Natural Crack Growth Research Articles

Development of Automatic Crack Growth Simulation Program Based on Finite Element Analysis

A crack growth simulation program based on the advanced iterative-finite element method (AI-FEM) was developed to predict realistic crack growth of structures. The developed program was suggested to calculate the exact stress intensity factor for arbitrary structures by regenerating the crack tip mesh as the crack grows. The main advantages of the developed program are to estimate each different crack growths along the crack tip line and to simulate the cracking transition from a surface crack to a through-wall crack under a complex stress field. For these purposes, the sensitivity analyses were performed for various influence variables on stress intensity factors, such as element types and crack dimensions. Based on the results of sensitivity analyses, the appropriate criteria for crack tip modeling to be used in AI-FEM were suggested to calculate sufficient converged SIF. The program developed in this research was validated through stress corrosion crack growth and natural crack growth examples including cracking transition, and it was confirmed that the program simulates crack growth well and has reasonable methods for cracking transition.

Surface to Through-Wall Crack Transition Model for Circumferential Cracks in Pipes

Abstract In this paper, finite element (FE) analyses were performed to update and also extend the applicable ranges of the existing KI and crack-opening displacement (COD) solutions for nonidealized through-wall cracks (TWCs). Then, a surface to TWC transition model was proposed based on these solutions. The proposed model provides a criterion which determines when the final surface crack (SC) should transition to a TWC. It also provides a criterion to determine the two crack lengths (at the inner diameter (ID) and outer diameter (OD) surfaces) of the initial nonidealized TWC. Furthermore, crack growth of nonidealized TWCs can be simulated by using the proposed method. Finally, the proposed model was verified by demonstrating that it can well predict the surface to through-wall transition behavior when compared to the natural crack growth simulations.

Mid- and High-Cycle Fatigue of Welded Joints in Steel Marine Structures: Effective Notch Stress and Total Stress Concept Evaluations

The characteristic far field response spectrum of welded joints – the governing fatigue sensitive locations in steel marine structures – is predominantly linear elastic, meaning mid- and high-cycle fatigue (MCF and HCF) is most important for design. Using the effective notch stress- and the total stress concept, involving respectively Se and ST as intact- and cracked geometry fatigue strength criterion, one MCF-HCF resistance curve has been obtained for all welded joints. A generalised random fatigue limit model explicitly incorporating the MCF life time and HCF strength limit scatter provides statistically the most accurate fatigue strength and fatigue life time estimates. Similar MCF performance is obtained for Se and ST. Although crack growth dominates the MCF damage process, the results for an initiation related criterion like Se and natural crack growth related criterion like ST are similar. Adopting Se rather than ST as fatigue strength criterion naturally related to the crack initiation dominated HCF region showing the largest data scatter may explain the better effective notch stress concept HCF performance. Since the HCF resistance scatter is relatively large, the MCF-HCF generalised random fatigue limit model design curves show approximately 1-slope behaviour. meaning that for design purposes a linear Basquin model approximation rather than a piecewise continuous bi-linear MCF-HCF formulation according to guidelines, standards and classification notes should be adopted.

Nonidealized Surface to Through-Wall Crack Transition Model for Axial Cracks in Cylinders

Recent studies have shown that a subcritical surface crack, due to primary water stress corrosion cracking (PWSCC), can transition to a through-wall crack (TWC) with significant differences between the inner diameter (ID) and outer diameter (OD) crack lengths. This behavior has been observed for both circumferential and axial cracks. Recently, a surface to TWC transition model has been developed for circumferential cracks using existing K and COD (crack opening displacement) solutions for nonidealized circumferential TWCs. In this paper, a similar crack transition model (CTM) was developed for axial cracks. As a first step, a study was conducted to define the appropriate crack front shape for nonidealized axial TWCs. Then, elastic finite element analyses were carried out to develop K and COD solutions using these crack front shapes. The newly developed solutions were utilized for the CTM. The present CTM includes a criterion for transitioning the final surface crack to the initial nonidealized TWC. This criterion determines when the transition should occur (based on surface crack depth) and determines the two crack lengths (at ID and OD surfaces) of the initial nonidealized TWC. Furthermore, nonidealized TWC growth calculation can be conducted using the proposed model. Example results (crack length and COD) obtained from the proposed model were compared to those obtained from the natural crack growth simulations. Results presented in this paper demonstrated the applicability of the proposed model for simulating axial crack transition.

Microstructural-based Analysis and Modelling of the Fatigue Behaviour of Cast Al-Si Alloys

This paper describes a microstructural-based high cycle fatigue behaviour model applied to cast Al-Si alloys used in an automobile context. These materials are characterized by the presence of different microstructural heterogeneities at different scales: the aluminium matrix (DAS/SDAS and the precipitation hardening level), inclusions (Si particles and intermetallic) and casting defects (porosity). It is shown that the effects of these factors on the HCF damage mechanisms are important and can depend on the loading mode. A multiaxial fatigue test campaign has been carried out using three cast aluminium alloys, fabricated by different casting processes (gravity die casting and lost foam casting), associated with several heat treatment(T7 and Hot Isostatic Pressing-HIP). The HIP treatment is used to eliminate or minimise the porosity. The first part of the article is dedicated to the experimental characterization of the HCF damage mechanisms. With regard to the effect of the casting defects, a study of natural fatigue crack growth and artificial long crack growth is presented and subsequently used to choose an appropriate fatigue strength criterion to take into account the effect of defects, for different loading modes (tension, torsion and combined tension-torsion). Finally, a flexible modelling framework, providing the possibility of combining any two suitable criteria, which leads to the construction of a multiaxial Kitagawa-Takahashi diagram, is used.

Natural Crack Growth Analyses for Circumferential and Axial PWSCC Defects in Dissimilar Metal Welds

The natural crack growth analysis (sometimes referred to as advanced finite element analysis (AFEA)) methodology has been developed by the US NRC and the nuclear industry to evaluate the natural crack growth due to primary water stress corrosion cracking (PWSCC) in nickel-based alloy materials. The natural crack growth (or AFEA) methodology allows the progression of a planar crack subjected to typical stress corrosion cracking (SCC)-type growth laws by calculating stress intensity factors at every nodal point along the crack front and incrementally advancing the crack front in a more natural manner. This paper describes the step-by-step procedure enhancements that have been made to the existing AFEA methodology. A significant enhancement was the feature to evaluate axial crack growth, where the crack was contained within the susceptible material. This methodology was validated by performing an AFEA evaluation for the axial crack that was found in the V.C. Summer hot-leg dissimilar metal weld (DMW). Other enhancements to the AFEA methodology include: feature to handle nonidealized circumferential through-wall cracks, mapping of weld residual stress for crack growth, and determination of limiting crack size using elastic-plastic J-integral analysis that included secondary stress (weld residual stress and thermal transient stress) effects.

Multiaxial fatigue behaviour of A356‐T6

ABSTRACTAluminum alloy A356‐T6 was subjected to fully reversed cyclic loading under tension, torsion and combined loading. Results indicate that endurance limits are governed by maximum principal stress. Fractography demonstrates long shear mode III propagation with multiple initiation sites under torsion. Under other loadings, fracture surfaces show unique initiation sites coincidental to defects and mode I crack propagation. Using the replica technique, it has been shown that the initiation life is negligible for fatigue lives close to 106 cycles for combined loading. The natural crack growth rate has also been shown to be comparable to long cracks in similar materials.

Detecting natural crack initiation and growth in slow speed shafts with the Acoustic Emission technology

This paper presents results of an experimental investigation to assess the potential of the Acoustic Emission (AE) technology for detecting natural cracks in operational slow speed shafts. A special purpose built test rig was employed for generating natural degradation on a shaft. It was concluded that AE technology successfully detected natural cracks induced on slow speed shafts.