Initiation and early crack growth in VHCF of stainless steels : Experimental and theoretical analysis

Mechanical fatigue is a failure phenomenon that occurs due to repeated application of mechanical loads. Very High Cycle Fatigue (VHCF) is considered as the domain of fatigue life greater than 10 million load cycles. Increasing numbers of structural components have service life in the VHCF regime, for instance in automotive and high speed train transportation, gas turbine disks, and components of paper production machinery. Safe and reliable operation of these components depends on the knowledge of their VHCF properties. In this thesis both experimental tools and theoretical modelling were utilized to develop better understanding of the VHCF phenomena. In the experimental part, ultrasonic fatigue testing at 20 kHz of cold rolled and hot rolled stainless steel grades was conducted and fatigue strengths in the VHCF regime were obtained. The mechanisms for fatigue crack initiation and short crack growth were investigated using electron microscopes. For the cold rolled stainless steels crack initiation and early growth occurred through the formation of the Fine Granular Area (FGA) observed on the fracture surface and in TEM observations of cross-sections. The crack growth in the FGA seems to control more than 90% of the total fatigue life. For the hot rolled duplex stainless steels fatigue crack initiation occurred due to accumulation of plastic fatigue damage at the external surface, and early crack growth proceeded through a crystallographic growth mechanism. Theoretical modelling of complex cracks involving kinks and branches in an elastic half-plane under static loading was carried out by using the Distributed Dislocation Dipole Technique (DDDT). The technique was implemented for 2D crack problems. Both fully open and partially closed crack cases were analyzed. The main aim of the development of the DDDT was to compute the stress intensity factors. Accuracy of 2% in the computations was attainable compared to the solutions obtained by the Finite Element Method.

Phase-field analysis of finite-strain plates and shells including element subdivision

With the theme of fracture of finite-strain plates and shells based on a phase-field model of crack regularization, we introduce a new staggered algorithm for elastic and elasto-plastic materials. To account for correct fracture behavior in bending, two independent phase-fields are used, corresponding to the lower and upper faces of the shell. This is shown to provide a realistic behavior in bending-dominated problems, here illustrated in classical beam and plate problems. Finite strain behavior for both elastic and elasto-plastic constitutive laws is made compatible with the phase-field model by use of a consistent updated-Lagrangian algorithm. To guarantee sufficient resolution in the definition of the crack paths, a local remeshing algorithm based on the phase- field values at the lower and upper shell faces is introduced. In this local remeshing algorithm, two stages are used: edge-based element subdivision and node repositioning. Five representative numerical examples are shown, consisting of a bi-clamped beam, two versions of a square plate, the Keesecker pressurized cylinder problem, the Hexcan problem and the Muscat-Fenech and Atkins plate. All problems were successfully solved and the proposed solution was found to be robust and efficient.

A novel two-stage discrete crack method based on the screened Poisson equation and local mesh refinement

We propose an alternative crack propagation algo- rithm which effectively circumvents the variable transfer procedure adopted with classical mesh adaptation algo- rithms. The present alternative consists of two stages: a mesh-creation stage where a local damage model is employed with the objective of defining a crack-conforming mesh and a subsequent analysis stage with a localization limiter in the form of a modified screened Poisson equation which is exempt of crack path calculations. In the second stage, the crack naturally occurs within the refined region. A staggered scheme for standard equilibrium and screened Poisson equa- tions is used in this second stage. Element subdivision is based on edge split operations using a constitutive quantity (damage). To assess the robustness and accuracy of this algo- rithm, we use five quasi-brittle benchmarks, all successfully solved.

Finite-strain laminates: Bending-enhanced hexahedron and delamination

With a new finite strain anisotropic framework, we introduce a unified approach for constitutive model- ing and delamination of composites. We describe a finite-strain semi-implicit integration algorithm and the application to assumed-strain hexahedra. In a laminate composite, the laminae are modeled by an anisotropic Kirchhoff/Saint-Venant material and the interfaces are modeled by the exponential cohesive law with intrinsic characteristic length and the criterion by Benzeggagh and Kenane for the equivalent fracture toughness. For the element formulation, a weighted least-squares algorithm is used to calculate the mixed strain. Löwdin frames are used to model orthotropic materials without the added task of per- forming a polar decomposition or empirical frames. To assess the validity of our proposals and inspect step and mesh size dependence, a least-squares based hexahedral element is implemented and tested in depth in both deformation and delamination examples.