4102 - Chap 3 FM Design PDF

FATIGUE & FRACTURE
MAAE 4102
P f
Professor
R B
R.
Bell
ll
Department of Mechanical & Aerospace
Engineering
Bell
Chapter 3 - Fracture Mechanics in

Design
Department of Mechanical &

Aerospace Engineering
MAAE 4102 Strength & Fracture
Ch t 3
Chapter
Fracture Mechanics in Design

Design


Design of large complex structures using fracture mechanics
usually means that an attempt is made to minimize fabrication
K K caused
C a
discontinuities which are initiation sites for failures
b b
by
brittle
i l ffracture, ffatigue,
i
stress corrosion
i cracking
ki etc.
IC
To use fracture mechanics in design the basic equation
is required.
Therefore the material toughness KIC must be known.
This material property is measured by laboratory testing.

Design

Crack Tip Deformation

Consider the stress equation in the y direction
KI

y
cos
1
2r 2 2
for 0 0 and y ys
1 K I
ry
2 ys
Plane Stress
Irwin suggested that for Plane

Strain the yield stress in tension
is increased by a factor of 3
1 K I
ry
6 yys
Plane Strain

Design

Cyclic Plastic Zone Size

For reversed or cyclic plastic zone
As the nominal tensile stress is
reduced, the plastic region near the
crack tip
p is p
put into compression
p
by the surrounding elastic body.
Thus the stress at the crack tip is
twice the value of the Yield Stress
2
1 K I
1 K I
ry
2 2 ys 8 ys
2
1
ry
6
KI

ys
Plane Strain
Plane Stress
1 K I
1 K I
ry
6 2 yys
24 . yys
Plane Strain

Design

Fracture Toughness Testing

KIC is the critical SIF at which rapid (unstable)
crack extension occurs.
KIC depends
d
d on:
Temperature
Strain
S
rate
Corrosive environment
constraint
t i t.
ASTM Spec. E399-83
E399 83
Design

Plane Strain Fracture Toughness KIC

Material Property
K IC C aC
E-399-83 is very restrictive with respect to specimen size

requirements in order to obtain elastic plane strain behaviour
This limits the KIC approach to:
In an elastic field
Brittle materials
Low testing temp below
service temp
Very high strain rates
3
y
cos 1 sin sin
2
2
2
2 r
Let
y ys
Design

Plane Strain Fracture Toughness KIC

Plastic zone size
1 K I
ry
2 ys
At instability K I K IC
Limiting plastic zone size
1
ry
2
K IC

ys
This is under PLANE STRESS

Under PLANE STAIN conditions
ry ( Plane Strain
K IC

ys

Design

KIC Testing
ASTM have established the following Conditions:
K IC
a 2 .5

ys
K
W 5.0 IC

ys
crack length
K IC
B 2. 5
ys
Specimen thickness
Specimen width
This gives a specimen thickness approximately 50 times ry

2
2.5 IC
YS
S i
Specimen
hi k
B
thickness

47
2
Plastic zone size ry 1 K IC
YS
6
These dimensions insure that:
1. The test specimen is large enough so that the elastic field is much larger than the plastic zone
Therefore the plastic zone ahead of the crack can be neglected
2 There is a tri-axial stress field
Therefore the shear stress can be neglected and Mode I plane strain opening mode is expected
Design

KIC Test Procedure

1. Determine specimen
dimensions
2. Select specimen
1.
2
2.
3.
4.
Three point bend specimen

Compact tension specimen
Arc shaped specimen
Disc shaped specimen

Design
10

KIC Specimens
Disc Specimen
p
C Specimen

Design
11

KIC Test Procedure

3. Fatigue
g crack the
specimen Kf < 0.6 KQ

Design
12

KIC Test Procedure

4 Test Procedure
4.
1. Loading
2. Test record
3 Measurement
3.

Design
13

KIC Test Procedure

5. P - Analysis
6 Establish
6.
E t bli h PQ

Design
14

KIC Test Procedure

5. P - Analysis
6 Establish
6.
E t bli h PQ

Design
15

KIC Test Procedure

7.
Calculate KQ for a bend specimen

3
5
7
9
1
2
2
2
PQ S a 2
a
a 2
a
a
2.9 4.6 21.8 37.6 38.7
KQ
3
w
w
w
w
BW 2 w
8.
Check the ASTM restrictions on a, B and W

K IC
a 2.5

ys
K IC
B 2.5

ys
crack length
g
K IC
W 5.0

ys
Specimen thickness
2
Specimen width

Design
16

KIC Test Procedure

9. Then KQ = KIC
10. KQ can be calculated for each
specimen from the equations below
PQ S
KQ
Bend Specimen
BW
Compact Tension Specimen
KQ
a
f
W
PQ
BW

Design
a
f
W
17

Example
p of KIC Test
High Strength Aluminum

Design
18

Examples of KIC Tests

Testt Specimen
T
S i
Dimensions
Mi i
Minimum
Required B
FYS
(ksi)
FT
(ksi)
B
(in
a
(in)
W
(in)
P5
(lb)
Pmax
(lb)
PQ
(lb)
KQ
(ksi%in)
7001-T75
very high
strength Al Fig 5.11
70.6
80.5
1.37
1.08
2.00
3,140
3,150
3,150
19.9
19.8
Valid
0.2
18 Ni maraging
steel - Fig 5.10
190.0
196.0
1.24
0.95
3.50
22,950
22,950
22,950
113.0
113.0
Valid
0.88
12 Ni maraging
steel - Fig 5.12
183.0
191.0
1.00
0.46
3.00
55,000
80,150
55,000
143.0
Invalid
3.2
A517 steel
Fig 5.13
110.0
121.0
2.00
2.60
6.00
47,800
66,000
47,800
150.0
Invalid
2.5
Material and Fig

Design
KIC
2
(ksi%in B 2.5 KIC
YS
19

Example of KIC Test

18 Ni maraging Steel

Design
20


Testt Specimen
T
S i
Dimensions
Mi i
Minimum
Required B
FYS
(ksi)
FT
(ksi)
B
(in
a
(in)
W
(in)
P5
(lb)
Pmax
(lb)
PQ
(lb)
KQ
(ksi%in)
7001-T75
very high
70.6
80.5
1.37
1.08
2.00
3,140
3,150
3,150
19.9
19.8
Valid
0.2
18 Ni maraging
steel - Fig 5.10
190.0
196.0
1.24
0.95
3.50
22,950
22,950
22,950
113.0
113.0
Valid
0.88
12 Ni maraging
steel - Fig 5.12
183.0
191.0
1.00
0.46
3.00
55,000
80,150
55,000
143.0
Invalid
3.2
A517 steel
Fig 5.13
110.0
121.0
2.00
2.60
6.00
47,800
66,000
47,800
150.0
Invalid
2.5
Material and Fig

Design
KIC
2
(ksi%in B 2.5 KIC
YS
21

Example of KIC Test
12 Ni,, 5 Cr,, 3 Mn
Maraging Steel

Design
22


Testt Specimen
T
S i
Dimensions
Mi i
Minimum
Required B
FYS
(ksi)
FT
(ksi)
B
(in
a
(in)
W
(in)
P5
(lb)
Pmax
(lb)
PQ
(lb)
KQ
(ksi%in)
7001-T75
very high
70.6
80.5
1.37
1.08
2.00
3,140
3,150
3,150
19.9
19.8
Valid
0.2
18 Ni maraging
steel - Fig 5.10
190.0
196.0
1.24
0.95
3.50
22,950
22,950
22,950
113.0
113.0
Valid
0.88
12 Ni maraging
steel - Fig 5.12
183.0
191.0
1.00
0.46
3.00
55,000
80,150
55,000
143.0
Invalid
3.2
A517 steel
Fig 5.13
110.0
121.0
2.00
2.60
6.00
47,800
66,000
47,800
150.0
Invalid
2.5
Material and Fig

Design
KIC
2
(ksi%in B 2.5 KIC
YS
23

Example
p of KIC Test
A517 Steel

Design
24


Testt Specimen
T
S i
Dimensions
Mi i
Minimum
Required B
FYS
(ksi)
FT
(ksi)
B
(in
a
(in)
W
(in)
P5
(lb)
Pmax
(lb)
PQ
(lb)
KQ
(ksi%in)
7001-T75
very high
70.6
80.5
1.37
1.08
2.00
3,140
3,150
3,150
19.9
19.8
Valid
0.2
18 Ni maraging
steel - Fig 5.10
190.0
196.0
1.24
0.95
3.50
22,950
22,950
22,950
113.0
113.0
Valid
0.88
12 Ni maraging
steel - Fig 5.12
183.0
191.0
1.00
0.46
3.00
55,000
80,150
55,000
143.0
Invalid
3.2
A517 steel
Fig 5.13
110.0
121.0
2.00
2.60
6.00
47,800
66,000
47,800
150.0
Invalid
2.5
Material and Fig

Design
KIC
2
(ksi%in B 2.5 KIC
YS
25

Effects on Toughness
Constraint
Temperature
Design
26

Effect of Loading Rate on Toughness
Loading Rate

Design
27

Effect Thickness on Toughness

Design
28


Goal: To p
provide safe, fracture resistant structures
Traditional Approach
Given:
Involves:
Material
Design stress level
Codes
Detailing members so that design stress is exceeded
Assumes:
Perfect fabrication no flaws

Design
29


Fracture Mechanics Approach
Selection of Material given
Discontinuities exist from:
Fabrication
Cyclic loading
St
Stress
corrosion
i cracking
ki
Some level of notch toughness is desirable
Fracture Mechanics makes this method more quantitative

Design
30


Fracture Mechanics Aids the Designer In:
Materials Selection
Design Stress Levels
Tolerable crack sizes for inspection and
quality control

Design
31


The design Process Involves:
Selecting type and overall dimensions of structure

Size of tension members
P f
Performance
criteria
it i
Minimum cost
Least cost
Maximum resistance to fracture
Specified design life
Loading rate
Operating temperature etc.
Stress or stress range

Design
32


We must accept that flaws exist:
We will confine ourselves to LEFM to:
HOWEVER
Design fracture resistant structures to prevent brittle fracture

Fortunately most materials behave in non plane strain at service
temperatures
When designs become more complex

Hi h strength
High
t
th or thi
thick
k sections
ti
are used
d in
i place
l
off rivetted
i tt d
sections
Fabrication and construction become more complex
Loading levels increase
Actual factors of safety decrease because of computer designs
The probability of brittle fracture in large complex structures

increase
Design
33

FM Design against final failure

K IC C aC
C crack geometry factor
Critical flaw size
K
ac IC
C
Determine KIC
Select probable flaw type

i e KI equation
i.e
Determine the stress vs flaw size curve

Design
34

FM Design against final failure

To include a safety factor
K
K I Design IC
2
To minimize the possibility of

Brittle Fracture the designer can control
3 primary factors
Other factors such as
Material toughness
Normal stress
Flaw size in structure
(inspection
Temperature
Loading rate
Residual stress
These only effect the primary

f t
factors
Design
35

Selection of Materials
Critical crack size
2
K IC
ac
YS
Can choose this as an index
How high must this be to ensure

Satisfactory performance
Choice depends on:
Type of structure
q
y of inspection
p
Frequency
Access for inspection
Quality of inspection
Design for inspection
Consequences of failure
Redundancyy of load p
paths
Probability of overload
Fabrication costs
Material costs

Design
36

Critical Crack Size as a Function of

Yield Strength and Toughness
Through
g thickness crack
in a wide plate
K IC design a
1 K IC
a
design
Fys
Assumed
KIcIc Values
(ksi%% in.)
F = 100%Fysys
F = 75%Fysys
F = 50%Fysys
F = 25%Fysys
260
80
0.06(260)
0.11(195)
0.24(130)
0.96(65)
220
110
0.16(220)
( )
0.28(165)
( )
0.64(110)
( )
2.55(55)
( )
180
140
0.39(180)
0.68(135)
1.54(90)
6.16(45)
180
220
0.95(180)
1.69(135)
3.80(90)
15.22(45)
140
260
2.20(140)
3.90(105)
8.78(70)
35.13(35)
110
170
1.52(110)
2.70(82.5)
6.08(55)
24.33(27.5)
80
200
3.98(80)
7.07(60)
15.92(40)
63.66(20)
40
100
3.98(40
7.07(30)
15.92(20)
63.66(10)
(ksi)
2 K IC
2a
design
Critical Flaw Size, 2a (in.)

(actual design stress level, ksi,
is shown in parenthesis)

Design
37

Leak Before Break

K <KIC
Leak before break
K >K
KIC
Brittle Fracture

Design
38

Leak Before Break - Example
Construction of a 3 ft. diameter pressure vessel

Operating pressure 2000 psi.
Material
Fracture toughness 60 ksiin

Yield strength 85 ksi at the operating temp
Wall thickness 0.75 in.

Design requirement Leak before break
Periodic inspection The technique can reliably detect a
crack with a surface length of > 0.5 in.
Will the vessel leak before burst when the surface length
off th
the crack
k is
i smaller
ll than
th this
thi size?
i ?
What is the largest crack which can develop and still
maintain the leak before burst criterion?
Design
39

Leak before Break - Solution

K IC 60 ksi in.
p 2000 psi
Y 85 ksi
r
d
18 in.
2
t 0.75 in.
Stress Intensity Factor
Thumbnail crack in a plate in tension
1
KI
1.12 a
Q
Q is the shape factor and depends on c and a
Vessel is thin r t
P r 2000 18
48 ksi
t
0.75
48
0.56
Stress ratio
Y 85
Hoop Stress

Design
40


For leak before burst criteria
K IC K for a crack of a 0.75 in.
K IC
60
a
Q
1.12
48.0 (0.75)
Q
1.12
Q 1.982
U i the
Using
th Fig.
Fi for
f Q 1.892
1 892 andd
0.56
Y
the surface length that can be found

a
0.40
0
2c
0.75
c
2 0.4
c 0.938 and
2c 1.875
Therefore a surface crack of length1.875 in.

O smaller
Or
ll will
ill ensure th
thatt th
the vessell will
ill
Leak before break.
Also the vessel will not fail catastrophically
Before a crack of 0
0.5
5 in
in. can be found
found.

Design
41

Cracking of CANDU Pressure Tubes
In 1974 water leaked from the primary transport system into the
gas annulus
The Zircaloy-2 tubes were removed and it was found that the
l k was in
leak
i the
th area off the
th rolled
ll d joint
j i t
Design
42

In a Pickering reactor there are 139 pressure tubes, each about 6 m (240 in) long,
4 1 mm (0.162
4.1
(0 162 in) wall thickness and 103 mm (4
(4.07
07 in) inside diameter
diameter.
They are made from a Zirconium alloy with 2.5% niobium Zr-Nb.
The pressure tubes are joined to end fittings which are made of stainless steel.

Design
43

Leak Before Break - Example
The stainless steel end fitting was

cut away and 3 cracks were
revealed in the tube
When rolling the tubes into the end

fittings the rolls extended beyond
the parallel part of the end fittings
to produce an over-extended joint
This introduced large residual

stresses
The cause of the cracking was

attributed to Delayed Hydride
Cracking (DHC)

Design
44

Delayed Hydride Cracking
The stainless steel end fitting was

cut away and 3 cracks were found
in the area of high residual stress
Hydrogen, normally in the pressure
tubes had migrated to the area of
high
g residual stress and a small
crack initiated
Propagation was by fracture of the
hydrides which are brittle when
cold
Once initiated the crack proceed to
grow through the wall thickness by
repeated formation and fracture of
the hydrides when the system was
cold
When the system was hot the
hydrogen was in solution and crack
growth did no proceed
Design
45

The cause of the rolling problem was

badly worn rolls which rolled the tubes
into the tapered section of the end fitting
The residual stress reached levels of 700
MPa
Properly rolled joints had levels of 150
MPa
Fuel channel safety was not significantly
effected because of the leak-before-break
criterion
Cracks were about 15-20 mm (0.6-0.8
in.) in surface length and were confined to
a very small region
The crack lengths were significantly less
than the critical crack length of about 3 in.
The leak-before-break criterion was well
demonstrated

Design
46

Leak Before Break - Candu
Tube diameter of 100 mm

Operating pressure 11.3 MPa.
Material - Zr-2-2.5Nb
Fracture toughness 60 MPam

Yield strength 433 MPa at the operating temp of 280oC
Wall thickness 4 mm.

Design requirement Leak before break
Include a safety factor of 3
What is the critical crack length
g ((CCL))

Design
47


Y 433 MPa
K IC 55 MPa m.
p 11.3 MPa
d
50 mm.
2
t 4 mm.
Stress Intensity Factor
Thumbnail crack in a plate in tension
1
KI
1.12 a
Q
Q is the shape factor and depends on c and a
Vessel is thin r t
P r 11.3 50
141 MPa
t
4
141
0.33
Stress ratio
Y 433
Hoop Stress

Design
48


For leak before burst criteria
K IC K for a crack of a 4 mm.
K IC
a
Q
1.12
55 141 (0.004)
1.12
3
Q
Q 0.936
U i the
Using
th Fig.
Fi for
f Q 0.936 andd
0.33
Y
the surface length can be found

a
0.08
2c
0.004
2c
0.08
2c 0.05m i.e. 2c 50mm
Therefore a surface crack of length 50 mm.

O smaller
Or
ll will
ill ensure th
thatt th
the vessell will
ill
Leak before break.
The CCL is ~ 50 mm

Design
49

References
J.M. Barsom and S.T. Rolfe, Fatigue & Fracture Control in Structures,
Prentice Hall, 1987.
P.A. Ross-Ross, The Investigation into the Cracking of Pressure Tubes in

Pickering Units 3 and4, From Steam to Space, CSME 1996.
Standard Method for Plane-Strain Fracture Toughness

g
of Metallic
Materials. ASTM Specification E-399-83
Chapter 3- Fracture Mechanics in

Design
50

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FATIGUE & FRACTURE

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

MAAE 4102 Strength & Fracture

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Fracture Mechanics in Design

To use fracture mechanics in design the basic equation

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Crack Tip Deformation

Irwin suggested that for Plane

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Cyclic Plastic Zone Size

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Fracture Toughness Testing

Department of Mechanical &

Plane Strain Fracture Toughness KIC

E-399-83 is very restrictive with respect to specimen size

Department of Mechanical &

Plane Strain Fracture Toughness KIC

This is under PLANE STRESS

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

This gives a specimen thickness approximately 50 times ry

Department of Mechanical &

KIC Test Procedure

Three point bend specimen

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Calculate KQ for a bend specimen

Check the ASTM restrictions on a, B and W

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

KIC Test Procedure

Compact Tension Specimen

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Examples of KIC Tests

Material and Fig

Chapter 3 - Fracture Mechanics in

Department of Mechanical &

Example of KIC Test