Crack Fracture Research Articles

Fatigue crack propagation life analysis of propeller

Fatigue crack fracture is a common failure mode in structures. For the propeller with initial crack, the hydrodynamic effect cannot be ignored when studying the fatigue crack propagation behavior. Taking the full-size KP505 propeller as the research object, its hydrodynamic performance is simulated and verified. By using the fluid-structure interaction (FSI), the pressure distribution and stress distribution of propeller under different working conditions are analyzed comprehensively, and the position of propeller hot spot stress is obtained. According to the principal stress and its direction of the hot spot stress, the location and orientation of possible macroscopic crack initiation are determined. By using the linear elastic fracture mechanics and finite element method (FEM), the propeller fatigue crack propagation law and life are calculated. The analysis results show that the Forman-Newman-de Koning (FNK) model predicts more complete fatigue crack propagation life than Paris model. The fatigue crack propagation of propeller has two stages, steady propagation stage, and accelerated propagation stage. The crack breaking blade thickness is the dividing point between the two stages. In addition, the effects of the advance coefficient, stress ratio, and initial crack size on the computed results are also analyzed, which provide reference for ship driving and propeller maintenance.

Fracture and multiple-cracking modelling of strain-hardening cementitious composites

Strain-hardening cementitious composites (SHCC), composed of short fibres embedded within brittle matrix, exhibit distinctive pre-peak strain-hardening characteristics and remarkable tensile ductility. The fracture and failure process of SHCC, involving both hardening and softening stages as a result of matrix multiple micro-cracking and strain localization, is highly complex and poses a significant challenge for numerical modelling. In the present paper, a novel numerical framework, characterized by the bi-layer superposed cohesive zone strategy, is developed for the numerical modelling of fracture and multiple cracking of SHCC, at both the material scale and structural scale. The developed model is based on diffused cohesive interface model, but with adaptions to consider fibre bridging mechanism. The crack interface is simulated by two cohesive elements sharing the same nodes: one for the matrix-cohesion effect and the other for the fibre-bridging effect. Cohesive constitutive relations of matrix cohesion and fibre bridging are carefully assigned. The proposed model is first validated on the material scale through a uniaxial tension test. With the aid of a random material field, multiple-cracking phenomenon and stress fluctuation are successfully predicted by the model. The model is then applied to the structural fracture modelling, where four case studies, including both pure mode I and mixed mode fracture, are performed. The size effect and boundary effect on the fracture behaviour are well captured by the numerical modelling. The model proposed in the current work has the potential to be extended to the multiple cracking modelling of other materials.

Crack growth and fracture mechanics of CuCrFeNiCo high-entropy alloy during tension testing

In this work, the crack growth and fracture mechanics of CuCrFeNiCo high-entropy alloy (HEA) during tension process are studied through molecular dynamics simulation method. The single-crystalline, nanocrystalline, and twinned-nanocrystalline CuCrFeNiCo HEA samples with an initial crack are prepared. The influences of boundary conditions, crack length and crystallographic orientation are considered in detail. The results indicate that the phase transition from face-centered cubic (FCC) structure into hexagonal close-packed (HCP) structure and the appearance of Shockley dislocations are the majority in all samples. The dislocations appear most densely in the twinned-nanocrstalline sample and most sparsely in the single-crystalline sample. The growth of the initial crack combined with the formation and expansion of new cracks along the grain boundaries (GBs) is the determining factor in the fracture mechanics of the CuCrFeNiCo HEA samples. The deformation capacity of the samples with free boundary conditions along the y-axis is better and the plastic deformation process is longer than the samples with periodic boundary conditions along the y-axis. The tensile strength values of the CuCrFeNiCo HEA samples change significantly in the range from 2.61 GPa to 7.75 GPa when changing the simulation conditions. The von Mises stress in the grains is markedly lower than that in the GBs.

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.

Force model of ultrasonic empowered minimum quantity lubrication grinding CFRP

As a weight-reducing material in aerospace applications, carbon fiber reinforced polymer (CFRP) requires precision grinding to ensure the accuracy and assembly of mating positioning surfaces. However, achieving low-damage machining of CFRPs remains challenging. Flood cooling reduces the mechanical properties, while dry grinding deteriorates the surface integrity, making minimum quantity lubrication (MQL) a viable alternative. However, nanolubricants struggle to penetrate the grinding area due to gas barrier obstruction. Consequently, a new CFRP grinding approach using multiangle 2D ultrasonic vibration-empowered nanolubricant MQL was proposed. An analytical force model is crucial for optimizing machining strategies and adjusting parameters. The aim is to reveal grinding mechanics and develop a force model under different ultrasonic and lubrication-cooling conditions. First, a uniform random fiber distribution model and a grinding wheel model were established, and the mechanical properties of the interface were predicted. Then, the intermittent grinding behavior and dynamic stiffnesses of the multiangle 2D ultrasonic vibration-assisted grinding (UVAG) system were investigated based on the geometric kinematics of the grains' trajectory. Furthermore, based on the deformation deflection curve, bending fracture force models for 45°, 90°, and 135° fibers were established with different contact and boundary conditions. The material removal mechanisms of shear and tension-compression buckling in 0° CFRP grinding were revealed, and an elliptical contact normal force model was established. The interlayer shear in 45° CFRPs was analyzed. The longitudinal compressive matrix cracking and fiber shear fracture in the 90° CFRPs were elucidated. Fiber microbuckling and fiber bundle removal of 135° CFRPs were investigated. Finally, grinding force models with different fiber orientation angles (FOAs) were interconnected and experimentally assessed. Experimental assessments demonstrated that the grinding force model has acceptable estimation error and effectively captures the mechanics of CFRPs with different FOAs.

A simple, fast, and robust criterion for predicting fracture load and crack growth path in notched elastoplastic plates under mixed-mode loading

This study assesses the combined in-plane tensile/shear failure of aluminum plates containing notches. With this aim, a numerical method, i.e., the so-called equivalent material concept (EMC) in association with the extended finite element method (XFEM), is introduced to simulate the fracture phenomenon. The predicted failure load, initiation angle, and growth path are compared to experimental results reported for aluminum alloys in the literature to evaluate the functionality of the proposed method. Also, the accuracy of the EMC-XFEM model was compared to the conventional Ductile Damage method. The EMC-XFEM combined model is found to be fast and robust with appropriate accuracy in fracture predictions of ductile samples in comparison with the elastoplastic damage model and experimental data.

Experimental Study of Avalanche Damage Protection Methods for Main Steel Gas Pipelines.

This paper conducted an experimental study of reduced models of a main gas pipeline for avalanche damage considering operational conditions. Two options were considered as a method of avalanche damage prevention: single steel rings at the crack edges and steel winding with a winding pitch of 0.25 m. For the tension force, 5% of the steel wire breaking force was taken, which was equal to 1 mm. The ambient environment was simulated by a climatic chamber, where two options of temperature loads were considered: +20 °C and -10 °C. It was found that reinforcement with single rings of pipeline models under conditions of positive (+20 °C) and negative (-10 °C) temperatures showed that the crack opening width in the ring direction decreased 1.63 times and 1.9 times, accordingly. The crack length (longitudinal direction) decreased 2.18 times and 2.45 times, accordingly. The reinforcement of the pipeline models with prestressed wire winding on the crack propagation under conditions of positive (+20 °C) and negative (-10 °C) temperatures showed that the width of the crack opening in the ring direction decreased 1.5 times and 1.46 times, accordingly. The crack length (longitudinal direction) decreased 1.4 times and 1.44 times accordingly, which is a positive moment in addressing the issue of the localisation and stoppage of a crack fracture in main gas pipelines. Simultaneously, the analysis of the prestressed pipelines model test results on crack fracture propagation showed that single rings are more effective, which decreased the crack opening width by 1.1 times and the crack length up to 1.5. Therefore, the experimental results obtained positively complement the available methods of crack localisation in main gas pipelines, which can be used by engineers and research communities when designing or reinforcing existing operating main steel gas pipelines.

An adaptive phase field approach to 3D internal crack growth in rocks

Modeling the 3D internal crack under compression entails complex fracture mechanics (mode I-II-III fracture), resulting in substantial computational costs and challenges in characterizing fracture morphology characterization for Phase Field Method (PFM) simulations. In the present paper, we developed a 3D adaptive crack propagation model integrated into the PFM to study the internal cracks in rocks. The proposed locally refined solution was implemented within the isogeometric analysis (IGA) framework, utilizing PHT-splines and employing the phase field variable as an error indicator to accurately capture non-smooth crack surfaces. The simulation begins with a coarser mesh, and the spatial discretization is adaptively refined in real-time as the computation progresses and the phase variable threshold is reached. By comparing our results with previous numerical tests, we validated the effectiveness of our model in simulating crack growth. Notably, a smaller length scale parameter led to a higher peak force in notched square plates under tension, and our adaptive PFM successfully reduced errors caused by length scale parameters. We further validated our model by comparing it with uniaxial compression experiments on 3D-printed resin samples with internal penny-shaped cracks, achieving good agreement with the experimental data. Using the 3D adaptive PFM, we predicted changes in crack morphology and fracturing mechanisms by varying the inclination angles of internal penny-shaped cracks. Our numerical results showed that as the inclination angle increased, wing cracks initiated closer to the end tips of the original crack, and their length decreased due to the wings wrapping effect. The corresponding fracturing mechanisms transition from mode I-III fracture (0°) to mode I-II-III fracture (30°, 45°, 60°), and eventually to mode I fracture (90°) as inclination angles increase. Comparing 2D and 3D models, we found that the growth of wing cracks in 3D was significantly influenced by the intermediate principal stress. We conclude that the extended 3D adaptive PFM-based model accurately predicted complex mechanical behavior and crack growth patterns in rock.

Numerical investigation on the crack resistance curve of thermally treated quartz‐diorite rock under mixed mode I + II loading

AbstractTo investigate the effects of thermal treatment and loading conditions on the crack initiation and propagation characteristics of quartz‐diorite, mixed mode I + II fracture tests were conducted by using three‐point bending (TPB) specimens. The numerical model, established on ABAQUS, couples the initial fracture toughness criterion and cohesive zone model to predict the crack initiation and propagation. The effects of thermal treatment and loading conditions on the crack propagation process, crack resistance curve, fracture path, and some fracture parameters at peak load have been analyzed and discussed. The results demonstrate that the thermal treatment has an obvious influence on the crack resistance curve of the specimen. The crack of the specimen will be dominated by the mode I fracture component with crack extension. The numerical results also show that the temperature and loading condition affect the crack length and fracture toughness at peak load.

Enhanced hydrogen embrittlement resistance of additive manufacturing Ti-6Al-4V alloy with basket weave structure

The hydrogen embrittlement (HE) behavior of tungsten inert gas arc additive manufacturing (AM) Ti-6Al-4V alloy was studied through tensile tests with/without hydrogen charging. The influence of hydrogen on the microstructure and crack propagation of AM Ti-6Al-4V alloy was investigated. The results indicated that the AM Ti-6Al-4V alloy with a basket weave structure alleviated local stress at grain boundaries during deformation, thus avoiding intergranular cracking and brittle fracture. The AM alloy displayed less HE susceptibility than that of the wrought alloy, which was due to the basket weave structure hindering the propagation of hydrogen-induced cracks, thereby improving the HE resistance.

Experimental and simulation study on quasi-static and dynamic fracture toughness of 2A12-T4 aluminum alloy using CTS specimen

Based on the study of dynamic fracture toughness of mixed mode I/II fracture crack, using compact tensile shear (CTS) specimen and the method of split Hopkinson tensile bar (SHTB) combined with special fixture, which complete the experiments of complex fracture modes of 2A12-T4 aluminum alloy material under quasi-static and dynamic tensile tests. By combining the results of finite element simulation with experimental–numerical method, the feasibility of Richard’s theory formula in dynamic fracture experiment is discussed. The variation law of fracture toughness under quasi-static and dynamic complex fracture under mixed-mode was analyzed by finite element simulation and experiment. The results show that, in the process of quasi-static and dynamic fracture, the fracture toughness of CTS specimen under mixed mode I/II crack loading is the highest. The conclusion is proved by Richard theorical formula and experimental–numerical methods jointly. When the specimen is subjected to pure mode I fracture, the quasi-static fracture toughness is consistent with that is in condition of dynamic experiment. However, when the specimen is subjected to mode II and mixed mode I/II fracture, the dynamic fracture toughness changes greatly compared with the quasi-static fracture toughness. In addition, in the dynamic fracture experiment, the dynamic fracture toughness of mixed mode I/II depends on the initiation time, and the quasi-static fracture criterion is no longer applicable.

Using borehole radar detecting hydraulic fracturing crack in near horizontal holes in coal mine

Using borehole radar detecting hydraulic fracturing crack in near horizontal holes in coal mine

Peridynamic contact models for fracture analysis based on the micro-beam bond

Contact problems are ubiquitous in engineering systems. Establishing contact models to predict the crack propagation and fracture is significant. Therefore, the present study proposes two peridynamic contact models for two-dimensional (2D) and three-dimensional (3D) contact problems based on the micro-beam bond and the Hertz theory, using the relative position of particles and the contact micromoduli to calculate the contact forces. Firstly, the strain is generated on the contact surface when two bodies come into contact. Simultaneously, the contact stiffness is obtained by the Hertz theory, and the contact forces are calculated according to the relationship between the strain of contact surface and the contact stiffness. Next, based on the peridynamic theory, the contact horizon and contact micromoduli are defined for the calculation of contact forces. Finally, the contact micromoduli for 2D and 3D contact problems are derived by equating the contact forces obtained from both theories. Additionally, this study defines the correction coefficients to reduce the calculation error of the proposed models and investigates the influence of different contact horizons on the calculation of contact forces. To validate the effectiveness of the proposed contact models, three numerical examples are compared with the results from the finite element method or experiments. It is demonstrated that the proposed contact models accurately calculate the contact forces and predict the crack propagation.

Effect of Mode II in the mixed-mode on the fatigue crack growth behaviour for SAPH440 material

In this study, the effect of mixed-mode loading on fatigue crack growth under varying applied loads for SAPH440 material was experimentally investigated. Previous research has either examined the effect of mixed-mode loading at a fixed angle or its effect on slanted cracks. This paper uses a CTS specimen and a loading device to apply varying angles of load during Mode I loading conditions. Initially, a numerical analysis was performed to validate existing equations for the stress intensity factor, which quantifies the crack driving force in the experiments. In the crack initiation region, load shedding techniques and load increasing techniques were used to confirm fatigue cracking considering mixed-mode effects. The change in the threshold value according to the loading angle was also evaluated. In the crack propagation region, a multi-level loading technique was employed to assess the mixed-mode effects under varying loading angles. This process verified the mixed-mode effect under conditions where the applied load angle varies. The fatigue crack fracture surfaces were examined using digital camera capture and SEM. It was found that when mixed-mode loading occurs during Mode I loading, the fatigue crack propagation rate varies depending on the mixed-mode loading angle.

Guided analysis of fracture toughness and hydrogen-induced embrittlement crack growth rate in quenched-and-tempered steels using machine learning

This study focuses on developing a machine learning (ML) model, specifically a Bayesian-optimized deep neural network, leveraging numerical simulation data for the prediction of fracture toughness (KIC) and crack growth rate (CGR) in Quenched-and-Tempered Steel (AISI 4140 alloy) under hydrogen embrittlement conditions. The proposed model demonstrated superior accuracy with Root Mean Squared Error (RMSE) values of 0.052 for KIC and 0.084 for CGR, surpassing conventional ML models including random forest (0.094 for KIC, 0.139 for CGR), gradient boosting (0.184 for KIC, 0.196 for CGR), support vector regression (0.142 for KIC, 0.110 for CGR), and decision tree regression (0.119 for KIC, 0.133 for CGR). The findings also revealed that input parameters such as temperature, hydrogen concentration, and hydrostatic stress carry higher weight factors compared to other parameters in predicting KIC. Similarly, the prediction of high CGR values, ranging from 5.9 × 10−5 to 9.5 × 10−5 m/s, was associated with the importance of hydrostatic stress, strain rate, and initial crack length in the prediction model. This underscores the model's ability to capture the intricate dependencies of output objectives on input features. Furthermore, a comprehensive case study, informed by the ML model, highlights the potential for tuning specific processing input parameters to manage hydrogen embrittlement effectively, contributing to a deeper understanding of its dynamics.

The optimal design of double-edge wedge-splitting tensile test for ultra high performance concrete

The double-edge wedge-splitting (DEWS) test is a new indirectly tensile test, those of stress distribution similar with the uniaxial tension state. However, there are no standard rules regarding the splitting specimen and groove dimensions suitable for the UHPC tensile properties. In this paper, DEWS test, conventional splitting test, and direct tensile test were performed to measure the tensile strength and tensile stress vs. crack opening response of UHPC. The digital image correlation (DIC) technique was utilized to detect the crack propagation paths and fracture modes. Two specimen shapes, three groove angles and three fiber types are utilized to this investigation. The experimental results of 18 DEWSs under tensile loading, including peak strength, tensile stress-COD curves, fracture modes and properties, and the crack paths, are presented. The results show that the UHPC tensile performance used with cubic specimen is less sensitive to groove angle than in the cylinder. An important finding is that DEWS test used with 45° grooved cube specimen presents the lowest variation in peak strength and stress-COD curve for UHPC tensile behaviors. After comparison, the tensile strengths using DEWS test and direct tension test are essential equal in first-cracking and peak strength. The crack paths and fracture mode are basically the same inside the DEWS and direct tension specimens. Accordingly, the DEWS test used with 45° grooved cubic specimen is suggested for measuring the UHPC tensile property.

Vibration fatigue assessment and crack propagation mechanism of directionally solidified superalloy with film cooling holes

Film cooling represents a critical protective measure for turbine blades, yet the presence of film cooling holes (FCHs) under vibrational loads can significantly impact structural strength and integrity. This study conducts random fatigue tests on DZ125L directionally solidified superalloy specimens with FCHs. It investigates how various FCH types and vibration signal intensities influence the vibration fatigue behavior of DZ125L alloy. Characterization of vibration fatigue fracture and surface cracks of FCH specimens utilizes ultra depth of field microscopy and scanning electron microscopy. Additionally, the crack propagation mechanism for FCH specimens under random processes is proposed based on finite element stress distribution and fracture morphology. Results reveal the generation of two types of cracks, namely hole cracks and edge cracks, under vibration load in FCH specimens. The crack propagation process produces water wave-like fatigue striations. Notably, a low stress zone exists between the two dangerous holes in the multi-hole specimen, mitigating the expansion trend of hole cracks between the FCHs compared to cracks expanding towards the edges. Furthermore, two novel models, New1 and New2, are introduced to enhance the applicability of the frequency domain method for predicting the fatigue life of FCH specimens under random processes. Accuracy and error analyses of the models suggest that New2, incorporating the FCH stress concentration coefficient KT and intensity function f(ξ), exhibits superior accuracy and stability.

The effect of runoff acidity on fatigue cracking of hot mix asphalt using thermodynamic concepts

This study examined the fatigue performance of hot mix asphalt (HMA) under the influence of runoffs entering the pavement with different acidity degrees. Based on the fatigue test results, changing the runoff acidity and increasing the temperature decreased the number of cycles leading to HMA fracture (fatigue life) and accelerated the damage. The results of the surface free energy (SFE) method were aligned with the fatigue test results, indicating that changing the runoff acidity increased the bitumen-water adhesion SFE, aggregate-water adhesion SFE, and bitumen-aggregate debonding SFE. These changes diminished the fatigue cracking resistance of HMA. According to the Pull-Off test results, altering the runoff acidity and increasing the temperature reduced the adhesion and cohesion strength. According to the two principal factors in fatigue cracking (fracture adhesion and cohesion), the reduced fatigue life of the samples due to variations in the runoff acidity and temperature increase was acceptable according to the SFE and Pull-Off test results. The independent samples t test revealed that changing the runoff acidity led to a significant decline in the asphalt samples' performance parameters compared to neutral conditions.

Ex vivo investigation on the effect of minimally invasive endodontic treatment on vertical root fracture resistance and crack formation

The evidence base on minimally invasive endodontic (MIE) treatment is limited. This study investigated the influence of MIE shaping on vertical root fracture (VRF) resistance and crack formation of root canal filled teeth. Human maxillary central incisors were randomized into six groups (n = 18, power = 0.9) and embedded in acrylic blocks with artificial periodontal ligaments. The root canals were either instrumented to size #40 and 0.04 taper (+MIE) or enlarged to ISO size #80 (−MIE). The canals were filled with cement-based (C) or adhesive resin-based (A) sealers in single-cone technique. The controls received no treatment or were left unfilled. After chewing simulation (staircase method, 25–150 N, 120,000×), the crack formation on the root surface was analyzed using stereomicroscope/digital imaging and classified (no defect, craze line, vertical crack, horizontal crack). Subsequently, the samples were loaded until fracture. The incidence of defects (56% vertical cracks) was not significantly different between the groups (p ≥ 0.077). VRF resistance was significantly higher in untreated teeth than in +MIE/C (p = 0.020) but did not significantly differ between the other groups (p ≥ 0.068). Minimal canal shaping did not reduce the risk of vertical root fracture and defects of root canal filled teeth.

Investigation of notch position and fiber ratio on the fracture mode and energy of sfrc beam under the impact load

When the literature is examined, it is seen that a lot of study has been done on the crack propagation and fracture modes that occur under the influence of static loads in reinforced concrete (RC) structures. Studies in the literature show the effect of crack initiation, concrete compressive strength, and fiber volume fraction on the tension mode (Mode-I), shear mode (Mode-II), and mixed fracture mode that occurs in crack propagation under static load. However, the literature has not found a comprehensive study in which the fracture modes are examined under the effect of dynamic impact loading. For this reason, an experimental study has been planned in which hybrid steel fiber reinforced concrete (SFRC) notched beams with varying compressive strength will be tested under impact loading with a free-fall drop weight device designed by the authors. The experimental variables studied were determined as the change of the crack initiation point in the beams, the compressive strength of the concrete used to produce the beams, and the fiber volume fraction in the concrete mixture. The acceleration and impact load-time histories under the constant-energy-level impact loading applied to the beams were measured. Also, the crack shape, fracture mode, crack angle, and energy absorption capacities of the beams under impact load were interpreted. While the transition from Mode-I fracture form to Mode-II fracture form occurs under impact loading, the effects of concrete compressive strength and steel fiber ratio variables on energy absorption capacity, crack angle, and crack shape are studied. Increasing the distance of the notch from the beam midpoint in notched beams produced with concrete without fiber from 0 to 40, 80 and 120 mm caused the energy absorption capacity values to increase by an average of 39 %, 66 % and 86 %, respectively. Increasing the distance of the notch to the beam midpoint from 0 to 40, 80 and 120 mm in beams with 0.75 % and 1.5 % fiber ratio increased the energy absorption capacity values by an average of 40 %, 65 % and 86 %, respectively. In beams with 2.25 % fiber ratio, increasing the notch distance from 0 to 40, 80 and 120 mm increased the energy absorption capacity values by an average of 38 %, 62 % and 83 %, respectively.