Kic Ctod시험법

KR
IS
(Fracture Toughness Testing)
KR
IS
KIC & CTOD

Yong-Hak Huh, yhhuh@kriss.re.kr,
Center for Environment & Safety Measurement
KIC
CTOD
KR
IS
KR
IS


Rocket Case failure
KR
IS
KR
IS
WWII Tanker failure

Excessive wear
on stabilizer
jackscrew
death 88 people
IS
Alaska MD-80 crash (1999)
KR
IS
KR
Failure an O-ring
seal(polymer)
Challenger (1986)

Failure Stress
Stress
Crack Size
KR
IS
Design Stress
S
No Failure
KR
Cracks can grow

during the life of a
component
Typical Range of Stress

Typical Stress in Service
Time or Load Cycles
IS
Time or Load Cycles
Highest Stress Expected
Failure
can occur
Failure
will occur
The strength of an engineering structure

is reduced by crack growth in service

Notches act as stress concentrators
KR
IS
(Stress concentration) : using the Inglis ellipse
IS
2b
Stress
KR
2a
Distance

max
a
= 1+ 2
max = maximum stress

= applied stress
KR
IS
(Fracture criteria)
(stable)
(unstable)
IS
Critical Work of Fracture (Gc)

Critical Stress Intensity Factor (Kc).
Critical Crack Tip Opening Displacement (c).
Critical J-Integral (Jc).
KR
Criteria :

(Stress)
(Fracture criteria)
KR
IS

:
( plastic deformation)
(stress
concentration)
(Yield Stress)
Distance
KR
IS

Different fracture criteria are needed to cope with cracked

structures:
Fracture before Yield (very small plasticity).

Fracture before Yield (significant plasticity).
Yield before Fracture (large plasticity).
IS
All the fracture criteria are related to the intrinsic toughness of

the material.
KR
KR
IS
(Fracture criteria)

(LEFM: Linear Elastic Fracture Mechanics)
KR
IS

( )
IS
LEFM
Critical Work of Fracture (Gc).
KR
Critical Stress Intensity Factor (Kc)

(Fracture toughness)
10
Critical work of Fracture
For a crack to propagate:

It must be energetically favourable, and
there must be a mechanism for crack propagation.
Energy is required to create fracture surfaces.
This energy is provided by the release of elastic strain energy due to
crack growth.
KR
IS
Thermodynamics and the Griffith Equation.
2
E
2a
at 2
2a
KR
Ue =
IS
Elastic Strain Energy
Thickness = t
Modulus = E
Surface Energy
U s = 4at s

Elastic strain
energy released
by crack
11
Surface energy
per unit area =
Critical work of Fracture :Griffith Eq.
STABLE
KR
IS
The total energy of the system is a function of crack length.

UNSTABLE
Total Energy
Energy, U
Elastic Strain Energy
Surface Energy
at
U s = 4at s
U = U s Ue
Surface Energy
Critical Crack Length

dU/da=0
Ue =
At the critical crack length

dU
da
2
=0
2 s = a
KR
IS
Crack Length, a
Strain Energy
f =
Total
Energy
U = Us-Ue

2E s
a
The Griffith Equation

critical stress to propagate a
crack of length 2a
12
Critical work of Fracture :Fracture toughness, Gc
EGc
Gc = 2 s + p
f =
KR
IS
The Fracture Toughness, Gc.
KR
IS
Gc is the energy required to propagate the crack

(surface energy s, plastic work p etc).
Gc includes all the work done in the fracture
process zone.
<<<
13
KR
IS
, K,
:

Stress Intensity Factor
IS
KR
= Y a

14
KR
IS
KR
IS
Stress Intensity Factor: Effect of Specimen Geometry

15
KR
IS
E.g. for the Griffith Crack
Equivalence of Gc and Kc
Fracture Toughness, Gc.
IS
Fracture Toughness, Kc.
KR
K c = EGc
f =
EGc
K c = f a
FOR ALL CRACK SHAPES

Kc is easier to use in engineering

16
PLANE
STRESS
K1c
KR
IS
This is due to constraint

and the crack tip plastic
zone size
PLANE
STRAIN
KR
IS
The fracture toughness

depends on specimen
thickness.
Measured Toughness, Kc
Fracture Toughness : Effect of thickness

1
thickness
17
Fracture Toughness : Plane strain & Plane Stress
Plastic Zone (Size ry)
Crack
1 K
ry
6 y
IS
1
ry
2
KR
Plane Stress
KR
IS
The plastic zone

size depends on
constraint
Plane Strain

Plane Strain
Plane Stress
Constraint reduces the
volume of the plastic zone
18
Fracture Toughness : Plane Strain Fracture Toughness, KIC
Thick structures may be less tough than thin structures.

K1c is usually used in engineering design
KR
IS
The plane strain toughness, K1c, is the lowest value.

It is a conservative measure of the toughness.
IS
PLANE STRAIN : Thickness ~ 50 x plastic zone
KR
PLANE STRESS : Thickness ~ plastic zone

19
Tough Materials.
KR
IS
LEFM is often not valid for tough materials.

For valid LEFM K1c measurement
K1c
a, B, W - a 2.5
y
KR
IS

20
General Yielding Fracture Mechanics.
IS
KR
IS
Methods are needed to measure the toughness of tough materials using

small test specimens.
The small test specimen may yield before fracture.
The same material in a large structure may fracture before yielding.
KR
Crack Tip Opening Displacement.

J-Integral.

21
The local conditions of stress and strain at the crack tip which
cause fracture are the same for small test specimens and large
structures.
These are described by the crack tip opening displacement
(c or CTOD)
KR
IS
Crack Tip Opening Displacement (c)
LARGE
SMALL
KR
IS
Plastic
Zone
Distance
Force
Plastic
Zone

Force
Distance
22
Equivalence of c and Gc.
c is measured during the toughness test.
KR
IS
Virtual Work W to extend crack by distance a:

Stress
y
IS
Plastic Zone
Virtual Work to open

crack by distance c
against stress y:
KR
Distance

23
W = Gc a
W = c y a
Kc2
Gc = y c =
E
PLANE STRESS (no constraint)
(c affected by thickness)
The J-Integral.
The J-Integral is a measure of the work done (elastic and

plastic) for crack growth.
KR
IS
W=Jc
Crack Length
a1 < a2
a1
IS
Force
W=Gc
Distance
Distance
ELASTIC

a1
a2
KR
a2
Force
ELASTIC-PLASTIC
24
KR
IS
The J-integral is affected by size in the same way as Gc and Kc

J-Integral measured in small test specimens.
Specimen size ~20x smaller than LEFM
J-integral calculated in yielding cracked structures using finite
element models.
The J-integral characterises the crack tip strain necessary for
crack propagation.
KR
IS
The J-Integral

25
Summary: Criteria for Fracture

The fracture toughness (Gc, dc, Kc, Jc) describes the resistance
to crack propagation.
KR
IS
All these toughness parameters are related

to the crack tip deformation required for
fracture
The measured toughness depends on constraint.

Specimen size and thickness.
Plane stress and plane strain.
The lowest toughness is in PLANE STRAIN.

G1c, K1c, J1c, 1c.
Minimum specimen size for measurement.
IS
KR
Valid measurement in smaller

specimens for J1c and 1c .
The actual toughness of a cracked engineering structure
depends on constraint.

26
KIC
CTOD
KR
IS
KR
IS

27
Standard
KR
IS
BS 7448 (1991) : Fracture Mechanics toughness Tests

ASTM E 1820 (2001) : Standard Test Method for Measurement of
Fracture Toughness
ASTM
BS 7448
E 399
KR
IS
E 1820
BS
E 1737
E 813
BS 5762
E 1290

28
BS 5447
KIC Testing
KR
IS
KR
IS
(ASTM)
: ASTM E399 -> E1820()
ISO 12737 :Metallic material-Determination of
plane-strain fracture toughness

29
KR
IS
ASTM E399 : Standard Test Method for Plane-Strain

Fracture Toughness of Metallic Material
Scope :
IS
Summary of Method
1.6mm KIC .
: Plane Strain Fracture Toughness KIC
KR
2 % -
LEFM
KIC .
30
Load, P
P
A'
KR
IS
Vg
PS=PQ
Pmax
IS
Vg
(A)
0.95
KR
Clip gage displacement, Vg

Autographic X-Y Recorder

31
Compact Specimen
KR
IS
KQ = (PQ/BW1/2) f(a/W)
Bend Specimen
KQ = (PQS/BW3/2) f(a/W)
IS
B : Specimen Thickness
KR
W : Specimen Width
a : Crack Length
S : Distance Between Centers of Rolls

32
start

KIC
KR
IS

Yes
, PQ

Yes
Pmax/PQ <1.10
No
IS
KQ
No
B,a2.5 (KQ/Y)2
KR
Yes
No
Yes
1
KIC=KQ' KIC
end

33
1.5
Rsb, Rsc

Number of Test : 3
Dimension Measurement :
KR
IS
B, W 0.025mm 0.1%
Alignment
Bend specimen
1) Support Roll 1%
2) Span nominal length 0.5%
IS
3) Roll 1%
KR
4) Roll 2
Compact Tension Specimen

1) Upper Rod Lower Rod : 0.76 mm
34
KR
IS
0.55 - 2.75MPa m1/2 /sec
Loading Rate : Stress Intensity Factor

30,000 - 150,000 psi in1/2 /min
Ex) W/B = 2, B = 2 in
Loading Rate : 0.34 - 1.7 kN/s
4,500 - 22,500 lbf/min
IS
Clip-on Gage Installation :
KR
Knife Edge Screw gage Screw


35
Test Record
KR
IS
* Load sensing transducer Displacement gage Output

autographic plot.
* Plot : 0.7 - 1.5

* Load .
IS
* Test Record PQ 1% .
Calculation and Interpretation :
KR
95% Secant Line PQ .

36
Fatigue Crack Length & Requirement
KR
IS
* Crack Length : KQ 3( 1/4, 2/4, 3/4)

0.5% .
* Fatigue Crack Front Requirement
1) ai - aj0.1 aav
2) For Chevron Notch Starter

a(s1, s2) - aav0.1 aav
a(s1) - a(s2)0.1aav
IS
3) For Straight-Through Starter Notch

amin - M(Notch Length) 1.3mm
KR
a(s1, s2) - aav0.15 aav

a(s1) - a(s2)0.1aav
4) Crack Plane 10

37
Pmax/PQ 1.10 : KQ is valid
(A)
KR
IS
Pmax/PQ >1.10 : KQ is invalid
B, a > 2.5 (KQ/sYS)2
(B)
KR
IS
(A), (B) 1.5 .

38
Fmax
KR
IS
F5=FQ
FQ
Fmax=FQ
Ty
p

Fmax
eI
II
eI
I
Ty
p
IS
KR
Ty
p
eI
F5
Force, F
Typical force-displacement records
39
Displacement, V
120
KR
IS
80
60
23 tests A
Kc(ksi in)
100
KR
IS
2.5
2
(Kc/Y)2
1 ksi in = 3.54 kgf/mm3/2

40
18 tests
KIC
in
0.0050 To 0.0057
0.0057 To 0.0062
0.0062 To 0.0065
0.0068 To 0.0071
in
1 1/4
2 1/2
0.0075 To 0.0080
0.0080 To 0.0085
3/4
0.0085 To 0.0100
1/2
0.0071 To 0.0075
KR
0.0065 To 0.0068
YS/E
IS
YS/E
Minimum Recommended
Thickness and Crack Length
KR
IS
Minimum Recommended
Thickness and Crack Length
Specimen dimensions necessary for a valid

determination of KIC
1 3/4
0.0100 or greater
1 1/2
Yong-Hak
Huh, yhhuh@kriss.re.kr,
2008-04-25
41
1/4
KR
IS
Plane Stress State
Plane Strain State
IS
KR
(A)
(Plane Strain)

(C)
(B)
42
()
KR
IS
a
(Kc/Y)2 > 2.5
100
80
IS
60
2.5
Kc(ksi in)
120
KR
a
(Kc/Y)2
1 ksi in = 3.54 kgf/mm3/2

43
10
KR
IS
Fatigue Cycle & Fatigue Force
Fatigue Cracking Machine

Load Accuracy : 1%
Testing Machine
Force signal & Gage Disp. Output X-Y Recorder
Load Accuracy : 1%
IS
Clevis & Pin for Compact Specimen
KR
Bend Test Fixture : Support Roll

Knife Edge : .

44
0.355W
2H=1.2W
+
- 0.01W
0.5W
0.188W DIA.
KR
IS
0.25W DIA.
2H=1.2W
+
- 0.01W
W+0.005W
-
0.375W
W+0.005W
-
0.5W
KR
IS
Alternative C(T) Specimen Designs
C(T) Specimen for pin of

0.24W(+0.000W/-0.005W)diameter


0.1875W(+0.000W/-0.001W)diameter
45
( )
0.6W
KR
IS
0.3W0.005W
1.25D
0.025W
R 2.54
IS
0.26W
0.25W0.005W
0.5W
R 1.270.254

0.25W
0.025W
KR
.
( 0.375in )
0.5W 0.015W
0.25W
0.5W 0.005W
A , 0.002in .
0.24W + 0.000W/- 0.005W .
Y 1379MPa 0.3W + 0.005W/-0.000W.
0.288W +0.000W/-0.005W .
46
Fatigue Pre-cracking
KR
IS
Pre-crack : .
Crack Length (Crack Starter Notch + Fatigue Crack) : 0.450.55 W

Fatigue Crack : 0.025 W 1.3 mm
: -1 < (/) < 0.1
KR
IS
Cycle Number : 104 -106

Specimen Size
Notch Preparation
Stress Intensity Factor Level

47
Fatigue Pre-cracking
KR
IS
Pre-cracking (2.5 % of Crack)

Kf
(max)
/ E 0.00032 mm1/2
Kf
(max)
0.6 KQ
Kf
(max)
f(min)
0.9 Kf
Crack Initiation
Pre-cracking : Kmax < 0.8 KQ
(max)
Sharp Notch Tip
IS
Statically Preloading : Compressive
KR
Negative Fatigue Load Ratio

Crack :
, 180.

48
KR
IS
30
30
af
1.5mmW/10
a1
a2
a3
120
120
KR
a1
a2
a3
IS
1.5mmW/10
( )
( )
Notch Radius
Straight-Across Notch : 0.08mm
Chevron Notch : 0.25 mm

49
af
KIC
CTOD
KR
IS
KR
IS

50
COD (Crack Opening Displacement)
.
BS 5762 (1979) :
Crack Opening Displacement(COD) Testing
ASTM E 1290 (1989) :
Crack-Tip Opening Displacement(CTOD) Fracture
Toughness Measurement
KR
IS
Crack Tip
IS
~
0y
Plastic zone size
KR
~
0ys
COD
Crack tip
rp*

(Dugdale model)
51
Definition of CTOD
Plastic zone
~
0y
~
0ys
Dugdale model
IS
Plastic zone size
r*
p

COD
KR
Crack tip
KR
IS
The displacement of the surfaces of a crack normal to the

original (undeformed) crack plane at the tip of the fatigue
precrack (mm).
52
KR
IS
KR
IS
( )

: COD
53
: CTOD
KR
IS
Notch Profile During Bending
(Measured With Clip Gage)
Knife Edge to
Support Clip Gage
Z
a
Apparent Center
of Rotation
)
COD
CTOD
IS
(W-a
CMD
r (cWa)
KR
Angle of Bend
CTOD = {(COD)r(W-a)}/{a+r(W-a)}

54
r(W-a)
KR
IS
Various physical definitions of CTOD
plastic zone
a) Early idealisation
c) Elastic plastic interface
KR
IS
b) More realistic shape
Original crack
Deformed crack
d) Tengent CTOD e) CTOD at original crack tip

position
(Dawes)

55
f) CTOD at position subtending @90

at crack tip (Rice)
Flowchart for CTOD Testing
KR
IS

()
CTOD
KR
IS

YES
CTOD

56
NO
KR
IS
C(T) Specimen Designs
0.5W
W+0.005W
-
0.5W
0.355W
W+0.005W
-
0.375W
2H=1.2W
+- 0.01W
0.188W DIA.
KR
IS
0.25W DIA.
2H=1.2W
+- 0.01W

0.1875W(+0.000W/-.001W)diameter

0.24W(+0.000W/-).005W)diameter

57
W+0.005W
-
KR
IS
Proportional SE(B) Specimens

: Dimensions and Tolerances
TEST SPECIMEN
a
2.25W
2.25W
B
B=W/2 +- 0.010W
TEST SPECIMEN
KR
W+0.005W
-
IS
(Rectangular Section),
2.25W
2.25W
(Square Section),

58
W+0.01W
-
KR
IS
@ 60
IS
KR
Notch Width N
= 0.065Wmax(if W is over 25mm)
1.5mm max (if W is less than or equal to 25mm)

59
Crack Plane Orientation Code for Rectangular Section

L
T-S
ROLLING DIRECTION
EXTRUSION DIRECTION
AXIS OF FORGING
KR
IS
LENGTH
LONGITUDINAL
S-T
L-S
IS
T-L
S-L
KR
L-T
WIDTH
LONG TRANSVERSE

THICKNESS
SHORT TRANSVERSE
60
SE(B) Test Fixture Design
KR
IS
S=4W+0.02W
-
TEST SPECIMEN
IS
DISPLACEMENT GAGE
TEST FIXTURE
KR

61
Clevis for CT Specimen

0.6W
KR
IS
0.3W0.005W
D
1.25D
.
( 0.375in
)
: 0.24W+0.000W
-0.005W
R 1.270.254
0.5W
IS
0.25W0.005W
0.025W
0.26W
Y 1379MPa
-: 0.3W + 0.005W
-0.000W.
- : 0.288W+0.000W
-0.005W
R 2.54
KR
0.025W

0.25W
0.5W 0.015W
0.25W
0.5W 0.005W
A , 0.002in .
62
Displacement Measuring Devices
KR
IS
0.188
0.186
1.625
1.620
0.188
0.186
T1
0.020
R
0.010
C1
C2
KR
IS
T2

70
110
0.006
R
0.004
90
0.021
0.019
60
0.030
0.025
63
701
0.375
0.373
Displacement Measuring Devices
KR
IS
: Knife Edge
0.07
0.06
0.125
0.100
IS
0.023in
KR
N
4560
90
0.25
0.20

.
2C+ W/2
0.06
0.05

.
Notch Width N
= 0.065Wmax(if W is over 25mm)
1.5mm max (if W is less than or equal to 25mm)

64
Fatigue precrack
Pf = 0.5(Bb0Y/S)
Pf = 0.4Bb02Y/(2W+a0)
KR
IS
Load for fatigue precracking < Pf
for SE(B) specimen

for CT specimen
Fatigue precrack length : Notch tip

1.25mm.
IS
Main problems during fatigue precracking
1 2 3 4 5 6 789
Machined notch
Fatigue crack
Slow crack growth
Post-test fracture
Post-test fracture
initiating saw cut
Fracture test piece face
KR
1). Crack tip bowing

2). Effects of residual stress
3). Crack tip location
65
KR
IS

Crack tip bowing
1 2 3 4 5 6 789
Notch tip
W
stress field :
Machined notch
Fatigue crack
Post-test fracture
KR
IS

Post-test fracture
initiating saw cut
.

66
KR
IS
Effects of residual stress
Notch
Fatigue
precrack
Notch
Fatigue
precrack
Multipass weld specimen : -

-
IS
Singlepass weld specimen : -

-
KR
Notch
Fatigue
precrack
1% Strain (Dawes) : Notch

Shape of crack Propagation
67
KR
IS
Crack tip location
COD toughness .
KR
IS
(, HAZ, )-

68
COD Testing
KR
IS
up to Pf
stress intensity factor : 0.55 ~ 2.75 MPam1/2 /s
(30000 ~ 150000 psi in 1/2 /min)
KR
IS
crosshead or clip gage displacement control

69
Popin
Pop-in
Pc
Pi
Pi
Vc
Vp
Vi
IS
(d)
KR
Vp
(c)
(b)
(a)
Vi
Vi
Vc
Pi
Vp
Vp
Vp
Vm
Vu
Vu
Load, P
Pm
Pu
Pu
Pc
KR
IS
Type of Load Versus Clip Gage

Displacement Records
(e)
Vp
Vp
Vp
Clip gage displacement, v g

70
(a), (b)
: critical CTOD
c
(c),(d),(e)
: u, m
Calculation of c, u, m
KR
IS
Max. pop-in crack extension > 0.04b0

- calculate c, u
Analysis of Experimental Data
= K2(1-2)/2YS E +rp(W-a0)p/[rp(w-a0)+a0+z]
K=YP/[BW1/2]
Qualifying CTOD values
KR
IS
- difference between the max. and min. of all 9 crack length < 0.1a0
- fatigue crack front
: not closer to the machined notch than the lesser of 0.025W or 1.3mm
- plane of the fatigue crack surface
: not exceed an angle of 10o from the plane of the notch
- crack front : not multi-planar or branched
71
KR
IS
Autographic test plot

Maximum load
5
12 3 4 5 6 789
IS
Load P
Machined notch
Fatigue crack
Slow crack growth
Post-test fracture
Post-test fracture
initiating saw cut
KR
Clip gauge displacement Vg

72
0.2mm
offset
KR
1.5mm
offset
1mm
offset
IS
0.15mm
offset
0.5mm
offset
KR
IS
CTOD vs Crack Extension

R-curve
= 0.4221(0.2972+ a p)
ap
73
0.5971
KR
IS
COD vs slow crack growth (R-curve)
COD
KR
IS
Initiation
Slow crack growth

74
Kf < 0.63 ys B
KR
IS
R = Pfmin / Pfmax < 0.1
1/2
0.45 < a/W < 0.55
ai - aj < 0.05W ( i, j = 1,2,3)
IS
amax - amin < 0.1W
KR
amin - M > 0.025W or 1.25 mm

75

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KR

(Fracture Toughness Testing)

KIC & CTOD

Yong-Hak Huh, yhhuh@kriss.re.kr,

WWII Tanker failure

Yong-Hak Huh, yhhuh@kriss.re.kr,

Alaska MD-80 crash (1999)

Yong-Hak Huh, yhhuh@kriss.re.kr,

Cracks can grow

Typical Range of Stress

Time or Load Cycles

Highest Stress Expected

The strength of an engineering structure

Yong-Hak Huh, yhhuh@kriss.re.kr,

Notches act as stress concentrators

(Stress concentration) : using the Inglis ellipse

Yong-Hak Huh, yhhuh@kriss.re.kr,

max = maximum stress

Critical Work of Fracture (Gc)

Yong-Hak Huh, yhhuh@kriss.re.kr,

Yong-Hak Huh, yhhuh@kriss.re.kr,

Different fracture criteria are needed to cope with cracked

Fracture before Yield (very small plasticity).

All the fracture criteria are related to the intrinsic toughness of

Yong-Hak Huh, yhhuh@kriss.re.kr,

(LEFM: Linear Elastic Fracture Mechanics)

Critical Work of Fracture (Gc).

Critical Stress Intensity Factor (Kc)

Critical work of Fracture

For a crack to propagate:

Thermodynamics and the Griffith Equation.

Elastic Strain Energy

Yong-Hak Huh, yhhuh@kriss.re.kr,

Critical work of Fracture :Griffith Eq.

The total energy of the system is a function of crack length.

Elastic Strain Energy

Critical Crack Length

At the critical crack length

Yong-Hak Huh, yhhuh@kriss.re.kr,

The Griffith Equation

Critical work of Fracture :Fracture toughness, Gc

The Fracture Toughness, Gc.

Gc is the energy required to propagate the crack

Stress Intensity Factor

Yong-Hak Huh, yhhuh@kriss.re.kr,

Stress Intensity Factor: Effect of Specimen Geometry

Yong-Hak Huh, yhhuh@kriss.re.kr,

E.g. for the Griffith Crack

Fracture Toughness, Gc.

Fracture Toughness, Kc.

FOR ALL CRACK SHAPES

Yong-Hak Huh, yhhuh@kriss.re.kr,

Kc is easier to use in engineering

This is due to constraint

The fracture toughness

Fracture Toughness : Effect of thickness

Yong-Hak Huh, yhhuh@kriss.re.kr,

Fracture Toughness : Plane strain & Plane Stress

Plastic Zone (Size ry)

The plastic zone

Yong-Hak Huh, yhhuh@kriss.re.kr,

Fracture Toughness : Plane Strain Fracture Toughness, KIC

Thick structures may be less tough than thin structures.