Crack Retardation Research Articles

Equations for efficient cycle-by-cycle computation of fatigue crack retardation and acceleration due to amplitude changes

The paper presents an efficient methodology for computation of the evolution of the fatigue crack retardation and acceleration effects due to crack closure during variable amplitude loading. The presented approach can lead to a very effective tool for estimation of residual fatigue life of engineering structures. Conventionally, consideration of variable-amplitude loading is either computationally too demanding, such as in finite element modelling, or challenging to unify the strip-yield model with another computational code. The simple analytical formulae available in literature are based on residual stress, which does not describe correctly the delayed retardation effect and in some cases it can be non-conservative. This work presents simple analytical equations describing the development of the crack closure based on the results of the strip-yield model for amplitude changes at the load ratio R = 0.1. The parabolic function enables simple computation of the maximum crack closure occurring after an overload without running any simulation. The equations also enable computation of crack closure behaviour following amplitude changes with the consideration of various cyclic material properties reflected in the tuneable ratio between the monotonic and cyclic plastic zone sizes.

Bonded and prestressed fatigue crack retarders based on Fe-SMA

A bonded and prestressed retarder concept is proposed in this work. The shape memory effect of an iron-based shape memory alloy (Fe-SMA) has been exploited to realize a desirable self-prestressing mechanism, resulting in compressive stresses in the parent structure. The synergistic prestressing and added fail-safe features of bonded and prestressed Fe-SMA retarders desirably restrain the fatigue crack growth. The fatigue crack growth behaviour in metallic plates reinforced with bonded and prestressed retarders is experimentally studied in this work. A test campaign has been implemented to investigate the effects of prestressing, as well as the influence of the relative location between the Fe-SMA retarders and the initial crack tip on the crack growth behaviour and fatigue crack life extension. The experimental results show that the prestressing of retarders desirably extends the fatigue crack growth life. More extension in fatigue life can be achieved by positioning the bonded prestressed retarders from 40 to 20 mm before the initial crack tip, the desirable retardation due to beneficial compressive prestressing and added load path on the small crack is significant. The findings in this work imply that it is beneficial to proactively reinforce the fatigue-prone locations in metallic structures with bonded and prestressed Fe-SMA retarders in order to extend the service life.

Finite element analysis of fretting fatigue properties of GH4169 superalloy considering the surface treatments

In the present work, the fretting fatigue properties of GH4169 superalloy at 650℃ were investigated through numerical simulation considering the influences of the surface treatments. As a detrimental phenomenon, fretting fatigue involves fatigue and wear simultaneously, where the coefficient of friction and residual stress fields induced by the surface coating or modification techniques may affect the fretting fatigue lifetimes by changing the complex stress state between the two contacting surfaces. The numerical solutions were implemented to compare the crack initiation angles and paths under different surface conditions. The simulation results indicated that fretting fatigue cracks in residual stress fields were tendentiously parallel to the surface resulting in crack retardation and debris peeling, as verified by experimental observations. Additionally, three propagation models were compared to study the effect of compressive loading on the driving force of crack propagation rates, especially where compressive residual stresses was present. The combination of the linear superposition model with the Harter-T method was proven to be more accurate in the fretting fatigue life prediction, which may provide a modeling basis for service life prediction of engineering components in many practical applications.

Численное исследование направления роста трещины в квазихрупком материале в градиентном поле температуры

The elliptical crack growth in a quasi-brittle material located in a gradient field of temperature next to the melting temperature for the thermodynamic phases of the material is studied. The elastic properties of the material are assumed to have an obvious dependence on temperature. This is typical for materials located close to the melting point. To determine the direction of crack growth, a gradient strain criterion is introduced, which assumes crack growth from the point of maximum elastic strain of the material toward its minimum. Depending on the orientation of the crack axis relative to the direction of the temperature gradient, the crack retardation, the change of the crack growth direction, or the appearance of secondary lateral cracks in the vicinity of the main crack tip are possible. The calculated results and the admissibility of applying the introduced criterion have been successfully validated by an experiment with thermal fracture of freshwater ice blocks. As a result, the phenomena predicted by finite element calculations have also been discovered experimentally.

Study on the influence mechanism of calcium carbonate particles on mechanical properties of microcrack cement

Restoration of cementitious materials using induced calcium carbonate precipitation is a highly anticipated research domain, offering a promising avenue of study within the realm of environmentally friendly methodologies. In this study, the numerical simulation software PFC is employed to simulate internal microcracks within cement stone subject to calcium carbonate remediation. The simulation outcomes unveil the repair mechanism from a microscopic perspective, providing theoretical guidance for indoor experiments. The research results reveal that microcracks detrimentally impact the compressive strength of cement stone, experiencing a drastic reduction of 79.51% at a 6.56% crack rate, reaching merely 6.65 MPa. Calcium carbonate serves to fill, bond, and support the microcracks, retarding crack development and structural deterioration, thereby enhancing the compressive strength of the cement stone. The compressive strength of the cement stone after repair correlates positively with the bonding strength and filling rate of calcium carbonate, while particle size has little effect. The repair effect on small-size microcracks with size of 0.3 mm × 1 mm is better, and large-size microcracks with size of 0.7 mm × 3 mm will have irreversible effects on cement stone. Calcium carbonate particles will play a better repair effect when the filling rate is in rage of 50%− 80%.

Proactive strengthening of U-rib butt-welded joints in steel bridge decks using adhesively bonded Fe-SMA strips

U-rib butt-welded joints are one of typical fatigue-prone details in early aging orthotropic steel bridge decks, which poses a potential threat to the structural behavior and safe operation of steel bridges. Therefore, it is of great importance to seek out an effective way for retrofitting fatigue cracks. This study proposes an efficient prestressing technique using bonded iron-based shape memory alloy (Fe-SMA) to strengthen cracked U-rib butt-welded joints proactively. A series of static and fatigue tests were conducted on the cracked specimens to investigate the feasibility and fatigue improvement of the proposed technique. Results from the experiments demonstrated that applying prestressing force by heating Fe-SMA strips is a convenient and reliable technique. Activated Fe-SMA strips could introduce significant compressive stresses and provide additional stiffness for the cracked components. This led to a reduction of the mean stress and fatigue stress ranges at the U-rib butt-welded joints under cyclic loading. All the cracked specimens strengthened with adhesively bonded Fe-SMA strips presented excellent fatigue performances, with a maximum equivalent fatigue life extension of 4.09 times compared to the specimen before cracking. Numerical simulation was also performed to better understand the test results. It was demonstrated that prestressed Fe-SMA strengthening could decrease the mode-I stress intensity factor (SIF) at the crack tip, indicating the beneficial effects of the prestressing in retarding crack and its further propagation. In conclusion, the use of adhesively bonded Fe-SMA strips for strengthening cracked butt welds is highly effective in improving the fatigue performance, even better than bonding CFRP.

Phase field modeling of fatigue crack growth retardation under single cycle overloads

A zone-based crack retardation model that responds to single cycle overloads is applied to a phase field fatigue framework. Fatigue crack growth is incorporated through the degradation of fracture toughness in the phase field fracture model where a representative loading strategy is followed instead of explicit cyclic loading. The model is demonstrated to capture Paris-Erdogan law type behavior. Crack growth retardation following an overload cycle is simulated through a zone ahead of the crack tip taking inspiration from existing plastic zone-based retardation models. The retardation zone is described through a strain energy density limit, with the overload ratio controlling the extent to which the fatigue damage accumulation rate is slowed inside the retardation zone. The model is implemented utilizing user subroutines in Abaqus with coupled-temperature displacement elements where temperature acts as a stand in for the phase field parameter. The model is found capable of reproducing experimental levels of fatigue life gains and reduction in crack growth rate for compact tension and center-cracked tension panel specimens when various overload levels are applied. Furthermore, the model is demonstrated to be able to capture complex crack paths with great accuracy.

Resistance of Heterogeneous Metal Compositions to Fracture under Dynamic and Cyclic Loads

This paper presents the results of experimental data analysis, which indicate an increased resistance of heterogeneous multilayer clad composites to dynamic loading destruction compared with homogeneous materials. The reason for this is the crack retardation caused by lamination at the boundary of the layers. The destruction of heterogeneous compact composite samples by cyclic off-center stretching also occurs with crack retardation, with the fractogram clearly demonstrating the transverse tightening of the sample section. We argue that crack nucleation plays a decisive role in the process of dynamic destruction of heterogeneous composites obtained by both multilayer cladding and explosion welding. This study presents generalized calculated data confirming the influence of the sign and magnitude of residual stresses (the appearance of a stress discontinuity) on the conditions of fatigue surface crack nucleation and propagation. Unlike homogeneous materials obtained by casting, forging (rolling), or cladding, which are characterized by a linear dependence of the crack propagation velocity on the dynamic stress intensity coefficient, for multilayer composites consisting of strong and viscous layers, a sharp crack deceleration is observed. This is due to the transition of the crack boundary between the strong and viscous layers. This paper presents studies of the corresponding properties of adjacent layers on the integral characteristics of the deposited composite.

Microstructural insights into fatigue short crack propagation resistance and rate fluctuation in a Ni-based superalloy manufactured by laser powder bed fusion

The microstructural sensitivity of fatigue short crack path and its propagation rate in a Ni-based superalloy GH4169 manufactured by laser powder bed fusion (LPBF) was investigated at room temperature. In-situ digital image correlation (DIC) observation and post-mortem microstructural analysis around the crack path were performed. The results show that the intragranular cracks developed in the shear cracking mode are closely aligned along the activated slip bands in the γ-matrix grains with the crystallographic characteristics of parallel to the γ-{111} slip planes. Multiple slip was also activated, causing the crack retardation or deflection. Low-angle grain boundaries and subgrain boundaries were shown to cause deflections of intragranular cracking, while high-angle grain boundaries significantly arrested the short crack propagation. Moreover, the resistance of grain boundaries to short cracking was assessed using combined metrics including the crystallographic and microstructural parameters of twist angle, the Schmid factor and the geometrical compatibility factor. These site-specific microstructural analyses around the crack path provide insights into the microstructural origins of resistance to the short crack propagation as well as an interpretation of the observed significant fluctuations in the crack propagation rate.

Effect of ultrasonic rolling on crack propagation behavior of Ti6Al4V titanium alloy laser welded joints

This study investigated the effect of ultrasonic rolling on the fatigue resistance of Ti6Al4V titanium alloy laser welded joints, with an emphasis on crack growth rate. Multiple analyses were conducted on samples subjected to different numbers of rolling passes, including analysis of surface roughness, morphology, cross-section structure, hardness, fatigue fracture, and residual stress. Ultrasonic rolling was found to considerably enhance the life cycle of the sample. One, three, and five rolling passes resulted in fatigue life increases of 17.14%, 46.38%, and 66.61%, respectively, when compared with untreated samples. Treated samples exhibited rough and intricate crack propagation paths on fracture surfaces, along with numerous secondary cracks. Fatigue striation width decreased by 48.6%, 62.5%, and 69.4% for samples receiving one, three, and five rolling passes, respectively. These fatigue striations, which were narrower and more densely distributed, indicate that ultrasonic rolling effectively increases fatigue life. The ultrasonic rolling treatment enhanced fatigue performance and reduced the rate of crack propagation due to changes in surface compressive residual stress, microstructure, microhardness, and improved surface quality. Crack retardation primarily occurred in initial stage of crack propagation and stable propagation stages, whereas inhibitory effects weakened during the final fracture stage due to superposition and offset of the higher driving force with compressive residual stress. In summary, the study demonstrates that treatment via ultrasonic rolling is an effective method for improving fatigue life and fracture toughness in Ti6Al4V titanium alloy laser-welded joints.

Crack propagation analysis of slewing bearings in wind turbines applying a modified sub-model technology

As slewing bearings in wind turbines are exposed to complex operational environments, they are prone to crack initiation, propagation and evolution that can lead to contact fatigue problems. Reliable crack extension prediction is a critical requirement. With the goal of obtaining more accurate crack characteristics, this study proposes a crack initiated contact finite element model (CI-CFEM) targeted at the raceway of slewing bearings by introducing a modified sub-model. In the application of the global finite element model (G-FEM) to the slewing bearing system, the rolling displacements of the ball and the boundary displacements are employed in CI-CFEM to take account of external ring deformations and the support conditions. The crack is embedded using FRANC3D, and the stress intensity factor distribution and propagation characteristics of the crack front are investigated. Furthermore, the effect of external load and the design parameters of the slewing bearing on crack propagation are explored, providing insight for optimizing the design of slewing bearings to extend service life. The results reveal that changing external loads and bearing parameters are an effective means of retarding crack propagation rate, while have relatively minor influence on crack growth angle.

Effect of Fiber Dosage On Mechanical Properties Of Geopolymer Mortar Under The Coupling Of Sulfate Erosion And Dry-Wet Alternation

Coastal buildings are susceptible to long-term sulfate erosion and alternating wet-dry cycles, leading to rapid degradation in mechanical properties and durability. Therefore, there is an urgent need to find a construction material that is superior to ordinary silicate concrete. Geopolymer concrete, an innovative environmentally-friendly material, offers advantages like early strength, fire resistance, and durability. Research reveals that even after sulfate erosion, geopolymer concrete outperforms regular silicate concrete in terms of mechanical properties and durability. However, geopolymer concrete suffers from high brittleness. A remedy is found in the incorporation of fibers, which substantially enhances its mechanical properties and durability. This study investigates the influence of carbon fibers and polypropylene fibers on the mechanical traits of metakaolin-geopolymer mortar, exposed to sulfate action and wet-dry cycles for 60 repetitions. Results indicate that the addition of 0.6% carbon fibers yields the highest compressive strength, while a 1:1 combination of carbon and polypropylene fibers produces peak flexural strength. Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS) confirm uniform fiber distribution within the mortar, reinforcing material bonds and retarding crack propagation. Consequently, mechanical properties and durability are improved.

Fatigue crack propagation in AA5083 structures additively manufactured via multi-layer friction surfacing

Multi-layer friction surfacing (MLFS) is a layer deposition technique that allows building structures from metals in solid state. As approach for additive manufacturing, the re-heating during subsequent deposition processes is significantly lower compared to fusion-based techniques. Available research work presents promising properties of MLFS structures from aluminum alloys, reporting no significant directional dependency in terms of tensile strength. The present study focuses on the fatigue crack propagation behavior and the role of layer-to-substrate (LTS) as well as layer-to-layer (LTL) interfaces. Compact tension specimens were extracted in different orientations from the MLFS stacks built from AA5083. The crack propagation parallel and perpendicular to the LTL interfaces as well as from the substrate material across LTS interface into the MLFS deposited material was investigated. The results show that LTL interfaces play no significant role for the crack propagation, i.e. specimens with LTL interfaces perpendicular and parallel to the crack presented no significant differences in terms of their fatigue crack propagation behavior. The specimens where the crack propagated from the substrate material across the LTS interface into the MLFS deposited material showed higher fatigue life than the specimens with crack propagation in the MLFS deposited material only. Crack retardation can be observed as long as the crack propagates within the substrate material, which is associated with compressive residual stresses introduced in the substrate during the layer deposition process.

Microscale failure analysis of the ultra-high-performance polypropylene fibre reinforced concrete panel subjected to high thermal loading induced by fire exposure

To date, many buildings are prone to fire from non-structure systems like high-pressure laminates and insulated cladding systems. Ultra-high-performance concrete (UHPC) has been applied to the cladding systems due to its excellent mechanical properties at room temperature and non-flammable characteristic. To improve its mechanical properties under fire condition, different fibres like PP fibre have been employed to reinforce UHPC. The tensile strengths of these ultra-high-performance PP fibre reinforced concrete (UHPPFRC) panels vary due to the different orientations of internal PP fibres. However, few studies have been carried out on the internal stress and fire resistance of these claddings. Study on understanding the fire behaviours and failure process of the UHPPFRC panel is essential for developing claddings with better fire resistance and durability. In this study, a coupled hygro-thermal–mechanical model is developed to predict the internal stress and temperature distribution within the UHPPFRC panel. The microscopic failure process of PP fibre and porosity change within the panel during heating are all embodied in the model, and its accuracy has been validated. The initial and the residual tensile strengths of the UHPPFRC panel are considered to fluctuate between two extrema due to the random fiber orientation. Based on this, Program Evaluation and Review Technique (PERT) is applied to investigate the effects of fibre dosage and heating rate on retarding crack propagation and failure of the UHPPFRC panel under high temperature. Results from the numerical investigation indicate that 0.55% dosage of PP fibre can effectively postpone crack occurrence and propagation within the UHPPFRC panel at linear elastic phase, and faster heating rate can accelerate the pore pressure generation process. Also, internal fibre orientation is a significant factor affecting the fire endurance of the UHPPFRC panel subjected to elevated temperature, which should be considered for safety and reliability evaluation of the structure.

Unraveling the superlattice effect for hexagonal transition metal diboride coatings

Superlattice structures enable the simultaneous enhancement in hardness (H) and fracture toughness (KIC) of ceramic-like coatings. While a deeper understanding of this effect has been gained for fcc-structured transition metal nitrides (TMN), hardly any knowledge is available for hexagonal diborides (TMB2). Here we show that superlattices can—similarly to nitrides—increase the hardness and toughness of diboride films. For this purpose, we deposited TiB2/WB2 and TiB2/ZrB2 superlattices with different bilayer periods (Λ) by non-reactive sputtering. Nanoindentation and in-situ microcantilever bending tests yield a distinct H peak for the TiB2/WB2 system (45.5 ± 1.3 GPa for Λ = 6 nm) but no increase in KIC related to a difference in shear moduli (112 GPa). Contrary, the TiB2/ZrB2 system shows no peak in H, but for KIC with 3.70 ± 0.26 MPa∙m1/2 at Λ = 4 nm originating from differences in lattice spacing (0.14 Å), hence causing coherent stresses retarding crack growth.

High-strain-rate superplasticity and microstructural evolution in ECAP-processed Mg–6.5Y–1.2Er–1.6Zn–0.5Ag alloy

A warm equal-channel angular pressing (ECAP) procedure was applied to a new Mg–6.5Y–1.2Er–1.6Zn (WEZ612)–0.5Ag alloy with a long-period stacking ordered (LPSO) phase. The microstructure, superplasticity, and deformation mechanism of the WEZ612–0.5Ag alloy were then systematically investigated. Three different precipitation phases formed in the alloy with trace Ag addition, namely LPSO, γ, and nanoprecipitate phases. A remarkable elongation of 726% was attained at 623 K and a strain rate of 0.01 s−1. The strain rate sensitivity index (m) and activation energy (Q) under these deformation conditions were 0.461 and 133.08 kJ mol−1, respectively. These m and Q values confirm that the primary deformation mechanism of the WEZ612–0.5Ag alloy at 623 K was grain boundary sliding assisted by lattice diffusion. The highly stable LPSO phases, γ precipitates, and nanoprecipitates synergistically improved the superplasticity of the alloy by retarding crack propagation and grain growth and by promoting the basal plane slip.

Distribution and evolution of (micro)strain and stresses in flexible, waterproofing membranes using digital image correlation and finite element modelling

High performance of one-component, flexible, waterproofing membranes is fundamental to prevent crack propagation from concrete substrates into coatings and finishing layers. This study investigates the influence of air pores and mineral inclusions in a polymer-cement matrix on stress concentrations and crack propagation by combining physical testing with finite element modelling. During physical testing, surface deformation is investigated and mapped using Digital Image Correlation. Finite element simulations of internal deformation reveal that pores and inclusions retard the crack propagation. Pores delay crack propagation actively by blunting crack tips. Inclusions act as force chains distributing stresses and elasto-plastic deformation over larger volumes inside the membrane. Consequently, yield stresses are locally reached at larger bulk strains retarding crack initiation and propagation. Varying distribution, size and content of pores/inclusions exposes their respective influence on the crack-bridging behavior. Optimizing these parameters can significantly improve the crack-bridging ability and therefore the overall performance of waterproofing membranes.

Numerical analysis of compliance and fatigue life of the CCC specimen

This study presents the numerical evaluation of the compliance in the CCC specimen aiming to assess the crack length inside the specimen. The numerical model considered the elastoplastic behaviour of the specimen, which is modelled using axisymmetric finite elements. The results shown that the propagation of the crack yields a non-linear increase of the compliance. Nevertheless, variation of the compliance is very small for small values of crack radius. Considering a loading sequence composed by four load blocks of constant amplitude, the fatigue crack growth was predicted both using the Paris law and the numerical model. Both predictions agree but only the numerical simulation is able to capture the crack retardation between load blocks.

Bonded and additively manufactured crack retarders: A comparative study of damage tolerance properties

Fatigue crack grows faster in the integral structure than in the riveted structure. This study compares the bonded, cold-sprayed and ultrasonically consolidated crack retarders to increase the fatigue life of integral airframe structure. The 2024-T351 aluminum M(T) specimen reinforced with crack retarders made of AISI 301 and 316L steels, Ti–6Al–4V titanium alloy and unidirectional CFRP laminate are evaluated in terms of fatigue life, delamination resistance and weight efficiency. Specimens were subjected to constant amplitude loading up to the final failure. A substantial decrease in fatigue crack growth rate was achieved using the ultrasonically consolidated AISI 301 crack retarder.

Fatigue crack growth behavior of 42CrMo high-strength steel with tempered sorbite/bainite microstructures: Roles of grain and constituent in microstructures

Microstructural differences through the thickness have always been an attention focus for large-scale steel structures, since they could significantly influence fatigue crack propagation (FCP) characteristics. Here, the effects of microstructure in FCP behaviors of 42CrMo steel were analyzed with emphasis on two different tempered sorbite/bainite (TS/B) microstructures: (i) fine TS/B structures (M42); (ii) coarse TS/B structures (M52). The results show that the FCP rate is relatively slower for M52 than for M42 in the regime through the later stage of near-threshold (I-L) to the early stage of Paris-regime (Ⅱ-E) with low ΔK, but is fairly similar for the two cases in the other ΔK regimes. Under relatively low ΔK, the FCP path of M52 is more tortuous with numerous micro-cracks in B and larger-sized crack deflections at the carbides and boundaries compared to M42, especially in the I-L where fatigue micro-cracks can deflect at the single coarse carbide, thereby resulting in roughness-induced crack closure and crack retardation behavior. Theoretical analysis shows that FCP behaviors are closely related to the cyclic plastic region size (Δrp) at the crack-tip. In the early stage of near-threshold region, Δrp is restricted within a grain-size scale for both steels, thus leading to a similar FCP rate. However, from the I-L to the Ⅱ-E, coarse B/ferrite-grains in M52 are always larger than the Δrp of fatigue crack-tip, and thereby lead to numerous micro-cracks formation and crack deflections at the carbides and B boundaries, inducing crack closure. In the later stage of Paris region, B/ferrite-grains in the two cases are much smaller than Δrp, so that FCP behaviors depend on the microstructure group effects, or overall strength and fracture toughness of materials, which cause the close FCP rate.