Fatigue crack closure: a review of the physical phenomena.

Plasticity-induced, roughness-induced and oxide-induced crack closures are reviewed. Special attention is devoted to the physical origin, the consequences for the experimental determination and the prediction of the effective crack driving force for fatigue crack propagation. Plasticity-induced crack closure under plane stress and plane strain conditions require, in principle, a different explanation; however, both types are predictable. This is even the case in the transition region from the plane strain to the plane stress state and all types of loading conditions including constant and variable amplitude loading, the short crack case or the transition from small-scale to large-scale yielding. In contrast, the prediction of roughness-induced and oxide-induced closures is not as straightforward.

Investigation of fatigue crack closure effect on the evaluation of edge cracks with the fundamental mode of edge waves.

Fatigue cracks often initiate and propagate from edges of structural components. Detection and evaluation of edge cracks could be very challenging, specifically, due to the crack closure phenomenon, which makes fatigue cracks to be partially closed when the applied loading is removed; this usually corresponds to maintenance and NDE inspection conditions. Despite that fatigue crack closure is well investigated, past experimental and theoretical studies related to guided wave-based NDEs largely ignored this phenomenon. In this article, the fundamental symmetric mode of edge waves (ES0) is used to evaluate crack closure effects on the evaluation of fatigue cracks. The experimental studies have demonstrated that the reflected and transmitted signals at different frequencies correlate very well with the length of the open region of fatigue cracks. However, an accurate evaluation of the total crack length can only be conducted under an applied loading, which fully separates the crack faces. Finally, a new FE model has been proposed to simulate the fatigue crack closure and its effects on propagation of ultrasonic bulk and guided waves. The outcomes of FE modelling and experimental study were found in a good agreement.

Influence of Failure-Load Prediction in Composite Single-Lap Joints with Brittle and Ductile Adhesives Using Different Progressive-Damage Techniques.

The usage of adhesively bonded joints, such as single-lap and double-lap joints, is increasing rapidly in aerospace composite structures as a popular alternative to bolts and rivets. Compared to the conventional joining methods such as fastening and riveting, adhesive-bonding technology better prevents damage to composite structures due to the smooth configuration and the mitigation of stress concentration around holes. In this work, the built-in progressive-damage-modeling techniques in Abaqus, including the cohesive zone model (CZM) and the virtual crack closure technique (VCCT), are used to predict the strength and progressive failure of composite single-lap joints subjected to tensile loading. Modeling of an adhesive layer by using a zero/non-zero-thickness cohesive element, cohesive surface, and VCCT is investigated, as is the effect of brittle and ductile adhesives. Two-dimensional finite-element models with different damage-modeling strategies are performed in this study. The failure-load predictions are compared with the experimental results obtained from the literature. For the ductile adhesive, the predicted failure loads using a zero/non-zero-thickness cohesive elements and a cohesive surface are all shown to be in good agreement with the experiments. However, the VCCT technique predicts higher failure loads. For a brittle adhesive, on the other hand, the predictions by zero/non-zero-thickness cohesive elements and cohesive surfaces reveal notable deviations compared to the experimental results. In contrast to the ductile adhesive, the VCCT technique is revealed to be accurate in predicting the brittle adhesive.

Short Fatigue-Crack Growth from Crack-like Defects under Completely Reversed Loading Predicted Based on Cyclic R-Curve.

Understanding short fatigue-crack propagation behavior is inevitable in the defect-tolerant design of structures. Short cracks propagate differently from long cracks, and the amount of crack closure plays a key role in the propagation behavior of short cracks. In the present paper, the buildup of fatigue-crack closure due to plasticity with crack extension from crack-like defects is simulated with a modified strip yield model, which leaves plastic stretch in the wake of the advancing crack. Crack-like defects are assumed to be closure-free and do not close even under compression. The effect of the size of crack-like defects on the growth and arrest of short cracks was systematically investigated and the cyclic R-curve derived. The cyclic R-curve determined under constant amplitude loading of multiple specimens is confirmed to be independent of the initial defect length. Load-shedding and ΔK-constant loading tests are employed to extend the cyclic R-curve beyond the fatigue limit determined under constant amplitude loading. The initiation stage of cracks is taken into account in R-curves when applied to smooth specimens.

Elasticity and Characteristic Stress Thresholds of Shale under Deep In Situ Geological Conditions.

The mechanical properties of shale are generally influenced by in situ geological conditions. However, the understanding of the effects of in situ geological conditions on the mechanical properties of shale is still immature. To address this problem, this paper provides insight into the elasticity and characteristic stress thresholds (i.e., the crack closure stress σcc, crack initiation stress σci, and crack damage stress σcd) of shales with differently oriented bedding planes under deep in situ geological conditions. To accurately determine the elastic parameters and crack closure and initiation thresholds, a new method-i.e., the bidirectional iterative approximation (BIA) method-which iteratively approaches the upper and lower limit stresses of the linear elastic stress-strain regime, was proposed. Several triaxial compression experiments were performed on Longmaxi shale samples under coupled in situ stress and temperature conditions reflecting depths of 2000 and 4000 m in the study area. The results showed that the peak deviatoric stress (σp) of shale samples with the same bedding plane orientation increases as depth increases from 2000 m to 4000 m. In addition, the elastic modulus of the shale studied is more influenced by bedding plane orientation than by burial depth. However, the Poisson's ratios of the studied shale samples are very similar, indicating that for the studied depth conditions, the Poisson's ratio is not influenced by the geological conditions and bedding plane orientation. For the shale samples with the two typical bedding plane orientations tested (i.e., perpendicular and parallel to the axial loading direction) under 2000 and 4000 m geological conditions, the ratio of crack closure stress to peak deviatoric stress (σcc/σp) ranges from 24.83% to 25.16%, and the ratio of crack initiation stress to peak deviatoric stress (σci/σp) ranges from 34.78% to 38.23%, indicating that the σcc/σp and σci/σp ratios do not change much, and are less affected by the bedding plane orientation and depth conditions studied. Furthermore, as the in situ depth increases from 2000 m to 4000 m, the increase in σcd is significantly greater than that of σcc and σci, indicating that σcd is more sensitive to changes in depth, and that the increase in depth has an obvious inhibitory effect on crack extension. The expected experimental results will provide the background for further constitutive modeling and numerical analysis of the shale gas reservoirs.

Study on Fatigue Crack Growth in Rail Steel at Numerical and Experimental Approaches.

Affected by the service environment, the actual service conditions of rail steel are complex, and the safety evaluation methods are limited. In this study, the fatigue crack propagation in the U71MnG rail steel crack tip was analysed by means of the DIC method, focusing on the shielding effect of the plastic zone at the crack tip. The crack propagation in the steel was analysed based on a microstructural approach. The results show that the maximum value of stress of the wheel-rail static contact and rolling contact is in the subsurface of the rail. The test grain size of the material selected along the L-T direction is smaller than that in the L-S one. Within a unit distance, if the grain size is smaller, the number of grains or grain boundaries will be greater so that the driving force required for a crack to pass through the grain boundary barriers will be larger. The Christopher-James-Patterson (CJP) model can well describe the contour of the plastic zone and can well characterize the influence of crack tip compatible stress and the crack closure effect on crack propagation under different stress ratios. The crack growth rate curve at the high-stress ratio is shifted to the left relative to the low-stress ratio, and the crack growth rate curves obtained under different sampling methods have good normalization.

Modeling the Crack Interference in X80 Oil and Gas Pipeline Weld.

Based on the numerical simulation method of the virtual crack closure technique (VCCT), an interference model was established to investigate the physical problem of two interacting cracks of different sizes in the welding zone of oil and gas pipelines. The obtained results of the current interference problem were compared with those of single crack case. Various crack configurations, such as different crack spacing and different crack sizes, were analyzed. The characteristic quantity fluid pressure load P during the crack propagation process, the peak value of the von Mises stress distribution field of the crack growth path, as well as the difference ∆Bx between the peak value of the magnetic induction intensity component at the crack and the value of the magnetic induction intensity component at its symmetrical position were calculated. The crack interaction scale factors, including γP, γMises, and γΔBx, were compared and analyzed. The numerical modeling results show that when the unequal-length double cracks interfere with each other, the cracks are more likely to propagate toward each other. The tendency of the double-cracks to propagate toward each other gradually weakens as the distance between the crack tips increases and is finally the same as that of single-crack cases. It was also found that the effect of large-sized cracks on small-sized cracks is greater than that of small-sized ones on large-sized ones. The numerical modeling results could be applied for the prediction and analysis of multicrack damage in oil and gas pipeline welds.

Effect of Through-the-Thickness Delamination Position on the R-Curve Behavior of Plain-Woven ENF Specimens.

In this study, the effect of through-the-thickness delamination plane position on the R-curve behavior of end-notch-flexure (ENF) specimens was investigated using experimental and numerical procedures. From the experimental point of view, plain-woven E-glass/epoxy ENF specimens with two different delamination planes, i.e., [012//012] and [017//07], were manufactured by hand lay-up method. Afterward, fracture tests were conducted on the specimens by aiding ASTM standards. The main three parameters of R-curves, including the initiation and propagation of mode II interlaminar fracture toughness and the fracture process zone length, were analyzed. The experimental results revealed that changing the delamination position in ENF specimen has a negligible effect on the initiation and steady steady-state toughness values of delamination. In the numerical part, the virtual crack closure technique (VCCT) was used in order to analyze the imitation delamination toughness as well as the contribution of another mode on the obtained delamination toughness. The numerical results indicated that by choosing an appropriate value of cohesive parameters, the trilinear cohesive zone model (CZM) is capable of predicting the initiation as well as propagation of the ENF specimens. Finally, the damage mechanisms at the delaminated interface were investigated with microscopic images taken using a scanning electron microscope.

A Literature Review of Incorporating Crack Tip Plasticity into Fatigue Crack Growth Models.

This paper presents an extensive literature review focusing on the utilisation of crack tip plasticity as a crucial parameter in determining and enhancing crack growth models. The review encompasses a comprehensive analysis of various methodologies, predominantly emphasising numerical simulations of crack growth models while also considering analytical approaches. Although experimental investigations are not the focus of this review, their relevance and interplay with numerical and analytical methods are acknowledged. The paper critically examines these methodologies, providing insights into their advantages and limitations. Ultimately, this review aims to offer a holistic understanding of the role of crack tip plasticity in the development of effective crack growth models, highlighting the synergies and gaps between theoretical, experimental, and simulation-based approaches.

A novel method for residual life assessment of used parts: a case study of used lathe spindles.

In the remanufacturing evaluation process of used spindles, the remaining life of each type is very different due to the differences in the original process, quality, and use conditions. Researching the prediction and evaluation of the remaining life of used spindles has essential engineering significance for improving the accuracy and economics of remanufacturability assessment. Aiming at the fatigue fracture, wear and excessive deformation of the wasted spindle, and considering the factors affecting crack closure and crack development, a residual life prediction evaluation model based on a nonlinear continuous fatigue damage model was proposed. Take the spindle of CAK5085 CNC lathe of a machine tool company as an example to evaluate its remaining life. The accuracy and feasibility of the modified model are verified by comparing the data of the test with the calculated results of the model. The results show that the proposed prediction model can calculate a more accurate stress-life curve, which provides a theoretical basis for the life prediction of remanufactured parts.

Effect of Residual Stresses on Fatigue Crack Growth: A Numerical Study Based on Cumulative Plastic Strain at the Crack Tip.

Residual stresses affect the fatigue behavior, given that compressive stresses delay the phenomenon, while tensile stresses accelerate it. However, the mechanisms behind the effect of residual stresses are not totally understood. A numerical study is developed here to understand the effect of thermal residual stresses (TRSs) on fatigue crack growth (FCG). The crack driving force was assumed to be the cumulative plastic strain at the crack tip. The heating of a region ahead of the crack tip produced elastic compressive TRS, which were 69% of material's yield stress. Alternatively, plastic deformation was produced by severe cooling followed by heating to generate compressive residual stresses. The crack propagation in the compressive residual stress field produced a decrease in the FCG rate. On the other hand, without the contact of crack flanks, the TRS showed no effect on FCG. Therefore, the TRSs only affect FCG by changing the crack closure level.

Empirical Solution of Stress Intensity Factors for the Inclined Inner Surface Crack of Pipe under External Pressure and Axial Compression.

Based on fracture mechanics theory, a finite element method was used to determine the stress intensity factors of the inclined crack on the inner surface of the pipe under axial compression load and external pressure. The effects of different influencing factors on the stress intensity factor along the crack front considering crack closure were systematically explored, which were different to those under internal pressure. The effects of high aspect ratio on KII, the crack inclination asymmetry caused by curvature and the effects of the friction coefficient on the stress intensity factors of the pipe with an inclined inner surface crack under axial compression load and external pressure were explored in this paper. To be fit for defect assessment, the solutions for stress intensity factors KII and KIII were derived, and new correction factors fθ and fµ were proposed in the empirical solutions to accommodate the crack inclination asymmetry and the friction coefficient, respectively.

Applications and Life Cycle Assessment of Shape Memory Polyethylene Terephthalate in Concrete for Crack Closure.

Shape memory polymer (SMP) products have been developed for application as crack closure devices in concrete. They have been made from PET in the form of both fibres and hollow tubes. Here, manufacturing methods using die-drawing and mandrel-drawing to induce shape memory are reported. The fibre-based devices are incorporated into concrete and, upon triggering, exert shrinkage restraint forces that close cracks in the concrete. The evolution of shrinkage restraint force in the fibres as manufactured was measured as a function of temperature, showing stresses in excess of 35 MPa. Tendons consisting of fibre bundles are incorporated into concreate beams subjected to controlled cracking. When activated, the tendons reduce the crack widths by 80%. The same fibres are used to produce another class of device known as knotted fibres, which have knotted ends that act as anchor points when they incorporated directly into concrete. Upon activation within the cracked concrete, these devices are shown to completely close cracks. The tubes are used to enclose and restrain prestressed Kevlar fibres. When the tubes are triggered, they shrink and release the prestress force in the Kevlar, which is transferred to the surrounding concrete in the form of a compressive force, thereby closing cracks. The Kevlar fibres also provide substantial reinforcement after activation. The devices are shown to be able to partially and fully close cracks that have been opened to 0.3 mm and achieve post-activation flexural strengths comparable to those of conventional reinforced and prestressed structural elements. Finally, a preliminary life cycle assessment study was used to assess the carbon footprint a nominal unit of concrete made with SMPs fibres compared to conventional concrete.

High-Selectivity imaging of the closed fatigue crack due to thermal environment using surface-acoustic-wave phased array (SAW PA).

Crack closure can cause the underestimation or misdetection of fatigue cracks in ultrasonic testing (UT). Fatigue-crack closure due to an environmental factor, i.e., high temperature, was found in eddy current testing (ECT), which is used to inspect the vicinity of surfaces. However, its effect and countermeasures have yet to be examined in UT. In this study, we examined the fatigue-crack closure induced by heat processing using a surface-acoustic-wave phased array (SAW PA). SAW PA is a phased-array imaging method using Rayleigh waves, which can sensitively visualize defects in the vicinity of surfaces. As a result, the intensity of crack responses visualized by SAW PA markedly decreased after the heat processing of a fatigue-crack specimen. Furthermore, we demonstrated that the combination of SAW PA with a crack opening method, global preheating and local cooling (GPLC), and a load difference phased array (LDPA) is useful for the high-selectivity imaging of closed fatigue cracks. We also discussed a possible mechanism of the fatigue-crack closure induced by heat processing.

Studies on the Mechanical Models and Behaviors for the Stamp/Film Interface in Microtransfer Printing.

The adhesion/delamination characteristics at the stamp/film interface are critical for the efficiency of film microtransfer printing technology. To predict and regulate the interface mechanical behaviors, finite element models based on the J-integral, Virtual Crack Closure Technology (VCCT), and the cohesive zone method (CZM) were established and compared. Then, the effects of pulling speed and interface parameters on the pull-off force, which is used to characterize the interface adhesion strength, were investigated. Comparisons between the simulation results and previous experimental results demonstrated that the model based on the CZM was more applicable than the models based on the J-integral and VCCT in analyzing the adhesion/delamination behaviors of the stamp/film interface. Furthermore, the increase in pulling speed could enlarge the pull-off force for the viscoelastic stamp/film interface, while it had no influence on the pull-off force for the elastic stamp/film interface. In addition, a larger normal strength and normal fracture energy resulted in a larger pull-off force, which was beneficial to the realization of the picking-up process in microtransfer printing.

Research on the Evolution Law Physical Short Fatigue Crack and Tip Deformation Fields during Crack Closure Process of the Q&P Steel.

In this paper, a novel dual microscopic fatigue-crack and tip-deformation-fields measurement method based on a hybrid image-processing technique is proposed that was used to research the physical short fatigue crack (SFC) closure effect and the evolution law of the tip deformation fields of Quenching-Partitioning (Q&P) steel during the crack-closure process. The measurement problems are solved, such as the small SFC tip region, large deformation gradient, and strong material anisotropy. Microscopic crack and speckle images are acquired simultaneously on both sides of a compact tensile (CT) specimen of Q&P steel by dual microscopic cameras. A digital image processing (DIP) method is used to identify crack-growth morphology and measure crack length in Q&P steel, and the SFC growth rates are analyzed under different stress ratios. Microscopic digital image correlation (Micro-DIC) is used to analyze displacement fields at the crack tip of SFC and, combined with virtual extensometer technology, analyze the evolution law of crack closure and the evolution of crack-growing morphologies during the closure process under different lengths and stress ratios. Accordingly, the evolution of strain fields at the crack tip in one load cycle for different crack lengths and stress ratios during the SFC closure process is analyzed. The results show that the stress ratio affects the crack-closure behavior and crack growth rate of Q&P steel in the physical SFC crack-growing stage. The crack-closure effect has an obvious influence on the evolution process of displacement and strain fields at the crack tip. The evolution of short-fatigue-crack-tip morphology and strain field of Q&P steel conforms to the crack-closure law. The research results provide experimental and theoretical support for the further study of the SFC growth mechanism and fatigue life prediction of Q&P steel.

Elasto-Plastic Fatigue Crack Growth Behavior of Extruded Mg Alloy with Deformation Anisotropy Due to Stress Ratio Fluctuation.

Fatigue crack growth (FCG) experiments were performed using a low-temperature extruded magnesium alloy AZ31 with texture. Under a constant maximum stress intensity factor (Kmax), the stress ratio R was changed from 0.1 to -1 during the fatigue crack growth process, and the FCG behavior before and after the R change was investigated. As a result, tensile twins were generated owing to the fatigue load on the compression side of R = -1, and the FCG velocity was accelerated. In addition, when the maximum compressive stress at R = -1 (|(σmin)R = -1|) exceeded the compressive yield strength of the material (σcy), the FCG velocity after R fluctuation greatly accelerated. On the other hand, under the condition |(σmin)R = -1| < σcy, the degree of acceleration of the FCG velocity due to R fluctuation was small. In either case, the degree of acceleration in the FCG increased as the Kmax value increased. The above FCG acceleration mechanism due to the R fluctuation was considered based on the observation of the deformation and twinning states of the fatigue crack tip, the fatigue crack closure behavior, and the cyclic stress-strain curve of the fatigue process. The FCG acceleration mechanism was as follows: First, the driving force of the FCG increased owing to the increase in crack opening displacement due to the generation of tensile twins. Second, the coalescence of the main crack and a plurality of microcracks were generated at the twin interface. The elasto-plastic FCG behavior after the stress ratio fluctuations is defined by the effective J-integral range ΔJeff.

Effect of Underload Cycles on Oxide-Induced Crack Closure Development in Cr-Mo Low-Alloy Steel.

Underload cycles with small load amplitudes below the fatigue crack growth threshold are dominantly considered as insignificant cycles without any influence on fatigue lifespan of engineering structural components. However, this paper shows that in some cases these underload cycles can retard the consequent crack propagation quite significantly. This phenomenon is a consequence of oxide-induced crack closure development during cyclic loading below the threshold. The experimentally described effect of fatigue crack growth retardation was supported by measurement of the width and the thickness of the oxide debris layer using the EDS technique and localized FIB cuts, respectively. Both the retardation effect and the amount of oxide debris were larger for higher number and larger amplitudes of the applied underload cycles. Crack closure measurement revealed a gradual increase of the closure level during underload cycling. Specimens tested in low air humidity, as well as specimens left with the crack open for the same time as that needed for application of the underload cycles, revealed no retardation effect. The results can improve our understanding of environmental effects on fatigue crack propagation and understanding the differences between the results of laboratory testing and the fatigue lives of components in service.

FCG Modelling Considering the Combined Effects of Cyclic Plastic Deformation and Growth of Micro-Voids.

Fatigue is one of the most prevalent mechanisms of failure. Thus, the evaluation of the fatigue crack growth process is fundamental in engineering applications subjected to cyclic loads. The fatigue crack growth rate is usually accessed through the da/dN-ΔK curves, which have some well-known limitations. In this study a numerical model that uses the cyclic plastic strain at the crack tip to predict da/dN was coupled with the Gurson-Tvergaard-Needleman (GTN) damage model. The crack propagation process occurs, by node release, when the cumulative plastic strain reaches a critical value. The GTN model is used to account for the material degradation due to the growth of micro-voids process, which affects fatigue crack growth. Predictions with GTN are compared with the ones obtained without this ductile fracture model. Crack closure was studied in order to justify the lower values of da/dN obtained in the model with GTN, when compared with the results without GTN, for lower ΔK values. Finally, the accuracy of both variants of the numerical model is accessed through the comparison with experimental results.

Experimental and Numerical Investigations on High Performance SFRC: Cyclic Tensile Loading and Fatigue.

In the present study, the capability of high-strength short steel fibers to control the degradation in high-performance concrete was experimentally examined and numerically simulated. To this end, notched prismatic high-performance concrete specimens with (HPSFRC) and without (HPC) short steel fibers were subjected to static and cyclic tensile tests up to 100,000 cycles. The cyclic tests showed that the rate of strain increase was lower for HPSFRC specimens and that the strain stagnated after around 10,000 cycles, which was not the case with HPC specimens. The microscopic examinations showed that in HPSFRC, a larger number of microcracks developed, but they had a smaller total surface area than the microcracks in the HPC. To further investigate the influence of fibers on the behavior of HPSFRC in the cracked state, displacement-controlled crack opening tests, as well as numerical simulations thereof, were carried out. Experiments have shown, and the numerical simulations have confirmed, that the inclusion of short steel fibers did not significantly affect the ultimate strength; however, it notably increased the post-cracking ductility of the material. Finally, the unloading/reloading behavior was examined, and it was observed that the unloading stiffness was stable even for significant crack openings; however, the hysteresis loops due to unloading/reloading were very small.