DR.

AL EMRAN ISMAIL

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

Liberty Ships-World War II

The hulls of Liberty Ships fractured without warning, mainly in the North Atlantic.
There were 2,751 Liberty Ships manufactured between 1941-1945.

Cracks propagated in 400 of these ships including 145 catastrophic failures; only 2 exist today which are sea-worthy.
The low temperatures of the North Atlantic caused the steel to be brittle.

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

These are the first ships mass produced with welds. Fractures occurred mainly in the vicinity of stress raisers.

The problem may be prevented by employing higher quality steels and improvement of the design of the ship.

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

The Aloha

Boeing 737 Accident On April 28, 1988, part of the fuselage of a Boeing 737 failed after 19 years of service. The failure was caused by fatigue (multisite damage).

10/16/2012

FATIGUE & FRACTURE BDC40403

AN INTRODUCTION TO FATIGUE & FRACTURE

10/16/2012

FATIGUE & FRACTURE BDC40403

FRACTURE MECHANICS APPROACH: MODE OF FRACTURE

x2

yy xy xx

x1
FATIGUE & FRACTURE BDC40403 8

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL have inherent flaws or Structures usually
cracks introduced during: 1) welding process due to welds, embedded slag, holes, porosity, lack of fusion and 2) service due to fatigue, stress corrosion cracking (SCC), impact damage and shrinkage. A fracture-control practice is vital for design engineers in order to assure the integrity of particular structure. This assurance can be accomplished by a close control of:

10/16/2012

FATIGUE & FRACTURE BDC40403

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

1.

Design constraints 2. Fabrication 3. General yielding 4. Maintenance 5. Nondestructive evaluation (NDE) 6. Environmental effects

10/16/2012

FATIGUE & FRACTURE BDC40403

10

FRACTURE MECHANICS APPROACH: FRACTURE CONTROLdetails for the above elements The pertinent

depend on codes and procedures that are required by a particular organization. However, the suitability of a structure to brittle fracture can be evaluated using the concept of fracture mechanics, which is the main subject in this course. For instance, the elapsed time for crackinitiation and crack-propagation determines the useful life of a structure, for which the combination of an existing crack size, applied stress, and loading rate may cause the stress intensity factor reach a critical value.
FATIGUE & FRACTURE BDC40403 11

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROLminimum detectable crack size However, the

depends on the available equipment for conducting nondestructive tests. But the critical crack size, ac can be predicted when the stress intensity factor reaches a critical value, which is commonly known as the plane strain fracture toughness (KI > KIC) for thick plates. In fact, KI < KIC can be taken as the material fracture constraint; otherwise, the crack becomes unstable when it reaches a critical length, a = ac which is strongly controlled by KIC.
FATIGUE & FRACTURE BDC40403 12

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

The critical crack length, ac = (1/)(KIC/F)2. This expression implies that the maximum allowable crack length depends on the magnitude of KIC and the applied stress < y. Conclusively, crack propagation occurs when the applied stress intensity factor is equal or greater than fracture toughness, KI KIC for plane strain or KI > KC for plane stress condition.
FATIGUE & FRACTURE BDC40403 13

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

A typical fracture-control plan includes the following: Plane strain fracture toughness, Actually, the applied stress intensity factor must be so that it can be used as a constraint, and the designer controls it. This design constraint assures structural integrity since crack propagation is restricted.
FATIGUE & FRACTURE BDC40403 14

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

Use of the following inequality for brittle materials assures that the thickness of designed parts do not fall below a minimum thickness.

10/16/2012

FATIGUE & FRACTURE BDC40403

15

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

If use of welding is necessary, then it must be used very cautiously since it can degrade the toughness of the welded material especially in the heat affected zone (HAZ), which may become brittle as a consequence of rapid cooling leading to smaller grains. Consequently, flaws development is detrimental to the structure or component since the local stresses may amplify at the crack tip.
FATIGUE & FRACTURE BDC40403 16

10/16/2012

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

The environment in which a structure is put into service. For instance, a corrosive environment may degrade the structure by developing stress corrosion cracks (SCC).

10/16/2012

FATIGUE & FRACTURE BDC40403

17

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

Limitations of the allowable crack size can be predicted by the given equation. Use of nondestructive test (NDT) techniques. NDT techniques must be employed in order to avoid catastrophic failure by examining structural components for flaws or cracks.

10/16/2012

FATIGUE & FRACTURE BDC40403

18

FRACTURE MECHANICS APPROACH: FRACTURE CONTROL

10/16/2012

FATIGUE & FRACTURE BDC40403

19

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

10/16/2012

FATIGUE & FRACTURE BDC40403

20

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

It is clearly shown that how fracture toughness is strongly dependent on the material thickness up to a limiting value. For a thin plate, plane stress condition (Z = 0) governs the fracture process because the plate is too thin to sustain through-the-thickness stress. For a thick plate, plane strain condition prevails in which becomes a materials property. It is this property, that the designer must use to assure structural integrity. The characteristics of a fracture surface, as schematically indicated the variation between both plane stress and plane strain modes of fracture.
FATIGUE & FRACTURE BDC40403 21

10/16/2012

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

The former fracture mode shows a slant fracture (shear lips at approximately 45) as an indication of partial ductile fracture, and the latter exhibits a flat fracture surface as a representation of brittle fracture. Any combination of these modes of fracture leads to a mixed mode fracture surface. In addition, plane stress fracture toughness (KC) is related to metallurgical features and specimen geometry, and plane strain fracture toughness (KIC) depends only on metallurgical features and temperature.
FATIGUE & FRACTURE BDC40403 22

10/16/2012

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

The effect of plastic zone size to plate thickness and macroscopic fracture surface appearance is also taken into account. For instance, plane stress-state is associated with a maximum toughness and slant fracture, and plane strain-state is related to a minimum toughness and flat fracture. Therefore, plane stress or plane strain condition depends on y.

10/16/2012 FATIGUE & FRACTURE BDC40403 23

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

10/16/2012

FATIGUE & FRACTURE BDC40403

24

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

Since the plane strain fracture toughness, KIC is a property for a given material, the applied stress level exhibits a dependency on the crack size. This is schematically shown in figure above for two hypothetical materials. Notice that both KIC and aC influence the stress and the curve is shifted upwards at higher KIC level. This means that ductility also has a major influence on the stress and KIC.

10/16/2012 FATIGUE & FRACTURE BDC40403 25

FRACTURE MECHANICS APPROACH: PLAIN STRAIN VS. PLAIN STRESS

This fracture phenomenon proceeds in a stable manner, provided that both crack size and applied stress are within a controllable range such as ao < a < ac and d < < y. Furthermore, crack instability occurs when a ac and This schematic representation of crack growth applies to both A and B curves, which represent the fracture behavior of two hypothetical materials. Conclusively, the higher KIC the greater ac since the resistance to fracture is controlled by the level of the plane strain fracture toughness.
FATIGUE & FRACTURE BDC40403 26

10/16/2012