Effects of grain size and microstructure on threshold values and near threshold crack growth in powder-formed Ni-base superalloy

Threshold stress intensity values, ranging from ∼6 to 16 MN m −3/2 can be obtained in powder-formed Nimonic AP1 by changing the microstructure. The threshold and low crack growth rate behaviour at room temperature of a number of widely differing API microstructures, with both ‘necklace’ and fully recrystallized grain structures of various sizes and uniform and bimodal γ′-distributions, have been investigated. The results indicate that grain size is an important microstructural parameter which can control threshold behaviour, with the value of threshold stress intensity increasing with increasing grain size, but that the γ′-distribution is also important. In this Ni-base alloy, as in many others, near threshold fatigue crack growth occurs in a crystallographic manner along {111} planes. This is due to the development of a dislocation structure involving persistent slip bands on {111} planes in the plastic zone, caused by the presence of ordered shearable precipitates in the microstructure. However, as the stress intensity range is increased, a striated growth mode takes over. The results presented show that this transition from faceted to striated growth is associated with a sudden increase in crack propagation rate and occurs when the size of the reverse plastic zone at the crack tip becomes equal to the grain size, independent of any other microstructural variables.

Application of the finite element method to problems in fracture mechanics

Numerical techniques have been finding increasing use in all aspects of fracture mechanics, and often provide the only means for analyzing fracture problems. The work presented here, is concerned with the application of the finite element method to cracked structures. The present work was directed towards the establishment of a comprehensive two-dimensional finite element, linear elastic, fracture analysis package. Significant progress has been made to this end, and features which can now be studied include multi-crack tip mixed-mode problems, involving partial crack closure. The crack tip core element was refined and special local crack tip elements were employed to reduce the element density in the neighbourhood of the core region. The work builds upon experience gained by previous research workers and, as part of the general development, the program was modified to incorporate the eight-node isoparametric quadrilateral element. Also. a more flexible solving routine was developed, and provided a very compact method of solving large sets of simultaneous equations, stored in a segmented form. To complement the finite element analysis programs, an automatic mesh generation program has been developed, which enables complex problems. involving fine element detail, to be investigated with a minimum of input data. The scheme has proven to be versati Ie and reasonably easy to implement. Numerous examples are given to demonstrate the accuracy and flexibility of the finite element technique.

Ductile fracture mechanisms in a structural steel

Microstructural fracture processes in a BS4360 Grade 50D structural steel with lower sulphur content were studied in smooth tensile specimen tests and Charpy-size bend bar tests. Based on the experimental analysis, an experimental void growth relation with the plastic strain and stress triaxiality and multiplying factor on void growth were determined. Experimental results show that the void growth relation can be reasonably used to estimate the constraint in the specimens containing the notch or crack, also they can be used to evaluate the variations of the stress triaxiality in front of the notch and crack tip under general yielding condition. Side-grooves obviously increase the constraint of the CVN specimens. Strain hardening leads to increasing the stress triaxiality, and decelerating the net void growth. This is especially true for the values of stress triaxiality more than about one. Additionally, the effect of the stress triaxiality on the critical void growth corresponding to the onset of ductile tearing was preliminarily investigated. In this work, a large number of smaller specimens were tested to investigate the ductile-brittle transition behaviour of the structural steel. A void growth rate explanation was suggested for evaluating the temperature transition behaviour. The elastic-plastic fracture tough-ness values based on small specimen tests, such as pre-cracked side-grooved bending specimen and short bar tensile specimen, may give large overestimates of the plane strain fracture toughness.

Fracture toughness of a series of high chromium abrasion resistant alloys

The fracture properties of a series of alloys containing 15% chromium and 0.8 to 3.4% carbon are investigated using strain fracture toughness testing techniques. The object of the work is to apply a quantitative method of measuring toughness to abrasion resistant materials, which have previously been assessed on an empirical basis; and to examine the relationship between microstructure and K10 in an attempt to improve the toughness of inherently brittle materials. A review of the relevant literature includes discussion of the background to the alloy series under investigation, a survey of the development of fracture mechanics and the emergence of K10 as a toughness parameter. Metallurgical variables such as composition, heat treatment, grain size, and hot working are ???? to relate microstructure to toughness, and fractographic evidence is used to substantiate the findings. The results are applied to a model correlating ductile fracture with plastic strain instability, and the nucleation of voids. Strain induced martensite formation in austenitic structures is analysed in terms of the plastic energy dissipation mechanisms operating at the crack tip. Emphasis is placed on the lower carbon alloys in the series, and a composition put forward to optimise wear resistance and toughness. The properties of established competitive materials are compared to the proposed alloy on a toughness and cost basis.

Intrinsic thresholds in polycrystalline Udimet 720

The long crack threshold behaviour of polycrystalline Udimet 720 has been investigated. Faceted crack growth is seen near threshold when the monotonic crack tip plastic zone is contained within the coarsest grain size. At very high load ratios R (=P min/P max) it is possiblefor the monotonic crack tip plastic zone to exceed the coarsest grain size throughout the entire crack growth regime and non1aceted structure insensitive crack growth is then seen down to threshold. Intrinsic threshold values were obtained for non1aceted and faceted crack growth using a constant K max, increasing K min, computer controlled load shedding technique (K is stress intensity factor). Very high R values are obtained at threshold using this technique (0.75-0.95), eliminating closure effects, so the intrinsic resistance of the material to crack propagation is reflected in these values. The intrinsic non1aceted threshold value ΔK th is lower (2.3 MN m -3/2) than the intrinsicfaceted ΔK th value (4.8 MN m -3/2). This is thought to reflect not only the effect of crack branching and deflection (in the faceted case) on the crack driving force, but also the inherent difference in resistance of the material to the two different crack propagation micromechanisms. © 1993 The Institute of Materials.