Optimal scaling in ductile fracture

This work is concerned with the derivation of optimal scaling laws, in the sense of matching lower and upper bounds on the energy, for a solid undergoing ductile fracture. The specific problem considered concerns a material sample in the form of an infinite slab of finite thickness subjected to prescribed opening displacements on its two surfaces. The solid is assumed to obey deformation-theory of plasticity and, in order to further simplify the analysis, we assume isotropic rigid-plastic deformations with zero plastic spin. When hardening exponents are given values consistent with observation, the energy is found to exhibit sublinear growth. We regularize the energy through the addition of nonlocal energy terms of the strain-gradient plasticity type. This nonlocal regularization has the effect of introducing an intrinsic length scale into the energy. We also put forth a physical argument that identifies the intrinsic length and suggests a linear growth of the nonlocal energy. Under these assumptions, ductile fracture emerges as the net result of two competing effects: whereas the sublinear growth of the local energy promotes localization of deformation to failure planes, the nonlocal regularization stabilizes this process, thus resulting in an orderly progression towards failure and a well-defined specific fracture energy. The optimal scaling laws derived here show that ductile fracture results from localization of deformations to void sheets, and that it requires a well-defined energy per unit fracture area. In particular, fractal modes of fracture are ruled out under the assumptions of the analysis. The optimal scaling laws additionally show that ductile fracture is cohesive in nature, i.e., it obeys a well-defined relation between tractions and opening displacements. Finally, the scaling laws supply a link between micromechanical properties and macroscopic fracture properties. In particular, they reveal the relative roles that surface energy and microplasticity play as contributors to the specific fracture energy of the material. Next, we present an experimental assessment of the optimal scaling laws. We show that when the specific fracture energy is renormalized in a manner suggested by the optimal scaling laws, the data falls within the bounds predicted by the analysis and, moreover, they ostensibly collapse---with allowances made for experimental scatter---on a master curve dependent on the hardening exponent, but otherwise material independent.

I. Impact spallation experiments: fracture patterns and spall velocities. II. Craters in carbonate rocks: an electron paramagnetic resonance analysis of shock damage

This work is divided into two independent papers.

PAPER 1.

Spall velocities were measured for nine experimental impacts into San Marcos gabbro targets. Impact velocities ranged from 1 to 6.5 km/sec. Projectiles were iron, aluminum, lead, and basalt of varying sizes. The projectile masses ranged from a 4 g lead bullet to a 0.04 g aluminum sphere. The velocities of fragments were measured from high-speed films taken of the events. The maximum spall velocity observed was 30 m/sec, or 0.56 percent of the 5.4 km/sec impact velocity. The measured velocities were compared to the spall velocities predicted by the spallation model of Melosh (1984). The compatibility between the spallation model for large planetary impacts and the results of these small scale experiments are considered in detail.

The targets were also bisected to observe the pattern of internal fractures. A series of fractures were observed, whose location coincided with the boundary between rock subjected to the peak shock compression and a theoretical "near surface zone" predicted by the spallation model. Thus, between this boundary and the free surface, the target material should receive reduced levels of compressive stress as compared to the more highly shocked region below.

PAPER 2.

Carbonate samples from the nuclear explosion crater, OAK, and a terrestrial impact crater, Meteor Crater, were analyzed for shock damage using electron para- magnetic resonance, EPR. The first series of samples for OAK Crater were obtained from six boreholes within the crater, and the second series were ejecta samples recovered from the crater floor. The degree of shock damage in the carbonate material was assessed by comparing the sample spectra to spectra of Solenhofen limestone, which had been shocked to known pressures.

The results of the OAK borehole analysis have identified a thin zone of highly shocked carbonate material underneath the crater floor. This zone has a maximum depth of approximately 200 ft below sea floor at the ground zero borehole and decreases in depth towards the crater rim. A layer of highly shocked material is also found on the surface in the vicinity of the reference bolehole, located outside the crater. This material could represent a fallout layer. The ejecta samples have experienced a range of shock pressures.

It was also demonstrated that the EPR technique is feasible for the study of terrestrial impact craters formed in carbonate bedrock. The results for the Meteor Crater analysis suggest a slight degree of shock damage present in the β member of the Kaibab Formation exposed in the crater walls.

Dynamic rupture simulation integrated with earthquake observations

Dynamic rupture simulations are unique in their contributions to the study of earthquake physics. The current rapid development of dynamic rupture simulations poses several new questions: Do the simulations reflect the real world? Do the simulations have predictive power? Which one should we believe when the simulations disagree? This thesis illustrates how integration with observations can help address these questions and reduce the effects of non-uniqueness of both dynamic rupture simulations and kinematic inversion problems. Dynamic rupture simulations with observational constraints can effectively identify non-physical features inferred from observations. Moreover, the integrative technique can also provide more physical insights into the mechanisms of earthquakes. This thesis demonstrates two examples of such kinds of integration: dynamic rupture simulations of the M_w 9.0 2011 Tohoku-Oki earthquake and of earthquake ruptures in damaged fault zones:

(1) We develop simulations of the Tohoku-Oki earthquake based on a variety of observations and minimum assumptions of model parameters. The simulations provide realistic estimations of stress drop and fracture energy of the region and explain the physical mechanisms of high-frequency radiation in the deep region. We also find that the overridding subduction wedge contributes significantly to the up-dip rupture propagation and large final slip in the shallow region. Such findings are also applicable to other megathrust earthquakes.

(2) Damaged fault zones are usually found around natural faults, but their effects on earthquake ruptures have been largely unknown. We simulate earthquake ruptures in damaged fault zones with material properties constrained by seismic and geological observations. We show that reflected waves in fault zones are effective at generating pulse-like ruptures and head waves tend to accelerate and decelerate rupture speeds. These mechanisms are robust in natural fault zones with large attenuation and off-fault plasticity. Moreover, earthquakes in damaged fault zones can propagate at super-Rayleigh speeds that are unstable in homogeneous media. Supershear transitions in fault zones do not require large fault stresses. In the end, we present observations in the Big Bear region, where variability of rupture speeds of small earthquakes correlates with the laterally variable materials in a damaged fault zone.

Discontinuous yielding and fracture initiation near a notch in mild steel

This thesis presents the results of an experimental investigation of the initiation of brittle fracture and the nature of discontinuous yielding in small plastic enclaves in an annealed mild steel. Upper and lower yield stress data have been obtained from unnotched specimens and nominal fracture stress data have been obtained from specimens of two scale factors and two grain sizes over a range of nominal stress rates from 10^2 to 10^7 lb/in.^2 sec at -111°F and -200°F. The size and shape of plastic enclaves near the notches were revealed by an etch technique.

A stress analysis utilizing slip-line field theory in the plastic region has been developed for the notched specimen geometry employed in this investigation. The yield stress of the material in the plastic enclaves near the notch root has been correlated with the lower yield stress measured on unnotched specimens through a consideration of the plastic boundary velocity under dynamic loading. A maximum tensile stress of about 122,000 lb/in.^2 at the instant of fracture initiation was calculated with the aid of the stress analysis for the large scale specimens of ASTM grain size 8 1/4.

The plastic strain state adjacent to a plastic-elastic interface has been shown to cause the maximum shear stress to have a larger value on the elastic than the plastic side of the interface. This characteristic of dis continuous yielding is instrumental in causing the plastic boundaries to be nearly parallel to the slip-line field where the plastic strain is of the order of the Lüder's strain.

The tensile fracture of mild steel

The fibrous and cleavage tensile fracture of an annealed mild steel was investigated. Round tensile specimens of two geometries, one straight and one with a circumferential notch, were pulled at temperatures between room temperature and liquid nitrogen temperature. Tensile fractures occurred at average strains from 0.02 to 0.87. The mechanism of fibrous fracture at room temperature was investigated metallographically. The stress-strain values at which fibrous and cleavage fractures are initiated were determined.

Many fine microcracks, which are associated with pearlite colonies and inclusion stringers, develop prior to fibrous fracture. The macrofracture, which leads to final separation of the tensile specimen, is initiated by the propagation of a microcrack beyond the microstructural feature with which it is associated. Thus, the fibrous fracture of mild steel does not develop by the gradual growth and coalescence of voids that are large enough to be visible in the optical microscope. When the microcracks begin to open and propagate, final fracture quickly follows. Axial cracks are a prominent feature of the macrofracture that forms in the interior of the specimen immediately before final fracture.

The Bridgman distribution of stresses is not valid in a notched tensile specimen. Fibrous and cleavage fractures occur at approximately the same value of maximum tensile stress. When the maximum tensile stress that is necessary for cleavage fracture is plotted against the corresponding maximum tensile strain, the result is an unique locus.

Micromechanical damage and fracture in elastomeric polymers

This thesis aims at a simple one-parameter macroscopic model of distributed damage and fracture of polymers that is amenable to a straightforward and efficient numerical implementation. The failure model is motivated by post-mortem fractographic observations of void nucleation, growth and coalescence in polyurea stretched to failure, and accounts for the specific fracture energy per unit area attendant to rupture of the material.

Furthermore, it is shown that the macroscopic model can be rigorously derived, in the sense of optimal scaling, from a micromechanical model of chain elasticity and failure regularized by means of fractional strain-gradient elasticity. Optimal scaling laws that supply a link between the single parameter of the macroscopic model, namely the critical energy-release rate of the material, and micromechanical parameters pertaining to the elasticity and strength of the polymer chains, and to the strain-gradient elasticity regularization, are derived. Based on optimal scaling laws, it is shown how the critical energy-release rate of specific materials can be determined from test data. In addition, the scope and fidelity of the model is demonstrated by means of an example of application, namely Taylor-impact experiments of polyurea rods. Hereby, optimal transportation meshfree approximation schemes using maximum-entropy interpolation functions are employed.

Finally, a different crazing model using full derivatives of the deformation gradient and a core cut-off is presented, along with a numerical non-local regularization model. The numerical model takes into account higher-order deformation gradients in a finite element framework. It is shown how the introduction of non-locality into the model stabilizes the effect of strain localization to small volumes in materials undergoing softening. From an investigation of craze formation in the limit of large deformations, convergence studies verifying scaling properties of both local- and non-local energy contributions are presented.

Strength, Deformation and Fracture in Metallic Nanostructures

An understanding of the mechanics of nanoscale metals and semiconductors is necessary for the safe and prolonged operation of nanostructured devices from transistors to nanowire- based solar cells to miniaturized electrodes. This is a fascinating but challenging pursuit because mechanical properties that are size-invariant in conventional materials, such as strength, ductility and fracture behavior, can depend critically on sample size when materials are reduced to sub- micron dimensions. In this thesis, the effect of nanoscale sample size, microstructure and structural geometry on mechanical strength, deformation and fracture are explored for several classes of solid materials. Nanocrystalline platinum nano-cylinders with diameters of 60 nm to 1 μm and 12 nm sized grains are fabricated and tested in compression. We find that nano-sized metals containing few grains weaken as sample diameter is reduced relative to grain size due to a change from deformation governed by internal grains to surface grain governed deformation. Fracture at the nanoscale is explored by performing in-situ SEM tension tests on nanocrystalline platinum and amorphous, metallic glass nano-cylinders containing purposely introduced structural flaws. It is found that failure location, mechanism and strength are determined by the stress concentration with the highest local stress whether this is at the structural flaw or a microstructural feature. Principles of nano-mechanics are used to design and test mechanically robust hierarchical nanostructures with structural and electrochemical applications. 2-photon lithography and electroplating are used to fabricate 3D solid Cu octet meso-lattices with micron- scale features that exhibit strength higher than that of bulk Cu. An in-situ SEM lithiation stage is developed and used to simultaneously examine morphological and electrochemical changes in Si-coated Cu meso-lattices that are of interest as high energy capacity electrodes for Li-ion batteries.

A phase-shifting vectorial-shearing interferometer with wedge plate phase-shifter

We present a novel phase-shifting vectorial-shearing interferometer with a wedge plate phase-shifter. The interferometer is based on a modified Mach-Zehnder configuration; the common-path nature makes it capable of testing the wavefront of a short coherence-length light source, such as a laser diode. Vectorial shear (shearing in the x and y directions simultaneously) in an arbitrary direction is introduced by inserting two wedge plates orthogonally in two arms, respectively. One of the wedge plates is split into two parts (parallel part and wedge part); phase shift is produced by moving the wedge part in contact along the parallel part. The moving distance for a 2 pi phase shift is a few millimetres in specific conditions. The wedge plate phase-shifter increases the moving distance for phase shift and makes the control of phase shift relatively easy. We also discuss the lateral shear error and phase shift errors induced by wedge plates. The lateral shear error is small enough to be ignored; the phase shift error is determined mainly by the wedge angle error. Lastly, we give the experimental results of phase-shifting interference fringes in vectorial shear mode.