Diseño y comportamiento de uniones estructurales mecánicas y adhesivas. Condiciones superficiales y operacionales

Las uniones estructurales mecánicas y adhesivas requieren la combinación de un número importante de parámetros para la obtención de la continuidad estructural que exigen las condiciones de diseño. Las características de las uniones presentan importantes variaciones, ligadas a las condiciones de ejecución, tanto en uniones mecánicas como especialmente en uniones adhesivas y mixtas (unión mecánica y adhesiva, también conocidas como uniones híbridas). Las propiedades mecánicas de las uniones adhesivas dependen de la naturaleza y propiedades de los adhesivos y también de muchos otros parámetros que influyen directamente en el comportamiento de estas uniones. Algunos de los parámetros más significativos son: el acabado superficial de los materiales, área y espesor de la capa adhesiva, diseño adecuado, secuencia de aplicación, propiedades químicas de la superficie y preparación de los sustratos antes de aplicar el adhesivo. Los mecanismos de adhesión son complejos. En general, cada unión adhesiva solo puede explicarse considerando la actuación conjunta de varios mecanismos de adhesión. No existen adhesivos universales para un determinado material o aplicación, por lo que cada pareja sustrato-adhesivo requiere un particular estudio y el comportamiento obtenido puede variar, significativamente, de uno a otro caso. El fallo de una junta adhesiva depende del mecanismo cohesión-adhesión, ligado a la secuencia y modo de ejecución de los parámetros operacionales utilizados en la unión. En aplicaciones estructurales existen un número muy elevado de sistemas de unión y de posibles sustratos. En este trabajo se han seleccionado cuatro adhesivos diferentes (cianoacrilato, epoxi, poliuretano y silano modificado) y dos procesos de unión mecánica (remachado y clinchado). Estas uniones se han aplicado sobre chapas de acero al carbono en diferentes estados superficiales (chapa blanca, galvanizada y prepintada). Los parámetros operacionales analizados han sido: preparación superficial, espesor del adhesivo, secuencia de aplicación y aplicación de presión durante el curado. Se han analizado tanto las uniones individuales como las uniones híbridas (unión adhesiva y unión mecánica). La combinación de procesos de unión, sustratos y parámetros operacionales ha dado lugar a la preparación y ensayo de más de mil muestras. Pues, debido a la dispersión de resultados característica de las uniones adhesivas, para cada condición analizada se han ensayado seis probetas. Los resultados obtenidos han sido: El espesor de adhesivo utilizado es una variable muy importante en los adhesivos flexibles, donde cuanto menor es el espesor del adhesivo mayor es la resistencia mecánica a cortadura de la unión. Sin embargo en los adhesivos rígidos su influencia es mucho menor. La naturaleza de la superficie es fundamental para una buena adherencia del adhesivo al substrato, que repercute en la resistencia mecánica de la unión. La superficie que mejor adherencia presenta es la prepintada, especialmente cuando existe una alta compatibilidad entre la pintura y el adhesivo. La superficie que peor adherencia tiene es la galvanizada. La secuencia de aplicación ha sido un parámetro significativo en las uniones híbridas, donde los mejores resultados se han obtenido cuando se aplicaba primero el adhesivo y la unión mecánica se realizaba antes del curado del adhesivo. La aplicación de presión durante el curado se ha mostrado un parámetro significativo en los adhesivos con poca capacidad para el relleno de la junta. En los otros casos su influencia ha sido poco relevante. El comportamiento de las uniones estructurales mecánicas y adhesivas en cuanto a la resistencia mecánica de la unión puede variar mucho en función del diseño de dicha unión. La resistencia mecánica puede ser tan grande que falle antes el substrato que la unión. Las mejores resistencias se consiguen diseñando las uniones con adhesivo cianoacrilato, eligiendo adecuadamente las condiciones superficiales y operacionales, por ejemplo chapa blanca aplicando una presión durante el curado de la unión. La utilización de uniones mixtas aumenta muy poco o nada la resistencia mecánica, pero a cambio proporciona una baja dispersión de resultados, siendo destacable para la superficie galvanizada, que es la que presenta peor reproducibilidad cuando se realizan uniones sólo con adhesivo. Las uniones mixtas conducen a un aumento de la deformación antes de la rotura. Los adhesivos dan rotura frágil y las uniones mecánicas rotura dúctil. La unión mixta proporciona ductilidad a la unión. Las uniones mixtas también pueden dar rotura frágil, esto sucede cuando la resistencia del adhesivo es tres veces superior a la resistencia de la unión mecánica. Las uniones híbridas mejoran la rigidez de la junta, sobre todo se aprecia un aumento importante en las uniones mixtas realizadas con adhesivos flexibles, pudiendo decirse que para todos los adhesivos la rigidez de la unión híbrida es superior. ABSTRACT The mechanical and adhesive structural joints require the combination of a large number of parameters to obtain the structural continuity required for the design conditions. The characteristics of the junctions have important variations, linked to performance conditions, in mechanical joints as particular in mixed adhesive joints (mechanical and adhesive joints, also known as hybrid joints). The mechanical properties of the adhesive joints depend of the nature and properties of adhesives and also of many other parameters that directly influence in the behavior of these joints. Some of the most significant parameters are: the surface finished of the material, area and thickness of the adhesive layer, suitable design, and application sequence, chemical properties of the surface and preparation of the substrate before applying the adhesive. Adhesion mechanisms are complex. In general, each adhesive joint can only be explained by considering the combined action of several adhesions mechanisms. There aren’t universal adhesives for a given material or application, so that each pair substrate-adhesive requires a particular study and the behavior obtained can vary significantly from one to another case. The failure of an adhesive joint depends on the cohesion-adhesion mechanism, linked to the sequence and manner of execution of the operational parameters used in the joint. In the structural applications, there are a very high number of joining systems and possible substrates. In this work we have selected four different adhesives (cyanoacrylate, epoxy, polyurethane and silano modified) and two mechanical joining processes (riveting and clinching). These joints were applied on carbon steel with different types of surfaces (white sheet, galvanized and pre-painted). The operational parameters analyzed were: surface preparation, thickness of adhesive, application sequence and application of pressure during curing. We have analyzed individual joints both as hybrid joints (adhesive joint and mechanical joint). The combination of joining processes, substrates and operational parameters has resulted in the preparation and testing of over a thousand specimens. Then, due to the spread of results characteristic of adhesive joints, for each condition analyzed we have tested six samples. The results have been: The thickness of adhesive used is an important variable in the flexible adhesives, where the lower the adhesive thickness greater the shear strength of the joint. However in rigid adhesives is lower influence. The nature of the surface is essential for good adherence of the adhesive to the substrate, which affects the shear strength of the joint. The surface has better adherence is preprinted, especially when there is a high compatibility between the paint and the adhesive. The surface which has poor adherence is the galvanized. The sequence of application has been a significant parameter in the hybrid junctions, where the best results are obtained when applying first the adhesive and the mechanical joint is performed before cured of the adhesive. The application of pressure during curing has shown a significant parameter in the adhesives with little capacity for filler the joint. In other cases their influence has been less relevant. The behavior of structural mechanical and adhesive joints in the shear strength of the joint can vary greatly depending on the design of such a joint. The shear strength may be so large that the substrate fails before the joint. The best shear strengths are achieved by designing the junctions with cyanoacrylate adhesive, by selecting appropriately the surface and operating conditions, for example by white sheet applying a pressure during curing of the joint. The use of hybrid joints no increase shear strength, but instead provides a low dispersion of results, being remarkable for the galvanized surface, which is the having worst reproducibility when performed bonded joints. The hybrid joints leading to increased deformation before rupture. The joints witch adhesives give brittle fracture and the mechanics joints give ductile fracture. Hybrid joint provides ductility at the joint. Hybrid joint can also give brittle fracture, this happens when the shear strength of the adhesive is three times the shear strength of the mechanical joint. The hybrid joints improve stiffness of joint, especially seen a significant increase in hybrid joints bonding with flexible adhesives, can be said that for all the adhesives, the hybrid junction stiffness is higher.

Modelado de fractura dúctil sobre aceros modificados superficialmente 545-A

Históricamente la fractura ha sido considerada siempre como un efecto indeseado entre los materiales, dado que su aparición supone un cese del material en servicio, puesto que un material fracturado carece de importancia desde el punto de vista comercial. Consecuentemente, la Mecánica de Fractura ha experimentado un desarrollo importante en las últimas décadas como no lo hizo en toda la historia de los materiales. El desarrollo de nuevos campos a nivel científico y técnico han estado de la mano con el desarrollo de nuevos materiales que satisfagan las necesidades particulares de cada sector o aplicación. Este requerimiento se ve acentuado cuando se incorpora el aspecto económico, dado que, así como se necesitan materiales con mayor resistencia a la fractura, corrosión etc, también se necesita que su precio en el mercado sea accesible y que permita una aplicación rentable. En los últimos 70 años, desde los requerimientos de nuevos materiales resistentes a la fractura con los buques Liberty hasta el boom petrolero, pasando por las aplicaciones aeroespaciales se han desarrollado diversas teorías que explican el comportamiento de los materiales, en cuando a la tenacidad a la fractura en distintas temperaturas, composiciones químicas, materiales compuestos etc. Uno de los sectores que más ha demandado un desarrollo, por su amplitud en cuanto a requerimientos y consumo global, así como su impacto en la economía mundial, es el sector de gas, petróleo y petroquímica. Muchos de los proyectos que se intentaron desarrollar hasta hace menos de 25 años eran inviables por su elevado coste de ejecución y su bajo retorno de inversión debido a la caída de los precios del petróleo. Con una demanda creciente a nivel mundial y unos precios que apuntan hacia la estabilización o alza moderada, nuevos sistemas de trasporte por tuberías han sido necesarios desarrollar, desde el punto de vista de ingeniería, con el menos coste posible y de un modo seguro. Muchas de estas aplicaciones se vieron incrementadas cuando nuevos requerimientos en cuanto a resistencia a la corrosión fueron necesarios: demanda de materiales que no se corroan, con prestaciones seguras a nivel mecánico y un bajo coste. Esta nueva etapa se conoce como Aleaciones Resistentes a la Corrosión (CRA´s por sus siglas en inglés) en las cuales uno de los factores de diseño seguro recaían indiscutiblemente en la mecánica de fractura. Por estas razones era necesario entender como influía en la resistencia a la fractura las aportaciones que podrían hacerse sobre una superficie metálica. Al realizar el presente estudio se comenzó analizando la influencia que tenían modificaciones en el rango iónico sobre aceros al carbono. Estudios previos sobre láminas de acero ferrítico usadas en reactores de fisión nuclear demostraron que aportes de iones, en este particular el Helio, influían en el comportamiento de la tenacidad a la fractura en función de la temperatura. De este modo, un primer análisis fue hecho sobre la influencia de iones de nitrógeno aportados sobre superficies de acero al carbono y como modificaban su tenacidad a la fractura. Este primer análisis sirvió para comprobar el impacto que tenían pequeñas dosis de iones de nitrógeno en la tenacidad a la fractura. Otro desarrollo con una mayor aplicación industrial fue hecho sobre superficies de acero al carbono con aporte por soldadura de los materiales más usados para evitar la corrosión. El análisis se centró fundamentalmente en la influencia que tenían distintos materiales aportados como el MONEL 400, DUPLEX 928, INCONEL 625 y STAINLESS-STEEL 316 en referencia a características de diseño como la tensión elástica y la tensión a la rotura. Este análisis permitió conocer el impacto de los materiales aportados en los ensayos de tracción en probetas de acero al carbono. Una explicación acerca del comportamiento fue soportada por el análisis macrofractográfico de los perfiles fracturados y las macro deformaciones en la superficie de las probetas. Un posterior desarrollo teórico permitió modelar matemáticamente la fractura de las probetas aportadas por soldadura en la región elástica por medio de la Ley de Hooke, así como la teoría de Plasticidad de Hill para la región de deformación plástica. ABSTRACT Fracture mechanics has been extensively studied in the last 70 years by the constant requirements of new materials with low costs. These requirements have allowed surface modified welded materials in which it is necessary to know the influence of design fundamentals with the material surface welded. Several specimens have been studied for ductile fracture in longitudinal tensile tests for carbon steel surface-modified by weld overlay MONEL 400, DUPLEX 928, INCONEL 625 and STAINLESS-STEEL 316. Similarly of macro photographic analyzes to level the fractured surfaces that explain the behavior curves obtained in Tensile – displacement charts. The contribution of weld overlay material shows a significant impact on the yield and tensile stress of the specimens which was modeled according to Hooke's law for elastic area and Hill´s theory of plasticity to the plastic one.

Influência do tempo de imersão em solução aquosa contendo H2S sobre a tenacidade de tubo API 5L X65 sour avaliada a partir de ensaio Charpy

Com o decorrer dos anos o consumo de petróleo e seus derivados aumentou significativamente e com isso houve a necessidade de se investir em pesquisas para descobertas de novas jazidas de petróleo como o pré-sal. Porém, não apenas a localização dessas jazidas deve ser estudada, mas, também, sua forma de exploração. Essa exploração e extração, na maioria das vezes, se dão em ambientes altamente corrosivos e o transporte do produto extraído é realizado através de tubulações de aço de alta resistência e baixa liga (ARBL). Aços ARBL expostos a ambientes contendo H2S e CO2 (sour gas) sofrem corrosão generalizada que promovem a entrada de hidrogênio atômico no metal, podendo diminuir sua tenacidade e causar falha induzida pela presença de hidrogênio (Hydrogen Induced Cracking HIC), gerando falhas graves no material. Tais falhas podem ser desastrosas para o meio ambiente e para a sociedade. O objetivo deste trabalho é estudar a tenacidade, utilizando ensaio Charpy, de um tubo API 5L X65 sour após diferentes tempos de imersão em uma solução saturada com H2S. O eletrólito empregado foi a solução A (ácido acético contendo cloreto de sódio) da norma NACE TM0284 (2011), fazendo-se desaeração com injeção de N2, seguida de injeções de H2S. Os materiais foram submetidos a: ensaios de resistência a HIC segundo a norma NACE TM0284 (2011) e exames em microscópio óptico e eletrônico de varredura para caracterização microestrutural, de inclusões e trincas. As amostras foram submetidas a imersão em solução A durante 96h e 360h, sendo que, após doze dias do término da imersão, foram realizados os ensaios Charpy e exames fractográficos. Foram aplicados dois métodos: o de energia absorvida e o da expansão lateral, conforme recomendações da norma ASTM E23 (2012). As curvas obtidas, em função da temperatura de impacto, foram ajustadas pelo método da tangente hiperbólica. Esses procedimentos foram realizados nas duas seções do tubo (transversal e longitudinal) e permitiram a obtenção dos seguintes parâmetros: energias absorvidas e expansão lateral nos patamares superior e inferior e temperaturas de transição dúctil-frágil (TTDF) em suas diferentes definições, ou seja, TTDFEA, TTDFEA-DN, TTDFEA-FN, TTDFEL, TTDFEL-DN e TTDFEL-FN (identificação no item Lista de Abreviaturas e Siglas). No exame fractográfico observou-se que o material comportou-se conforme o previsto, ou seja, em temperaturas mais altas ocorreu fratura dúctil, em temperaturas próximas a TTDF obteve-se fratura mista e nas temperaturas mais baixas observou-se o aparecimento de fratura frágil. Os resultados mostraram que quanto maior o tempo de imersão na solução A, menor é a energia absorvida e a expansão lateral no patamar superior, o que pode ser explicado pelo (esperado) aumento do teor de hidrogênio em solução sólida com o tempo de imersão. Por sua vez, os resultados mostraram que há tendência à diminuição da temperatura de transição dúctil-frágil com o aumento do tempo de imersão, particularmente, as TTDFEA-DN e TTDFEL-DN das duas seções do tubo (longitudinal e transversal). Esse comportamento controverso, que pode ser denominado de tenacificação com o decorrer do tempo de imersão na solução A, foi explicado pelo aparecimento de trincas secundárias durante o impacto (Charpy). Isso indica uma limitação do ensaio Charpy para a avaliação precisa de materiais hidrogenados.

Anisotropic characterization of crack growth in the tertiary flow of asphalt mixtures in compression

Asphalt mixtures exhibit primary, secondary, and tertiary stages in sequence during a rutting deterioration. Many field asphalt pavements are still in service even when the asphalt layer is in the tertiary stage, and rehabilitation is not performed until a significant amount of rutting accompanied by numerous macrocracks is observed. The objective of this study was to provide a mechanistic method to model the anisotropic cracking of the asphalt mixtures in compression during the tertiary stage of rutting. Laboratory tests including nondestructive and destructive tests were performed to obtain the viscoelastic and viscofracture properties of the asphalt mixtures. Each of the measured axial and radial total strains in the destructive tests were decomposed into elastic, plastic, viscoelastic, viscoplastic, and viscofracture strains using the pseudostrain method in an extended elastic-viscoelastic correspondence principle. The viscofracture strains are caused by the crack growth, which is primarily signaled by the increase of phase angle in the tertiary flow. The viscofracture properties are characterized using the anisotropic damage densities (i.e., the ratio of the lost area caused by cracks to the original total area in orthogonal directions). Using the decomposed axial and radial viscofracture strains, the axial and radial damage densities were determined by using a dissipated pseudostrain energy balance principle and a geometric analysis of the cracks, respectively. Anisotropic pseudo J-integral Paris' laws in terms of damage densities were used to characterize the evolution of the cracks in compression. The material constants in the Paris' law are determined and found to be highly correlated. These tests, analysis, and modeling were performed on different asphalt mixtures with two binders, two air void contents, and three aging periods. Consistent results were obtained; for instance, a stiffer asphalt mixture is demonstrated to have a higher modulus, a lower phase angle, a greater flow number, and a larger n1 value (exponent of Paris' law). The calculation of the orientation of cracks demonstrates that the asphalt mixture with 4% air voids has a brittle fracture and a splitting crack mode, whereas the asphalt mixture with 7% air voids tends to have a ductile fracture and a diagonal sliding crack mode. Cracks of the asphalt mixtures in compression are inclined to propagate along the direction of the external compressive load. © 2014 American Society of Civil Engineers.

Effect of crack depth and specimen width on fracture toughness of a carbon steel in the ductile-brittle transition region

The effects of crack depth (a/W) and specimen width W on the fracture toughness and ductile±brittle transition have been investigated using three-point bend specimens. Finite element analysis is employed to obtain the stress-strain fields ahead of the crack tip. The results show that both normalized crack depth (a/W) and specimen width (W) affect the fracture toughness and ductile±brittle fracture transition. The measured crack tip opening displacement decreases and ductile±brittle transition occurs with increasing crack depth (a/W) from 0.1 to 0.2 and 0.3. At a fixed a/W (0.2 or 0.3), all specimens fail by cleavage prior to ductile tearing when specimen width W increases from 25 to 40 and 50 mm. The lower bound fracture toughness is not sensitive to crack depth and specimen width. Finite element analysis shows that the opening stress in the remaining ligament is elevated with increasing crack depth or specimen width due to the increase of in-plane constraint. The average local cleavage stress is dependent on both crack depth and specimen width but its lower bound value is not sensitive to constraint level. No fixed distance can be found from the cleavage initiation site to the crack tip and this distance increases gradually with decreasing inplane constraint.

Effect of constraint on ductile crack growth and ductile-brittle fracture transition of a carbon steel

Ductile-brittle fracture transition was investigated using compact tension (CT) specimens from -70oC to 40oC for a carbon steel. Large deformation finite element analysis has been carried out to simulate the stable crack growth in the compact tension (CT, a/W=0.6), three point-point bend (SE(B), a/W=0.1) and centre-cracked tension (M(T), a/W=0.5) specimens. Experimental crack tip opening displacement (CTOD) resistance curve was employed as the crack growth criterion. Ductile tearing is sensitive to constraint and tearing modulus increases with reduced constraint level. The finite element analysis shows that path-dependence of J-integral occurs from the very beginning of crack growth and ductile crack growth elevates the opening stress on the remaining ligament. Cleavage may occur after some ductile crack growth due to the increase of opening stress. For both stationary and growing cracks, the magnitude of opening stress increases with increasing in-plane constraint. The ductile-brittle transition takes place when the opening stress ahead of the crack tip reaches the local cleavage stress as the in-plane constraint of the specimen increases.

A finite element analysis of dynamic fracture initiation by ductile failure mechanisms in a 4340 steel

In some recent dropweight impact experiments [5] with pre-notched bend specimens of 4340 steel, it was observed that considerable crack tunneling occurred in the interior of the specimen prior to gross fracture initiation on the free surfaces. The final failure of the side ligaments happened because of shear lip formation. The tunneled region is characterized by a flat, fibrous fracture surface. In this paper, the experiments of [5] (corresponding to 5 m/s impact speed) are analyzed using a plane strain, dynamic finite element procedure. The Gurson constitutive model that accounts for the ductile failure mechanisms of micro-void nucleation, growth and coalescence is employed. The time at which incipient failure was observed near the notch tip in this computation, and the value of the dynamic J-integral, J d, at this time, compare reasonably well with experiments. This investigation shows that J-controlled stress and deformation fields are established near the notch tip whenever J d , increases with time. Also, it is found that the evolution of micro-mechanical quantities near the notch root can be correlated with the time variation of J d .The strain rate and the adiabatic temperature rise experienced at the notch root are examined. Finally, spatial variations of stresses and deformations are analyzed in detail.

Dynamic growth of tensile cracks by ductile and brittle fracture mechanisms in a viscoplastic material

In this paper, a finite element analysis of steady-state dynamic crack growth under Mode I, plane strain, small-scale yielding conditions is performed in a rate dependent plastic material characterized by the over-stress model. The main objective of the paper is to obtain theoretically the dependence of dynamic fracture toughness on crack speed. Crack propagation due to a ductile (micro-void) mechanism or a brittle (cleavage) mechanism, as well as transition from one mode to another are considered. The conversion from ductile to brittle has been observed experimentally but has received very little attention using analytical methods. Local fracture criteria based on strains and stresses are used to describe ductile and brittle fracture mechanisms. The results obtained in this paper are in general agreement with micro-structural observations of mode conversion during fracture initiation. Finally, the particular roles played by material rate sensitivity and inertia are examined in some detail.

Numerical simulations of fracture initiation in ductile solids under mode I, dynamic loading

In this paper, an overview of some recent computational studies by the authors on ductile crack initiation under mode I, dynamic loading is presented. In these studies, a large deformation finite element procedure is employed along with the viscoplastic version of the Gurson constitutive model that accounts for the micro-mechanical processes of void nucleation, growth and coalescence. A three-point bend fracture specimen subjected to impact, and a single edge notched specimen loaded by a tensile stress pulse are analysed. Several loading rates are simulated by varying the impact speed or the rise time and magnitude of the stress pulse. A simple model involving a semi-circular notch with a pre-nucleated circular hole situated ahead of it is considered. The growth of the hole and its interaction with the notch tip, which leads to plastic strain and porosity localization in the ligament connecting them, is simulated. The role of strain-rate dependence on ductile crack initiation at high loading rates, and the specimen geometry effect on the variation of dynamic fracture toughness with loading rate are Investigated.

On the variability in fracture toughness of `ductile' bulk metallic glasses

The mode I fracture toughness, K-Ic, of ductile bulk metallic glasses (BMGs) exhibits a high degree of specimen-to-specimen variability. By conducting fracture experiments in modes I and II, we demonstrate that the observed high variability in mode I, vis-a-vis mode II, is a result of highly variable propensity for the conversion of shear bands into cracks in mode I whereas in mode II, crack growth direction is fixed. Thus, the measured variability in K-Ic is intrinsic to the nature of BMGs. (C) 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Characterization of the Fracture Work for Ductile Film Undergoing the Micro-Scratch

The interface adhesion strength (or interface toughness) of a thin film/substrate system is often assessed by the micro-scratch test. For a brittle film material, the interface adhesion strength is easily obtained through measuring the scratch driving forces. However, to measure the interface adhesion strength (or interface toughness) for a metal thin film material (the ductile material) by the microscratch test is very difficult, because intense plastic deformation is involved and the problem is a three-dimensional elastic-plastic one. In the present research, using a double-cohesive zone model, the failure characteristics of the thin film/substrate system can be described and further simulated. For a steady-state scratching process, a three-dimensional elastic-plastic finite element method based on the double cohesive zone model is developed and adopted, and the steady-state fracture work of the total system is calculated. The parameter relations between the horizontal driving forces (or energy release rate of the scratching process) and the separation strength of thin film/substrate interface, and the material shear strength, as well as the material parameters are developed. Furthermore, a scratch experiment for the Al/Si film/substrate system is carried out and the failure mechanisms are explored. Finally, the prediction results are applied to a scratch experiment for the Pt/NiO material system given in the literature.

Measurement Of Fracture Toughness And Interfacial Shear Strength Of Hard And Brittle Cr Coating On Ductile Steel Substrate

The fracture toughness and interfacial adhesion properties of a coating on its substrate are considered to be crucial intrinsic parameters determining performance and reliability of coating-substrate system. In this work, the fracture toughness and interfacial shear strength of a hard and brittle Cr coating on a normal medium carbon steel substrate were investigated by means of a tensile test. The normal medium carbon steel substrate electroplated with a hard and brittle Cr coating was quasi-statically stretched to induce an array of parallel cracks in the coating. An optical microscope was used to observe the cracking of the coating and the interfacial decohesion between the coating and the substrate during the loading. It was found that the cracking of the coating initiated at critical strain, and then the number of the cracks of the coating per unit axial distance increased with the increase in the tensile strain. At another critical strain, the number of the cracks of the coating became saturated, i.e. the number of cracks per unit axial distance became a constant after this critical strain. Based on the experiment result, the fracture toughness of the brittle coating can be determined using a mechanical model. Interestingly, even when the whole specimen fractured completely under an extreme strain of the substrate, the interfacial decohesion or buckling of the coating on its substrate was completely absent. The test result is different from that appeared in the literature though the identical test method and the brittle coating/ductile metal substrate system are taken. It was found that this difference can be attributed to an important mechanism that the Cr coating on the steel substrate has a good adhesion, and the ultimate interfacial shear strength between the Cr coating and the steel substrate has exceeded the maximum shear flow strength level of the steel substrate. This result also indicates that the maximum shear flow strength level of the ductile steel substrate can be only taken as a lower bound estimate on the ultimate shear strength of the interface. This estimation of the ultimate interfacial shear strength is consistent with the theoretical analysis and prediction presented in the literature.

Ductile To Brittle Transition In Dynamic Fracture Of Brittle Bulk Metallic Glass

We report an unusual transition from a locally ductile to a pure brittle fracture in the dynamic fracture of brittle Mg65Cu20Gd10 bulk metallic glass. The fractographic evolution from a dimple structure to a periodic corrugation pattern and then to the mirror zone along the crack propagation direction during the dynamic fracture process is discussed within the framework of the meniscus instability of the fracture process zone. This work might provide an important clue in understanding of the energy dissipation mechanism for dynamic crack propagation in brittle glassy materials. (C) 2008 American Institute of Physics.