Ultrasonic Analysis of Cracking Propagation Morphology in the Fusion Zone of High Strength Steel

Cracking morphology in the fusion zone of HQ130 high strength steel was researched by 'the y-slit test' and 'three-point bend test', ultrasonic test and microscope. HQ130 and QJ63 high strength steel was welded by Ar+CO2 gas shielded arc welding under the condition without preheating. Experimental results indicated that welding cracks were produced in the partially melted zone of the weld root of HQ130 steel side and propagated parallel to the fusion zone. The cracks were developed alternatively between the weld and the partially melted zone, and are not strictly ruptured at W/F (weld metal/fusion zone) boundary surface. Controlling weld heat input (E) about 16 kJ/cm could make the cracking rate lowest and satisfy the performance requirement of welded joint zone.

CRACK PROPAGATION IN POLYCRYSTALLINE ELASTIC-VISCOPLASTIC MATERIALS USING COHESIVE ZONE MODELS

Cohesive zone model was used to simulate two-dimensional plane strain crack propagation at the grain level model including grain boundary zones. Simulated results show that the original crack-tip may not be separated firstly in an elastic-viscoplastic polycrystals. The grain interior＇s material properties （e.g. strain rate sensitivity） characterize the competitions between plastic and cohesive energy dissipation mechanisms. The higher the strain rate sensitivity is, the larger amount of the external work is transformed into plastic dissipation energy than into cohesive energy, which delays the cohesive zone rupturing. With the strain rate sensitivity decreased, the material property tends to approach the elastic-plastic responses. In this case, the plastic dissipation energy decreases and the cohesive dissipation energy increases which accelerates the cohesive zones debonding. Increasing the cohesive strength or the critical separation displacement will reduce the stress triaxiality at grain interiors and grain boundaries. Enhancing the cohesive zones ductility can improve the matrix materials resistance to void damage.

PLASTIC ZONE OF SEMI-INFINITE CRACK IN PLANAR KAGOME AND TRIANGULAR LATTICES

The fracture investigations of the planar lattices made of ductile cell walls are currently limited to bending-dominated hexagonal honeycomb. In this paper, the plastic zones of stretching-dominated lattices, including Kagome and triangular lattices, are estimated by analyzing their effective yield loci. The normalized in-plane yield loci of these two lattices are almost identical convex curves enclosed by 4 straight lines, which is almost independent of the relative density but is highly sensitive to the principal stress directions. Therefore, the plastic zones around the crack tip of Kagome and triangular are estimated to be quite different to those of the continuum solid and also hexagonal lattice. The plastic zones predictions by convex yield surfaces of both lattices are validated by FE calculations, although the shear lag region caused by non-local bending effect in the Kagome lattice enlarges the plastic zone in cases of small ratio of rp/l.

Strip-coalesced interior zone model for two unequal collinear cracks weakening piezoelectric media

In this paper, a mathematical strip-saturation model is proposed for a poled transversely isotropic piezoelectric plate weakened by two impermeable unequal-collinear hairline straight cracks. Remotely applied in-plane unidirectional electromechanical loads open the cracks in mode-I such that the saturation zone developed at the interior tips of cracks gets coalesced. The developed saturation zones are arrested by distributing over their rims in-plane normal cohesive electrical displacement. The problem is solved using the Stroh formalism and the complex variable technique. The expressions are derived for the stress intensity factors （SIFs）, the lengths of the saturation zones developed, the crack opening displacement （COD）, and the energy release rate. An illustrative numerical case study is presented for the poled PZT-5H ceramic to investigate the effect of prescribed electromechanical loads on parameters affecting crack arrest. Also, the effect of different lengths of cracks on the SIFs and the local energy release rate （LERR） has been studied. The results obtained are graphically presented and analyzed.

Moving line crack accompanied with damage zone subject to remote tensile loading

In the 1920s, a closed-form solution of the moving Criffith crack was first obtained by Yoffe. Based on Yoffe＇s solution, the Dugdale model for the moving crack case gives a good result. However, the Dugddle model fails when the crack speed is closed to the Rayleigh wave speed because of the discontinuity occurred in the crack opening displacement （COD）. The problem is solved in this paper by introducing a restraining stress zone ahead of the crack tip and two velocity functions. The restraining stresses are linearly distributed and related to the velocity of the moving crack. An analytical solution of the problem is obtained by use of the superposition principle and a complex function method. The final result of the COD is continuous while the crack moves at a Rayleigh wave speed. The characteristics of the strain energy density （SED） and numerical results are discussed, and conclusions are given.

THE DAMAGE PROCESS ZONE CHARACTERISTICS AT CRACK TIP IN CONCRETE

This paper presents a comprehensive derivation of fracture process zone size which closely parallels similar work in fracture of metals and anisotropic solid, but is adapted to conrete. Some nonlinear mechanics models of concrete materials will be discussed by using uniaxial stress assumptions. For uniaxial stress assumption, energy model and fracture model will be presented for nonlinear softening models. Finally, we make a comparison with those models.

Optimisation Method for Determination of Crack Tip Position Based on Gauss-Newton Iterative Technique

In the digital image correlation research of fatigue crack growth rate,the accuracy of the crack tip position determines the accuracy of the calculation of the stress intensity factor,thereby affecting the life prediction.This paper proposes a Gauss-Newton iteration method for solving the crack tip position.The conventional linear fitting method provides an iterative initial solution for this method,and the preconditioned conjugate gradient method is used to solve the ill-conditioned matrix.A noise-added artificial displacement field is used to verify the feasibility of the method,which shows that all parameters can be solved with satisfactory results.The actual stress intensity factor solution case shows that the stress intensity factor value obtained by the method in this paper is very close to the finite element result,and the relative error between the two is only−0.621%;The Williams coefficient obtained by this method can also better define the contour of the plastic zone at the crack tip,and the maximum relative error with the test plastic zone area is−11.29%.The relative error between the contour of the plastic zone defined by the conventional method and the area of the experimental plastic zone reached a maximum of 26.05%.The crack tip coordinates,stress intensity factors,and plastic zone contour changes in the loading and unloading phases are explored.The results show that the crack tip change during the loading process is faster than the change during the unloading process;the stress intensity factor during the unloading process under the same load condition is larger than that during the loading process;under the same load,the theoretical plastic zone during the unloading process is higher than that during the loading process.

CRACK TIP STRUCTURE AND DUCTILE-BRITTLE TRANSITION IN BULK SINGLE CRYSTALS

Based on the crack tip structure a new model of ductile -brittle transition was proposed. Using this new model we calculated the dependence of the transition temperature-strain rate over a wide range of strain rate. Finally the significance of this new model is discussed in detail.

Coupled simulation of recirculation zonal firebox model and detailed kinetic reactor model in an industrial ethylene cracking furnace

A coupled system simulating both firebox and reactor is established to study the naphtha pyrolysis in an industrial tubular furnace.The firebox model is based on zone method including combustion,radiation,and convection to simulate heat transfer in the furnace.A two-dimensional recirculation model is proposed to estimate the flow field in furnace.The reactor model integrates the feedstock reconstruction model,an auto-generator of detail kinetic schemes,and the reactor simulation model to simulate the reaction process in the tubular coil.The coupled simulation result is compared with industrial process and shows agreement within short computation time.

General forms of elastic-plastic matching equations for mode-Ⅲ cracks near crack line

Crack line analysis is an effective way to solve elastic-plastic crack problems. Application of the method does not need the traditional small-scale yielding conditions and can obtain sufficiently accurate solutions near the crack line. To address mode- Ⅲ crack problems under the perfect elastic-plastic condition, matching procedures of the crack line analysis method axe summarized and refined to give general forms and formulation steps of plastic field, elastic-plastic boundary, and elastic-plastic matching equations near the crack line. The research unifies mode-III crack problems under different conditions into a problem of determining four integral constants with four matching equations. An example is given to verify correctness, conciseness, and generality of the procedure.

Weldability and liquation cracking behavior of ZhS6U superalloy during electron-beam welding

The weldability of the ZhS6U nickel-based superalloy, which is prone to solidification cracking during electron-beam welding(EBW) repair processes, was investigated. The effects of two different pre-weld heat-treatment cycles on the final microstructure before and after welding were examined. Welds were made on flat coupons using an EBW machine, and the two heat-treatment cycles were designed to reduce γ′ liquation before welding. Microstructural features were also examined by optical and scanning electron microscopy. The results showed that the change in the morphology and size of the γ′ precipitates in the pre-weld heat-treatment cycles changed the ability of the superalloy to release the tensile stresses caused by the matrix phase cooling after EBW. The high hardness in the welded coupons subjected to the first heat-treatment cycle resulted in greater resistance to stress release by the base alloy, and the concentration of stress in the base metal caused liquation cracks in the heat-affected zone and solidification cracks in the weld area.

EXACT SOLUTIONS OF NEAR CRACK LINE FIELDS FOR MODE I CRACK UNDER PLANE STRESS CONDITION IN AN ELASTIC－PERFECTLY PLASTIC SOLID

The near crack line analysis method has been used in the present paper,The classical small scale yielding conditions have been completely abandoned in the analyses and one inappropriate matching condition used to be used at the elasticplastic boundary has been corrected.The reasonable solution of the plastic stresses near the crack line region has been established.By matching the plastic stresses with the exact elastic stresses at the elastic-plastic boundary,the plastic stresses the length of the plastic zone and the unit normal vector of the elastic-plastic boundary near the crock line region have been obtained for a mode I crack under uniaxial tension,as well as a mode I crack under biaxial tension,which shows that for both conditions the plastic stress componentsσy, and σsy.he length of the plastic zone and the unit normal vector of the elastic-plastic boundary are quite the same while the plastic stress σs is different.

TEM Study on Hydrogen-Induced Cracking of Fe_3Al Alloy

Hydrogen-induced cracking (HIC) of Fe3Al alloy was studied by in situ transmission electron microscope (TEM). Electron transparent specimens were mounted onto a constant displacement device. Stress was applied to the specimen by using a bolt through the device. The results showed that hydrogen enhanced the dislocation emission and motion in Fe3Al alloy. A dislocation free zone (DFZ) was formed following the dislocation emission. Microcrack initiated in the DFZ or at the main crack tip when the emission reached a critical extension. Hydrogen played an important role in the process of brittle fracture of Fe3Al alloy.

Microscopic study of mode I crack tip deformation

By simulating edge dislocation emissions from a mode I crack tip along multiple inclined slip planes, the plastic zone and dislocation-free zone around the crack tip are obtained. It is found that the shape of the mode I plastic zone consists of two leaning forward loops which is better agreement with experimental observations. Except at the crack tip there are also stress peaks in front of the crack tip. A formula of the maximum peak stress as a function of the applied stress intensity factor and the friction stress has been regressed.

Modeling and numerical investigation of slow crack growth and crack arrest in ceramic polycrystals

ntergranular slow crack growth in zirconia polycrystal is described with a cohesive zone model that simulate mechanically the reaction-rupture mechanism underlying stress and environ- mentally assisted failure. A 2D polycrystal is considered with cohesive surfaces inserted along the grain boundaries. The anisotropic elastic modulus and grain-to-grain misorientation are accounted for together with an initial stress state related to the processing. A minimum load threshold is shown to originate from the onset of the reaction-rupture mechanism to proceed where a minimum traction is reached locally and from the magnitude of the initial compression stresses. This work aims at providing reliable predictions in long lasting applications of ceramics.

Effects of strength matching and crack depth on the fracture parameters for welded joints

Fracture parameters of welded joints with different strength matching and crack depth in weld metal are investigated by using the methods of elastoplastic finite element analysis and three point bend specimen test. The results show that for shallow crack, the plastic zone turns large in loading process, and the fracture toughness turns high. The extent of the plastic zone of overmatched joint is larger than that of undermatched joint because it will extends to parent metal from the weld metal in loading process for the same CTOD value. The plastic zone of undermatched joint is restricted within the weld, and the size of that is small. Overmatched joint shows the fracture behaviour of shallow crack may more easily than the undermatched joint, while the two sorts of joint specimens have the same crack depth. Therefore, the fracture-resistant capability of overmatched weld is better than that of undermatched weld. when the toughness of weld metals is similar for both overmatched and undermatched joints.

Effect of deteriorated microstructures on stress corrosion cracking of X70 pipeline steel in acidic soil environment

In order to investigate stress corrosion cracking （SCC） of X70 pipeline steel and its weld joint area in acidic soil environ- ment in China, two simulating methods were used： one was to obtain bad microstructures in heat affected zone by annealing at 1300 ℃ for 10 min and then, quenching in water; the other was to get different simulating solutions of acidic soil in Yingtan in south- east China. The SCC susceptibilities of X70 pipeline steel before and after quenching in the simulating solutions were analyzed using slow stain rate test （SSRT） and potentiodynamic polarization technique to investigate the SCC electrochemical mechanism of different microstructures further. The results show that SCC appears in the original microstructure and the quenched microstructure as the polarization potential decreases. Hydrogen revolution accelerates SCC of the two tested materials within the range of-850 mV to -1200 mV vs. SCE. Microstructural hardening and grain coarsening also increase SCC. The SCC mechanisms are different, anodic dissolution is the key of causing SCC as the polarization potential is higher than the null current potential, and hydrogen embrittlement will play a more important role to SCC as the polarization potential lower than the null current potential.

Elastic-plastic analysis of antiplane crack near crack surface region

The elastic-plastic stress distribution and the elastic-plastic boundary con- figuration near a crack surface region are significant but hard to obtain by means of the conventional analysis. A crack line analysis method is developed in this paper by consid- ering the crack surface as an extension of the crack line. The stresses in the plastic zone, the length, and the unit normal vector of the elastic-plastic boundary near a crack surface region are obtained for an antiplane crack in an elastic-perfectly plastic solid. The usual small scale yielding assumptions are not needed in the analysis.

EXPERIMENTAL GH SINGULARITY FIELD AROUND GROWING CRACK-TIP

The displacement fields u_x,u_y at growing crack tip of LYI2-M specimens with double edge cracks are measured using moire method.The experimental singularity fields are compared with GH theoretical field [12-14].The size and shape of the experimental GH singularity fields are obtained.The error in both the experimental and theoretical evaluations is controlled within ±10%.The experiments show that there is (In A/r)^(+1)singularity dominant around a growing crack tip.The shape of this dominant region ranges from butterfly wing to oblate and circular.Inside GH-field,there is a 3-D deformed damage zone where no GH sin- gularity exists.

Effect of fine precipitates on initiation and propagation of micro-cracks in low alloy Cr-Mo-V steel

The effect of fine precipitates on the initiation and propagation of micro cracks and the length of dislocation free zone (DFZ) in a low alloy Cr Mo V steel was studied by in situ TEM observation for the specimens both in embrittled and toughened conditions. The results show that in the embrittled specimen, dislocations emitted from the crack tip can easily slip by cutting through the precipitates and move away from the crack tip region, so that a long DFZ forms and the brittle fracture occurs via cleavage cracks initiating and propagating. The size of DFZ mainly depends upon the diameter and the interparticle distance of the precipitates in the matrix. In the toughened specimens, the size of DFZ extremely changes with the interparticle distance. Mobile dislocations are emitted from the crack tip and bypassing the particles. The interaction between the dislocations and the particles results in the dislocation pile up and tangle, leading to diminishing of the DFZ. The crack tip is easy to blunt or chang the propagating direction and the crack propagation shows a jagged path.