Crack Initiation Research Articles

Impact toughness behaviour of A516 GR. 60 steel welded joints

Impact fracture behaviour of welded joints made of A516 Gr. 60 is analysed as a commonly used carbon structural steel for welded structures. Impact testing on Charpy instrumented pendulum is performed using specimens with a notch at positions: the base metal (BM), heat-affected-zone (HAZ), and weld metal (WM). The total impact energy is presented as a sum of energies for crack initiation and crack propagation to make the analysis more sophisticated and comprehensive. The effect of temperature up to -60 °C was also analysed to prove the A516 Gr. 60 steel usability at subzero conditions.

Effect of gradually decreasing laser power on the microstructure and properties of laser melting deposited Inconel 718Plus alloy thin-wall

Laser melting deposition (LMD) technology offers a novel method for fabricating superalloy thin-walled parts because of its significant advantage of rapidly producing near-net-shape moldings. However, the coarse columnar crystals in these deposited thin-walled parts resulted in poor mechanical properties, which significantly limited its wide application. To address this problem, a layer-by-layer decreasing laser power deposition strategy (LT) is proposed in this study, which can increase the cooling rate of the molten pool by reducing the thermal cycling. Results indicate that the thin walls of Inconel 718Plus alloy deposited by the LT strategy exhibit dendrites at heights of 4.5 mm (bottom region), 16.5 mm (middle region) and 28.5 mm (top region). The Laves phase at the bottom of the LT alloy thin-wall was randomly distributed granular, which gradually transformed into granular, short-chain and its mixed structures with increasing height. Formation of long-chain Laves phases was hindered by the connection of dendrites. The densely distributed granular Laves phase in the LT strategy alloy thin wall could effectively transfer and dispersed the stress and hindered the crack initiation and extended. Compared to the bottom region, the yield strength of the LT alloy thin-wall in the middle and top region increased by 6.7 % and 12.6 %, and the tensile strength increased by 10.7 % and 16.2 %. In conclusion, the alloy thin-walls fabricated by the LT strategy exhibit superior strength and more balanced mechanical properties.

Fatigue Crack Segmentation and Characterization of Additively Manufactured Ti‐6Al‐4V Using X‐Ray Computed Tomography

ABSTRACTX‐ray computed tomography (XCT) is extremely useful for the non‐destructive analysis of additively manufactured (AM) components. AM components often show manufacturing defects such as lack‐of‐fusion (LoF), which are detrimental to the fatigue life of components. To better understand how cracks initiate and propagate from internal defects, we fabricated Ti‐6Al‐4V samples with an internal cavity using electron beam powder bed fusion. The samples were tested in high‐cycle and very high‐cycle fatigue regimes. XCT was used to locate crack initiation sites and to determine characteristic properties of cracks and defects with the aid of deep learning segmentation. LoF defects exposed to the outer surface of the samples after machining were found to be as detrimental to fatigue life as the internal artificial defects. This work can benefit industries that utilize the AM of high‐strength, lightweight alloys, in the design and manufacturing of components to improve part reliability and fatigue life.

Tailoring the microstructure by prior treatment to achieve 37.6 GPa·% PSE in a room-temperature quenched and partitioned steel

In this work, different initial microstructures, including deformed cold-rolled structure, quenched martensite, granular bainite, and lathy bainite, were intentionally designed through cold rolling and prior treatment. Meanwhile, a novel room-temperature quenching and partitioning (RT-Q&P) process was proposed to further enhance strength-ductility combination of Cu-Ni bearing Q&P. The present study aims to investigate the influences of initial microstructures on the formation kinetics of austenite, the mechanical stability of RA, microstructure evolution, and mechanical performance in Q&P steel treated by RT-Q&P process. Compared to sample without prior treatment, samples with prior treatment showed a larger austenization degree due to more nucleation sites on martensite/bainite matrix. DICTRA simulation indicates the lathy bainite matrix with low C and low Mn is more conducive to the refinement of parent austenite, thus leading to fine and dispersive TM/A. During tensile deformation, the fine and dispersive lath-structures can effectively alleviate strain localization on the interfaces which resulted from the deformability difference between the soft and hard phases, thereby delaying crack initiation and propagation. After RT-Q&P treatment, the outstanding mechanical properties with UTS of 1152 MPa, TEL of 32.6 %, YS of 754 MPa, and PSE of 37.6 GPa·% was achieved in sample with lathy bainite matrix, far exceeding the properties of traditional Q&P steels, which was mainly attributed to higher work-hardening ability of fine and dispersive structure and sustained TRIP effect of RA.

Interaction of propagating crack with microstructure in CGI: In situ tensile test and numerical simulation

Compacted graphite iron (CGI) is a double-phase material, in which complex graphite morphology greatly influences crack initiation and propagation. Despite its wide use and considerable past research on the fracture behaviour of CGI, the understanding of the interaction of propagating cracks with CGI's microstructure is still limited. In this study, a novel method is employed that integrates scanning electron microscopy (SEM) and an optical high-speed camera. This approach allows the clear visualisation of microstructures before and after fracture, as well as the calculation of crack-propagation rate during tensile tests. It is also revealed for the first time that in the case of graphite particles situated at a specific distance from the primary crack path, the initiation of secondary micro-cracks, near particles does not occur. A critical distance from the main crack path for crack initiation is analysed. Further, finite-element simulations are developed to study the effect of microstructure on the fracture behaviour of the tested microstructures. A Johnson-Cook (JC) damage model is calibrated and used in all simulations. The crack path and velocity of simulation results are in good agreement with the experimental data, demonstrating that the JC damage model can be used to predict the crack initiation and propagation of CGI. It is found that interface debonding and crack initiation always tend to appear near the tip of vermicular graphite. Thus, large vermicular graphite particles can affect negatively the toughness of CGI. Graphite particles situated farther from the primary crack significantly reduce the likelihood of crack initiation in that specific location. Furthermore, large nodular graphite particles absorb energy and generate secondary cracks, while small graphite particles have little effect on the crack-path direction. The newly discovered fracture mechanisms and simulation results provide new insights for the design and manufacture of metal-matrix composites (e.g., Al/SiC) with optimal mechanical properties.

A coupled scaled boundary finite element and phase-field algorithm for seismic loading

Seismic-induced damage, integral to the safety evaluations of major engineering projects, persists as a key focus of research worldwide. Based on the Scaled Boundary Finite Element Method (SBFEM) and the Phase-Field Method (PFM), a coupled algorithm tailored for reciprocal loading was introduced in this paper, integrating strategies including "closure constraints," "numerical threshold strategy," and "subdomain block integration." Adopting object-oriented principles, a universal coupling solution framework has been built and seamlessly embedded within GEODYNA, a self-developed finite element software system. The accuracy was validated through rigorous benchmark tests. The entire process of crack initiation, propagation, and dynamic opening-closing cycles in the Koyna concrete gravity dam was reproduced. Furthermore, the effect of mesh size and computational timestep on the structural seismic response, crack localization, and the extent of damage in the dam were explored. The outcomes demonstrated that the SBFEM-PFM coupling algorithm performs effectively and meets the engineering precision criteria for seismic evaluations and reinforcement analyses of crucial structures.

Effect of texture on the fatigue crack initiation of a Dual-Phase Titanium alloy

Fatigue indicator parameters (FIPs) can serve as a measure of fatigue crack initiation (FCI) in metals and alloys. FIPs are volume averaged over grains, bands, and sub bands in crystal plasticity (CP) simulation to investigate the influence of texture on FCI under low cycle fatigue. The equiaxed microstructure of Ti–6Al–4V was generated with three different textures: basal, basal/transverse and transverse. FIPs analysis shows that basal texture has the highest FCI resistance, basal/transverse texture has intermediate resistance, and transverse texture has the lowest resistance when tested along plate direction. All textures exhibit a lower FIP when deformed along rolling direction (RD) than that along transverse direction (TD). The interior of the alloys has a larger FCI resistance than the free surface. Further analysis shows a strong relationship between FIP distribution features and damage nucleation characteristics, with basal texture exhibiting the lowest and wider FIP distributions as a result of high resistance to damage and fatigue cracking; in contrast, the transverse texture exhibits intense and narrow FIP and damage nucleation along the grain boundaries (GBs), basal/transverse texture exhibits FIP and damage nucleation with mixed characteristics. The results can be used as a theatrical reference for the fatigue performance design of Ti alloy.

Analysing Flexural Response in RC Beams: A Closed-Form Solution Designer Perspective from Detailed to Simplified Modelling

This paper presents a detailed analytical approach for the bending analysis of reinforced concrete beams, integrating both structural mechanics principles and Eurocode 2 provisions. The general analytical expressions derived for the curvature were applied for the transverse displacement analysis of a simply supported reinforced concrete beam under four-point loading, focusing on key limit states: the initiation of cracking, the yielding of tensile reinforcement and the compressive failure of concrete. The displacement’s results were validated through experimental testing, showing a high degree of accuracy in the elastic and crack propagation phases. Deviations in the yielding phase were attributed to the conservative material assumptions within the Eurocode 2 framework, though the analytical model remained reliable overall. To streamline the computational process for more complex structures, a simplified model utilising a non-linear rotational spring was further developed. This model effectively captures the influence of cracking with significantly reduced computational effort, making it suitable for serviceability limit state analyses in complex loading scenarios, such as seismic impacts. The results demonstrate that combining detailed analytical methods with this simplified model provides an efficient and practical solution for the analysis of reinforced concrete beams, balancing precision with computational efficiency.

Extracting ductile cast iron microstructure parameters from fracture surfaces: A deep learning based instance segmentation approach

This study investigates the deep-learning based microstructural analysis from SEM images of ductile cast iron fracture surfaces. A Mask R-CNN model was trained, achieving 70% precision and 75% recall in graphite particle detection. Combined with a fracture surface reconstruction using the.4-quadrant backscattered electron signal, key parameters, including the particle size, shape and distance were extracted accurately. Compared to micrograph analysis, following probabilistic simulations showed the impact of the higher microstructural variance for the fracture surfaces on crack initiation, leading to higher scatter and elevated crack resistance curves. This highlights the potential of deep-learning based analysis for comprehensive microstructural characterization.

Analysis of initiation and growth of new transverse cracks in high crack density regions in cross-ply laminates

In cross-ply laminates under loading, multiple intralaminar (transverse) cracking in the 90-layers causes laminate stiffness reduction which can be predicted by analytical models studying average of the stress perturbation between transverse cracks. The commonly used analytical models such as shear-lag type or variational-type models assume that stress in damaged 90-layers does not depend on the laminate thickness coordinate. But with increase in crack density, the stress perturbations created by transverse cracks start to interact, generating high stress gradients in through-the-thickness direction in the 90-layers. Location of a new crack and features of its propagation in a high stress gradient region between two cracks in a cross-ply laminate are analyzed in this paper. FEM is used to calculate stress distribution between two cracks. The location of the next crack and its initial orientation is found using principal stresses and orientation of principal axes. Most often these cracks are initiated at ply interface in the middle between already existing cracks. Their propagation across the layer thickness is analyzed using energy release rate based criterion. It is shown that at very high crack density the crack propagation across the layer thickness is unstable in the beginning, but it is stopped when approaching the middle of the layer where the crack opening becomes zero. Presence of local delaminations at the tips of existing cracks changes the energy release rate for propagation of new transverse cracks.

A non-melting additive approach to structural repair of aluminum aircraft fastener holes

The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.

Investigation on fatigue damage of buton rock asphalt mixtures using semi-circular bending (SCB) and digital image correlation (DIC) techniques

The fatigue performance evaluation indices of Buton rock asphalt (BRA) modified asphalt mixture struggles to accurately characterize damage evolution process under repeated loads of the traffic. This study employs digital image correlation (DIC) technology to assess the fatigue behavior of BRA modified asphalt mixture, quantify the correlation between macroscopic response and local deformation, and verify the accuracy of evaluation indices. By capturing strain and displacement fields, the fatigue damage evolution of BRA modified asphalt is analyzed. Based on fracture mechanics theory, BRA’ s improvement of fatigue performance is quantified. Results show that vertical displacement captured by DIC can divide the three stages of fatigue cracking. The global horizontal strain(GExx)and cumulative horizontal strain(CExx) proposed in this study better characterize the nonlinear fatigue damage evolution compared to horizontal strain(Exx). Adding BRA delays crack initiation, reduces propagation rate, and enhances fatigue performance. Strain field evolution was quantitatively analyzed, and horizontal strain density(DE) and global horizontal strain density(GDE) were proposed as fatigue damage indicators. At the same load level, these indicators in BRA modified asphalt mixture, both pre- and post-aging, exceeded those of neat asphalt mixture. These findings provide a novel and accurate approach for evaluating the fatigue damage behavior of BRA modified asphalt mixture, laying the foundation for future performance-based designs.

In-situ experimental characterization and numerical investigation of the crack initiation of SMC composite under uniaxial tension

This paper explored the crack initiation of sheet molding compound (SMC) composite under uniaxial tensile loads by integrating in-situ experimental characterization and subsequent numerical analysis. Firstly, a synchrotron micro-X-ray computed tomography was utilized to character the morphology and evolution of the microstructure and fracture features of the SMC sample with different loading conditions. Meanwhile, the digital volume correlation technology was employed to determine the internal three-dimensional deformation. Then, a numerical analysis was conducted to describe the relationships among the microstructure, deformation distribution, and position of the crack initiation. Finally, a predictive model was developed based on the internal microstructure and the deformation distribution and then utilized to predict the location and sequence of crack initiation. The good agreement between the predicted results with the experimental ones reveals the feasibility of the proposed model in exploring the fracture behaviors of carbon fiber reinforced polymer composites with complex internal microstructure.

Research on high‐pressure abrasive water jet slotting and pressure relief technology for hard rock roof

AbstractTo solve the problem of severe rock pressure near coal mining face tunnels, a high‐pressure abrasive water jet slotting and roof breaking pressure relief technology is proposed. First, the laneway deformation mechanism and the process of hard rock slotting using high‐pressure abrasive water jets under long‐distance cantilever conditions are analyzed, and the crack initiation conditions of roof strata are obtained. Second, slotting tests under different slotting pressures, nozzle diameters, abrasive particle sizes and slotting times were carried out, and the slotting parameters of a high‐pressure abrasive water jet on a typical roof rock were obtained. Finally, industrial application was carried out in the 81,403 working face of Huayang No.1 Mine. After the hydraulic roof slotting measures were implemented in the test area, the maximum axial force of the anchor cable was reduced to 67 kN, which was 35.5% lower than that of the comparison. The average stress of the coal seam was 15 MPa, which was approximately 25% lower than that of the comparison. The deformation of the tunnel in the experimental area was significantly controlled, with an average movement of 30.0% toward the roof and floor of the tunnel and an average movement of 23.2% toward the two sides of the tunnel. Compared with the movement in the comparison section, the movement toward the roof and floor of the laneway was 42.3% lower, and the movement toward the two sides was 38.2% lower. The industrial application results show that high‐pressure abrasive water jet roof slotting and pressure relief technology can cut off the stress transmission path between the roof rock on both sides, effectively improve the stress state of the surrounding rock of the laneway, reduce the deformation of the roof, floor and two sides of the working face in the later stage of the mining laneway.

In-depth molecular dynamics analysis of crack evolution in polycrystalline chromium under uniaxial tensile deformation

Because of its excellent wear resistance and high hardness, chromium is widely used in coating materials. Under external load, micro-cracks on the surface of electroplated chromium coating will cause crack propagation and reduce the performance of the material. Therefore, in this study, the crack evolution process of polycrystalline chromium under uniaxial tension was studied using molecular dynamics. The effects of average grain size, strain rate, and crack location on crack propagation behavior were analyzed, which provided a scientific basis for optimizing the performance of chromium materials. The results show that cracks in polycrystalline chromium tend to fracture along grain boundaries and that stacking faults and holes are the main factors for crack propagation. As the grain size decreases, the crack passivation becomes more pronounced and the rate of crack expansion slows down. As the strain rate increases, the crystal structure of polycrystalline chromium changes more sharply, and the ultimate stress increases. At high strain rates, the direction of crack propagation changes. The degree of crack tip passivation is affected by the initial crack location, and the crack tip can be effectively passivated when it is located at the grain boundary, thus hindering crack propagation. The results of these studies reveal the influence of multiple factors on the crack propagation mechanism of polycrystalline chromium and provide theoretical guidance for the reduction of chromium coating damage.

Fatigue performance of Q420C high-strength steel at room and low temperatures

Steel structures are frequently exposed to the environment with variable temperature, where the fatigue failure of steel is difficult to be predicted. In this paper, the standard Q420C high-strength steel specimens were tested to explore their fatigue performance at room (25°C) and low temperatures (0°C, −15°C and −30°C). Before fatigue tests, the tensile tests have been done, and the results indicate that the yield and ultimate strengths of Q420C steel significantly grew when the temperature decreased. The fatigue behavior of Q420C steel was discussed from different perspectives, including the crack initiation, crack growth, fracture mode and fatigue life. The fatigue failure was observed mainly near the arc transition section of specimen, with the fatigue crack initiated from the surface and internal discontinuity defects. Furthermore, the test fatigue life was compared with the recommended S-N curves provided by specifications from various countries. These comparison results suggest that recommended S-N curves were excessively conservative to evaluate the steel fatigue life at low temperature, leading to a potential economic cost for the steel structures at extremely cold conditions. To avoid needless loss, a calculation method of steel fatigue life considering the effect of low-temperature, stress range and yield strength was proposed.

Study on Multi-Crack Damage Evolution and Fatigue Life of Corroded Steel Wires Inside In-Service Bridge Suspenders

The parallel steel wires used in arch bridge suspenders experience random corrosion damage on their surfaces during service. Corrosion damage, including micro-cracks, pitting, and a combination of both, leads to significant stress concentration under axial loading, which affects the performance of the steel wires. The change in the stress field caused by surface damage alters the stress intensity factor at the crack tip, and the presence of adjacent crack tips significantly amplifies the stress intensity factor, thereby accelerating crack propagation. The development of small surface damages in the steel wires is difficult to control and observe through experiments. By utilizing finite element methods for simulation, it is possible to intuitively analyze the crack propagation process, the trend of stress changes at the crack tip, and the interaction between damages. Numerical simulation results based on Paris’ law indicate that corrosion pits have a certain impact on the stress intensity factor at the crack tip. The propagation process of coplanar double cracks is highly sensitive to the initial crack size and the distance between adjacent crack tips. When the crack spacing is less than the crack depth, the stress intensity factor at the adjacent crack tips exhibits significant amplification. Based on this phenomenon, the coplanar double-crack system can be simplified to a complete single crack for analysis. By comparing the fatigue life of the double-crack system with that of the equivalent single crack, the effectiveness of the simplification rule has been validated.

Exploring Fatigue Crack Initiation in Helical Gears: Impact of Carburization and Frictional Influences

A computational model is presented to analyze the fatigue crack initiation period in helical gears, incorporating considerations for heat treatment via carburization and friction effects. The aim is to determine the number of stress cycles necessary for the initiation and growth of initial cracks, while investigating the impact of dynamic behavior. This study employs a dynamic gear model with two degrees of freedom in torsion, developed using MATLAB, and incorporates the Papadopoulos criterion for fatigue analysis. The computational results are benchmarked against the strain-life method. The findings underscore the significant influence of the friction coefficient between surfaces, heat treatment, and dynamic loads on the growth of initial fatigue cracks. For instance, with a friction coefficient (μ) of 0.5, the initial crack forms on the tooth surface (y=0) in both methods, with the (ε-N) method suggesting 28-65 cycles and the Papadopoulos criterion indicating 101-156 cycles. The latter accounts for the greater influence of residual stresses. Additionally, untreated gears exhibit a minimum number of loading cycles for initial crack appearance at 1.07 × 104 cycles. In contrast, carburized gears demonstrate an extended lifespan, requiring 1.45 × 105 loading cycles for crack initiation in our example. This emphasizes the efficacy of carburization in enhancing gear durability.

Particle flow simulation of crack propagation and penetration in Brazilian disc under uniaxial compression

The presence of rock mass fractures has always been a subject of study for the prevention and control of related natural disasters. To understand the effects of different dip angles and horizontal distances on crack development, numerical simulation experiments on Brazilian disks under uniaxial compression were con-ducted using the PFC2D particle flow program. A function module was utilized to monitor the expansion and quantity of cracks. The numerical simulation results under 0° conditions were in good agreement with the experimental results, validating the rationality of the numerical simulation. The simulation results indicate that: under single fracture conditions with different dip angles, samples with angles between 30° and 60° produced typical wing-shaped cracks. At 0°, cracks propagat-ed through the center of the fracture, while at 90°, cracks initiated from the tip of the fracture and propagated through the sample. The peak stress and the number of cracks in the samples first decreased and then increased with the increase of the dip angle, reaching a maximum at 90°. For samples with double fractures and varying horizontal distances, all produced wing-shaped cracks. Their peak stress and the number of cracks increased monotonically with the increase in distance, reaching a maximum at a distance of 30mm. The experimental results confirmed that the PFC2D program can effectively simulate the process of crack initiation and development, and the research findings provide a reference for correctly understanding the fracture mechanics of fractured rock masses.

Enhancing concrete beam performance with PVA fibers, coal ash, and graphene fabric: a comprehensive structural analysis

ABSTRACT This study evaluates the structural performance of Polyvinyl Alcohol Cementitious Composites (PVCC)-layered reinforced concrete beams with coal ash under static loading. Experimental investigations included first crack load, ultimate load, load-deflection behavior, ductility, stiffness, and energy absorption. Results highlight the influence of Polyvinyl Alcohol-(PVA) fiber dosage on structural behavior. The control specimen exhibited an initial crack load of 80kN, with subsequent specimens showing varied crack initiation loads influenced by PVA fiber content. Optimal performance was observed at 1.2% PVA fiber dosage, with higher dosages leading to earlier crack initiation. Ultimate load carrying capacity increased with PVA fiber addition, reaching a peak at 1.2% dosage before slight decreases occurred with higher dosages. Load-deflection behavior demonstrated the superior performance of PVCC layered beams, particularly specimen BP3, attributed to optimal fiber content. Ductility, stiffness, and energy absorption increased with PVA fiber reinforcement, with 1.2% dosage yielding optimal results. Excessive fiber content led to diminishing returns. Energy index analysis revealed superior energy dissipation in specimens with higher PVA fiber content, emphasizing the effectiveness of fiber reinforcement in enhancing structural performance. Overall, the study underscores the importance of optimizing PVA fiber dosage to maximize structural resilience and load-bearing capacity in PVCC-layered concrete beams with coal ash.