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Mechanical Testing

Job knowledge77:
Compact tension and J integral tests
The previous Connect article in this series, number 76, dealt entirely with the
CTOD test and illustrated the use of a single edged notched bend (SENB)
specimen. This test was developed at TWI as a cost effective method of
determining fracture toughness in a metal that exhibits some degree of plasticity -
plane stress conditions - before fracture, the analysis of the results being carried
out using elastic plastic fracture mechanics (EPFM).
The failure mode is a function of the material properties, the rate of loading, the
temperature and the material thickness. The lower the material toughness or
temperature, the faster the loading rate or the thicker the specimen the more
likely it is that brittle fracture will occur. With carbon manganese steels toughness
is generally sufficiently high that it is difficult to achieve plane strain conditions
except at low temperatures ie on the lower shelf, or with thick plate.
The SENB specimen that is used for the CTOD test can also be used in linear
elastic fracture mechanics (LEFM), a situation where the failure mode is
accompanied by little or no plastic deformation - plane strain conditions. Any
displacement that occurs is essentially elastic, a situation that pertains when
brittle fracture occurs. Both types of fracture, brittle or ductile, can therefore be
characterised by the SENB test.
The compact tension (CT) specimen and the J integral test, the two test methods
briefly described in this article, may also be used to characterise fracture
behaviour by using the appropriate calculation techniques irrespective of the
failure mode.
The compact tension specimen is, in some respects, similar to the SENB specimen
in that it is a proportional specimen of full plate thickness containing a fatigue
crack. The sides of the specimen are approximately twice the specimen thickness
as illustrated in Fig.1. The specimen has a notch machined into one face in the
area - weld, HAZ etc - to be tested and a fatigue crack is then grown from the tip
of the machined notch to give a total 'crack' length approximately equivalent to
the specimen thickness. The specimen is tested in tension with deformation
measured by means of a clip gauge mounted across the mouth of the notch. Load
and deformation are recorded and crack length is measured on the broken test
piece. A decision may then be made as to the failure mode and the appropriate
analysis tools then used to calculate toughness.

Fig.1. Compact tension
The compact tension test has the advantage compared with the SENB test that
the specimen is more economical in material and this can be important when thick
plates are to be tested. The specimen is, however, more expensive in machining
costs and the method of loading tends to give lower toughness results than the
SENB specimen. For this reason the CT test is favoured by the nuclear industry,
where safety is crucial and lower bound results are preferred.
The J integral is a third method of determining toughness and is based on the
amount of energy required to propagate a crack. Both CTOD and J can be
measured on the same specimen by using two clip gauges, one to measure CTOD,
the other to measure J. To determine J the specimen is loaded at successively
higher loads and the displacement and crack length at each load is measured. The
area beneath the load/displacement curve gives the amount of energy required
for fracture propagation to occur. Analysis of the results enables a J factor to be
calculated as a measure of fracture toughness.
Qualitative tests
All the above tests - the SENB test, the CT test or the J integral - enable critical
defect sizes to be calculated and decisions made about fitness for service of a
structure or the required level and sensitivity of NDE. They are therefore
quantitative tests. There are however a number of qualitative tests that have
been developed where the test regime attempts to simulate service conditions
and the test gives a 'go - no go' result. Typical of this family of tests is the NDT or
drop weight test.
This test was developed in the USA for the testing of naval steels where the
temperature at which the failure mode of a plate subjected to impact loading
would change from ductile to brittle behaviour. The sample size is standardised
with three sizes depending upon plate thickness. A 20mm thick plate, for instance,
would require a specimen measuring 125mm x 50mm and full plate thickness.
A brittle crack starter weld is made along one side of the sample, often using a
hard facing electrode. This weld deposit is notched and the sample laid, notch
down, across two supports. A standard weight hammer is then dropped on to the
sample and this initiates a crack in the hard facing as illustrated in Fig.2 which
shows weld metal being tested. The test is carried out on a number of samples at
progressively lower temperatures until the test piece breaks. This temperature is
known as the 'nil-ductility temperature' (NDT). A further two tests are carried out

at a temperature 50C above the NDT to demonstrate that complete failure does
not occur and that a crack will arrest provided the test sample is above NDT.

Fig.2. Drop weight
testing of weld
The test may be used to characterise and compare weld metals and plates or as
an acceptance criterion by specifying the NDT temperature.
There are a number of other tests available some of which may be called up in
application standards or in contract specifications. One such test is the dynamic
tear test - a test that is, in principle, similar to the Charpy test. The test piece,
however, is 15.8mm thick, 38mm deep and 180mm in length with a notch
pressed into the edge instead of being machined. The test results are absorbed
energy, temperature and, if requested, the amount of crystallinity on the fracture
face. One other test worth mentioning is the Wells wide plate test, developed here
at TWI in the early 1960's and illustrated in Fig.3. This uses a full size plate with a
machined notch and/or fatigue crack. Service conditions, residual stresses etc are
simulated as closely as possible. Large scale and very expensive tests such as this
have been almost entirely replaced by the more cost effective SENB and compact
tension specimen methods.

Fig.3. Wells wide plate test
Relevant specifications are given in the Table.

Related specifications
BS 7448 Parts 1-4 Fracture Mechanics Toughness Tests
BS 6729 Determination of the Dynamic Fracture Toughness of Metallic
BS 7910 Guide on Methods for Assessing the Acceptability of Flaws in Metallic
ASTM E1820 Standard Test Method for Measurement of Fracture Toughness

This article was written by Gene Mathers.
Copyright 2005 TWI Ltd
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