, the growth of α'-phase in the δ-ferrite was accelerated with increasing distance from the δ/γ and δ/C interfaces.

Study of the dynamic impact spalling of ductile materials based on Gurson-type phase-field model

The formation of void damage and spalling failure in ductile metallic materials under strong impact is a well-established phenomenon. In aerospace and defense technology engineering design, understanding the spalling failure process and related mechanisms is of utmost importance. This paper develops an explicit Gurson-type phase-field model that can simulate the void evolution and spalling damage of three-dimensional ductile metallic materials under high-velocity impacts based on the study of Aldakheel et al.. The model incorporates the Gurson-type void evolution equation and the phase-field approach while taking into account the pressure-dependent bulk modulus and inertia effects. This model is used to study the main processes and mechanisms of impacted layer cracking of metals in different dimensions. Meanwhile based on the study of complex spallation cracking processes in metals in two and three dimensions, observing and proposing the formation mechanism of complex spallation cracking modes in materials due to lateral and edge (base angle) rarefied effects.

Depth and angle evaluations of oblique linear cracks in metal using multi-speed laser lock-in thermography method

Cracks can develop obliquely to the metal surface. The multi-speed laser lock-in thermography method is suited for the contactless estimation of open crack angles and depths in metal with oblique linear cracks. A continuous laser source regularly scans the studied sample leading to a periodical heating. The heat diffusion disturbances induced by a crack located in the thermal diffusion area are measured synchronously with the repeated continuous laser scan passes. The thermal signature of the crack is extracted from the amplitude of surface temperature images for various scanning speeds of the thermal source. The asymmetry of the thermal signatures obtained on each side of the crack is analysed as a function of a length relying on the thermal diffusion length. The local crack depth and crack angle are evaluated simultaneously. The method, explained with 3D simulations, is experimentally implemented and tested with calibrated oblique linear cracks. The results demonstrate the potentiality of multi-speed laser lock-in thermography method as a contactless measurement tool for the evaluation of oblique crack shapes up to 3.5 mm depth.

Signatures of fatigue crack growth from acoustic emission repeaters

Since the discovery of fatigue phenomena, scientific research has constantly sought to understand and anticipate the failure of materials due to fatigue to mitigate unforeseen accidents and malfunctions in various technical fields. Numerous studies using acoustic emission (AE) – a key method in non-destructive testing – have shown a correlation between acoustic activity and fatigue damage. However, these measurements suffer from the non-specific nature of AE signals, which may be due to various physical sources. To investigate further the mechanisms of AE emission associated with fatigue, we study the groups of acoustic signals generated by fatigue cracking in metals. These so-called acoustic multiplets are characterized by highly correlated waveforms, are repeatedly triggered over many successive loading cycles at nearby stress levels and originate from a single location. These acoustic signatures produced during the propagation of fatigue cracks in alloys are automatically detected by a dedicated algorithm, grouped into multiplets and analyzed to understand the physical mechanisms from which they originate. By synchronizing their detection with digital image correlation measurements of fracture mechanics quantities, the investigation of this acoustic emission phenomenon shows that two mechanisms are at the origin of the multiplets: repeated local friction over fracture surfaces, and incremental crack propagation in the Paris regime, probably due to the reactivation of crack tip plasticity at each cycle. These two multiplet types serve as acoustic signatures, distinctly indicating the existence and propagation of a fatigue crack.

Developing Flexible Carbon Nitride Quantum Dots Decorated Polyaniline Nanocomposite Layer for a Non-Invasive Wearable Sweat Biosensor for Glucose Monitoring

Understanding dynamic biomarker fluctuations, particularly glucose, is vital for early diabetes therapy. Novel non-invasive wearable sweat biosensors are gaining appeal, enabling constant severity monitoring. Nevertheless, the key challenges are that multiplexed motions may result in undesirable metal cracking by the rigid electrocatalytic layer, leading to decreased sensitivity and stability. In this work, we designed carbon nitride quantum dots (CNQDs) decorated polyaniline (PANI) nanocomposite to realize flexible wearable biosensors with high detection accuracy. Upon the enhanced electron transfer by CNQDs, CNQDs/PANI nanocomposite offers greater sensitivity in H2O2 detection compared to pristine PANI, resulting in a sensitivity of 37.21 μA mM-1 cm-2. Therefore, after the glucose oxidase (GOx) immobilization, GOx/CNQDs/PANI-based biosensors is expected to show excellent performance for glucose detection in artificial sweat. Figure 1

Dislocation structures in micron-sized Ni single crystals produced via tension–compression cyclic loading

The strength and deformation characteristics of micron-sized metals under monotonic loading have long been investigated. In contrast, despite its practical significance, their fatigue behavior remains unexplored. To this end, tension–compression fatigue tests were conducted herein on micron-sized Ni single crystals to elucidate their fatigue behavior and internal dislocation structures. Specimens with square cross sections of 5 and 2 μm on a side were prepared and subjected to cyclic loading at low stress amplitudes, which did not induce fatigue cracking in bulk metals. Remarkably, fatigue cracks were not present in 5-μm-wide specimens, whereas intrusions/extrusions were observed in 2-μm-wide specimens, leading to crack initiation. Vein-like structures comprising edge dislocations were observed in 5-μm-wide specimens, which are commonly observed in bulk metals. Conversely, the dislocation structure in 2-μm-wide specimens resembled that associated with persistent slip bands, which cause intrusions/extrusions and fatigue cracking in bulk metals under high stress amplitudes. The experimental findings indicate that the fatigue behavior of small-sized metal single crystals is characterized by the absence of vein formation.

Investigation on fracture resistance behaviour of dissimilar metal weld joint of modified 9Cr–1Mo steel and AISI 316LN SS

Fracture behavior of dissimilar metal weld joint consisting of mod. 9Cr–1Mo steel, AISI 316LN stainless steel, Inconel 82 butter layer and Inconel 182 weld has been investigated through experiments and FE simulations. The metallographic studies on weld joint and its interfaces have been carried out to determine the influence of microstructure on tensile and fracture properties. Tensile properties of different weld regions viz., weld metal, butter layer and HAZ have been evaluated using sub-size specimens. Fracture resistance behavior of weld joint has been studied through testing of compact type specimens with initial cracks machined at different locations. The plastic η factors for estimation of J-R curve have been obtained using FE analysis for crack in different regions viz., weld metal, butter layer and HAZ. Crack in weld metal exhibits lower fracture resistance as compared to butter layer and HAZ. Further, the constraint acting on crack and its susceptibility for deviation have been discussed in terms of stress triaxiality ahead of crack tip.

Crack initiation during environment-induced cracking of metals: current status

Abstract Environment-induced cracking (EIC) research spanning the last 80 years for ferrous and non-ferrous metals in aqueous environments at ambient and elevated temperatures has concentrated on crack propagation. Studies clearly reveal EIC involves two differentiable processes, one controlling initiation and the other propagation. Utilization of advanced high-resolution electron microscopy over the last 20 years has enabled more focused studies of crack initiation for stainless steel and nickel-based alloys at elevated temperatures exposed to environments associated with the nuclear industry. More recently, when coupled with advanced in-situ experimental techniques such as time-lapse X-ray computed 3D-tomography, progress has also been made for aluminum alloys suffering EIC at ambient temperatures. Conventional wisdom states that chemical processes are typically rate-controlling during EIC initiation. Additionally, experimental evidence based on primary creep exhaustion ahead of the introduction of an aggressive environment indicates that time-dependent mechanically-driven local microstructural strain accommodation processes (resembling creep-like behavior) often play an important role for many metals, even for temperatures as low as 40 % of their melting points (0.4 Tm). EIC studies reveal initial surface conditions and their associated immediate sub-surface alloy microstructures generated during creation (i.e. disturbed layers) can dictate whether or not EIC initiation occurs under mechanical loading conditions otherwise sufficient to enable initiation and growth. The plethora of quantitative experimental techniques now available to researchers should enable significant advances towards understanding EIC initiation.

Bending of Sheet Metal (st37) Using 90 Degree to Estimate Blank Dimensions

Several factors must be considered whendesigning parts that are being made by bending. Theprimary factor is minimum radius and angle of bending thatcan be bent successfully without metal cracking. Lowcarbon steel metal (st37), manufactured by Libyan Iron andsteel Company, was used in this study. Various bendingprocesses by Vee die for different radii and calculatethickness were conducted and bending zones were tested tofind the mean radius and calculate the bending allowance.These calculations depend upon the inner bend radius andthickness of the sheet metal. The thickness was reduced andthe neutral axis were moved up in the direction ofcompression side. Form the values of reduction in thicknessand different radii of bending a chart was drawn. Anotherchart was drawn to minimums the process of trial and errorfor estimating the blank length of the bending sheet metal.Form these charts, the initial blank sizes can be determined,so that products can bend without loss and crack in thematerial. As a result time and material can be saved. Theresults of the present study can have practical applicationsfor this material (st37) which is in common use by theLibyan industry.

Fatigue life prediction of metal materials under random loads based on load spectrum extrapolation

The impact of random loading on the fatigue life of mechanical components contains numerous uncertainties. This study aims to enhance the precision of life prediction by developing mean and amplitude distribution models based on the road load spectrum and extrapolating the operational load beyond the threshold value in the time domain. Additionally, it considers the influence of high cycle fatigue (HCF) and low cycle fatigue (LCF) loads on the initiation life of metal cracks. To address this, a load correction factor is introduced, and critical stresses for high and low cycle loads are proposed. Furthermore, a two-dimensional programmed load spectrum is prepared, taking into account the mean and amplitude. The accuracy and rationality of the fatigue life model are validated through examples using 45# steel and 316L, while experiments on engine support are conducted to confirm the effectiveness and accuracy of the over-threshold extrapolation life prediction method under random loading.

Numerical study on ultrasonic detection of cracks in metallic structures with variable cross-sectional thickness

The metal structures are widely used in aerospace engineering, especially in joints and spars. The safety of these parts is important to ensure the safe service of the whole structures. The ultrasonic wave is a traditional technique to detect cracks in metals. However, it is usually difficult to find all the cracks because of its difficulty in variable directions of the crack and the irregular shapes of the metals. This paper aims to address the challenge of detecting cracks in metallic structures with varying cross-sectional thicknesses using ultrasonic methods. The research investigates the behavior of ultrasonic longitudinal and transverse waves as they propagate through aluminum plates with variable cross sections. Additionally, it examines how cracks in different orientations influence these wave types. The theoretical analyses are performed which explore the reflection of oblique incidence waves and the diffraction of ultrasonic waves when they encounter semi-infinite cracks. Subsequently, numerical simulations are performed to validate the theoretical findings and to detect both horizontal and vertical cracks within metal plates of varying cross-sectional thicknesses. The findings indicate that both longitudinal and transverse waves are effective in identifying the location of damage caused by horizontal cracks. However, when it comes to vertical cracks, only transverse waves are successful in detecting their precise location. From the research of this paper, transverse ultrasonic wave is suggested to detect cracks in metal structures with irregular cross sections.

Calculation and Discussion for Crack Driving Force of Dissimilar Metal Welded Joint of Nuclear Power Equipment Nozzle and Safe End

This study investigates the effects of the material mechanical properties heterogeneity and strength mismatch variation on crack driving forces for cracks in a dissimilar metal welded joint (DMW) of a reactor pressure vessel inlet nozzle to the safe end. Linear elastic and elastic-plastic analyses are carried out to calculate the stress intensity factor (SIF) and J-integral for cracks in the DMW. The effects of crack locations, crack depths, and strength mismatch factors on the SIF and J-integral are studied. The SIF results obtained by finite element analysis are compared with those obtained by the influence function method adopted in the nuclear power code. Results show that the effect of crack location on the SIF can be ignored. The SIFs calculated by the influence function method for cracks in the DMW are basically reasonable, although its conservatism is slightly insufficient. Moreover, with moving the crack location from the nozzle through buttering and weld metal to the safe end, the J-integral increases. The effect of the crack location and strength mismatch factors on the J-integral is essentially caused by variation of the plastic zone and the material properties of the crack front. The crack sizes affect the level of influence of the crack location and the strength mismatch factors on the J-integral. The J-integral increases with decrease of the strength mismatch factor.

Characterization of Mechanical Heterogeneity and Study of the Mechanical Field at the Tip of the Stationary-Growing Crack in Dissimilar Metal Welded Joints

Abstract The mechanical heterogeneity in local areas of dissimilar metal welded joints and the micro-area mechanical state at the crack tip are key factors in determining Environment-Assisted Cracking (EAC). Traditional methods for acquiring material mechanical properties often result in destructive damage to specimens, while conventional “sandwich” models exhibit abrupt changes in interfacial mechanical properties and a lack of research into the mechanical field at the tip of the stationary or growing crack. In light of these challenges, this study, based on the analysis of microstructures in localized regions of the welded joint and the acquisition of material mechanical properties through indentation tests, developed a user-defined material subroutine (UMAT) to characterize the mechanical properties of non-uniform local areas within the welded joint. Additionally, it investigated the mechanical field at the tip of the stationary—growing crack using an integral method and a de-bond technique. The results indicate that non-destructive indentation tests can accurately acquire the material mechanical properties of local areas in the welded joint. Notably, significant changes in mechanical properties typically occur in the material interface regions, making them vulnerable points for potential failure. Furthermore, under the same load, mechanical heterogeneity significantly influences the distribution of the mechanical field at the crack tip. Crack propagation induces alterations in crack tip stresses, resulting in noticeable residual stresses and strains along the propagation path.

A Phase Shift-Based and Quadrant-Distinguishable Passive Microstrip Antenna Sensor for Metal Crack Detection

A Phase Shift-Based and Quadrant-Distinguishable Passive Microstrip Antenna Sensor for Metal Crack Detection

Development of a scanning acoustic microscopy-based structural prior for microtexture region characterization

Nondestructive evaluation (NDE) plays a crucial role in ensuring aircraft availability. The current NDE paradigm often relies on mono-modal testing and signal-over-threshold criteria to provide robust defect or damage detection, not characterization. One example is found in the risk-based management of surface-breaking cracks in metal, where cracks of a given size can be detected by eddy current testing (ECT) with a calculable probability. Yet, there are cases where detection proves insufficient. Consider the case of microtexture regions (MTR) found in certain titanium alloys, which can increase the risk of cold dwell fatigue failure when found above a certain size and in specific orientations relative to the surrounding material. At present, the size and orientation of MTR cannot be characterized using only one NDE modality. In this work, a data fusion-based solution to MTR characterization is developed. First, two inspection methods—scanning acoustic microscopy (SAM) and ECT—are selected, where each method is individually capable of only partial characterization. Then, matching component analysis is used to develop a surrogate forward model relating MTR orientation to ECT output. This data is then inverted using boundaries provided from the SAM data as a structural prior.

Ultrasensitive and ultrastretchable metal crack strain sensor based on helical polydimethylsiloxane.

The majority of crack sensors do not offer simultaneously both a significant stretchability and an ultrahigh sensitivity. In this study, we present a straightforward and cost-effective approach to fabricate metal crack sensors that exhibit exceptional performance in terms of ultrahigh sensitivity and ultrahigh stretchability. This is achieved by incorporating a helical structure into the substrate through a modeling process and, subsequently, depositing a thin film of gold onto the polydimethylsiloxane substrate via sputter deposition. The metal thin film is then pre-stretched to generate microcracks. The sensor demonstrates a remarkable stretchability of 300%, an exceptional sensitivity with a maximum gauge factor reaching 107, a rapid response time of 158 ms, minimal hysteresis, and outstanding durability. These impressive attributes are attributed to the deliberate design of geometric structures and careful selection of connection types for the sensing materials, thereby presenting a novel approach to fabricating stretchable and highly sensitive crack-strain sensors. This work offers a universal platform for constructing strain sensors with both high sensitivity and stretchability, showing a far-reaching significance and influence for developing next-generation practically applicable soft electronics.

Full‐scale testing of near‐neutral pH stress corrosion cracking growth behavior of a vintage X52 oil pipe

AbstractThis study presents an experimental investigation conducted on a 40‐year‐old vintage X52 oil pipe segment to assess the growth behavior of near‐neutral pH stress corrosion cracking (SCC). Six cracks were introduced on the pipe specimen, each of which was associated with a unique combination of metallurgical and environmental condition. SCC growth was evident in two base metal cracks respectively exposed to C2 and NS4. Stress intensity factors at the two cracks were evaluated using extended finite element method. Near‐neutral pH environment effects were observed to have a more pronounced effect on the stress intensity factor threshold for growth than on the growth rate. Higher stress levels and aging likely contribute to the difference in growth rates of different cracks. Electrochemical analysis suggests the corrosion‐crack propagation interplay, with a faster corrosion in the NS4 solution than that in the C2 solution consistent with the observed slower crack growth in NS4.

Restoration of tensile properties in cracked aluminum specimens via composite patching

This study investigates the tensile behavior and crack repair of aluminum using fiberglass-reinforced composite patches. Tensile testing compared uncracked, pre-cracked, and repaired aluminum specimens. Pre-cracking by hole drilling decreased strength and ductility from stress concentrations. Composite patching recovered strength, with 4-ply laminates optimal. Uncracked samples failed by necking, pre-cracked by crack growth, and repaired by adhesive detachment. Results demonstrate composite patching effectively restores strength to cracked aluminum by mitigating stress concentrations when appropriately designed. Finite element modeling simulated stress reduction after patching. This work provides experimental data on composite patch performance for metal crack repair and confirms the approach as an effective strengthening technique, although further optimization is needed.

Nondestructive Testing of Metal Cracks: Contemporary Methods and Emerging Challenges

There are high demands for the early and reliable detection of metal components used in safety-critical structures. Nondestructive testing (NDT) is a pivotal technique used across industries to assess a material’s integrity without causing damage and has been used in early crack detection of metals, mainly based on changes in the crystal structure and magnetic properties of metals. This review provides an overview of internal and external detection technology based on nondestructive testing methods such as ultrasonic, electromagnetic, ray, magnetic particle, etc. Especially, the integration of advanced methodologies such as machine learning and artificial intelligence deserves a place in NDT methods. Furthermore, the multifactorial detection method is promoted to enhance the sensitivity and detection range due to advantage integration but still has emerging challenges for safer equipment and applications. The review aims to compare these methods and outline the future challenges of NDT technologies for metal crack detection.