Video Lecture On Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 1
Video Lecture On Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 1
We have been discussing concepts related to crack initiation and life estimation in this
chapter. And we had looked at in the last class, for the growth of a fatigue crack, Paris came
out with a very elegant empirical relation relating da by dN and delta k. We call that as the
Paris law. And I said, it is a very important contribution to fracture mechanics. In fact, the
designers looked at utilizing concepts of LEFM, only when they came across the contribution
by Paris. Because that provided a mechanism for them to implement in practice and find out
whether the structure would be safe or not, by knowing how the crack propagates due to
fatigue. And I also mentioned, it’s a very complex phenomena.
And environment has a very important role to play in crack growth. The ingenuity of Paris
law was, he got the kernel of how the crack grows. If he had looked at all issues and
attempted to arrive at an empirical relation, he may not have arrived at an empirical relation
at all. And now, we will see in the discussion today, how modifications of Paris law are
utilized to explain various phenomena observed in actual experimentation? And in fact,
before this chapter, we had also discussed modeling of plastic zone at the crack-tip. That
knowledge would be useful to understand the phenomena observed in the experiments.
See, you will have to keep in mind, fatigue is one of the most difficult type of loading that
acts on the structure. You will invariably have variable amplitude loading. And one of the
difficulties is, finding out the actual load spectrum. It’s not simple. There are methodologies
available. And you have to study the literature. And then only calculate the actual load
spectrum. So invariably, you will have variable amplitude loading. From modeling point of
view, we may study, under constant amplitude loading, how the crack grows? But if you
want to take the knowledge to the field, you will have to account for random loading. And if
you go for random loading, you will have to bring in the observations of crack closure into
your life estimation calculation.
Video Lecture on Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 2
So, one of the difficulties is, how to see whether the crack is fully opened or not. And how do
you judge, whether a specimen displays crack closure phenomena. People also have
methodologies to look at that. And one of the simplest way is, to get the load deflection
curve. So, if you get the load deflection curve for a cracked body experiencing crack closure
is bilinear. This is the observation. And you have the displacement versus applied stress.
And if you look at, the stress displacement relationship is bilinear.
And the question here is, how will you identify when does the crack closes? And when does
the crack opens? This is a very difficult to measure experimentally. And people have found
various ways to do that. One way of describing this is, you say at this stress, when there is a
translation of the slope, the crack is fully opened. And when you have a curved portion
becomes straight here, this you say, that crack is closed. Part of the crack is closed. So, this
is one way of estimation. You know, at this stage, it’s also wise to look at, what was the
history in the case of crack closure. Initially, people did not believe that crack closure could
happen. This was done by Elber. There was an article written by him in Current Contents in
1983. And in that, he says, the original discovery of the crack closure phenomenon was
made when I was a graduate student at the University of New South Wales in Sydney,
Video Lecture on Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 3
Australia. Rather than being the result of years of directed effort, it was a split second
observation made while cutting up a fatigue cracked plate. See, this is very important.
You know, sometimes you do a very systematic study yet you don’t get a result. Here, he
admits it was not a systematic study. He chanced upon an interesting observation. He was a
good experimentalist. He did not miss out the details. See, this is very important.
Experimentalists have to be alert. Look at anything deviating from your basic understanding,
record it. And scrupulously honest. Because if you report what you observe in all its totality,
new theories can develop. That’s what happened in crack closure concept. In fact, when he
reported, it was not accepted by the community. It was rejected also. I will read his quote for
that. He says, because of the geographic location, I was not aware during the ensuing
months, during which I wrote up that discovery into my thesis that I was going to contradict
many of the existing teachings in fracture mechanics. Or how much that phenomenon
contributed to the resolution of the complexity of crack growth under variable amplitude
loading. And what is interesting is, the next few sentences, it says like this. After having my
thesis initially rejected by the first American reviewer, I went to the Federal Republic of
Germany to continue my research’. And the story goes like this. You know, poor fellow, he
found a very nice observation. And when he reported because the conventional thinking was
not able to accept that crack can close. So, they rejected the thesis. Then he carried on. He
joined NASA Langley research center. Now, it is an accepted practice. In fact, what I am
reading is from Current Contents. This says, this week’s citation classic. It was published in
December 12, 1983 where his paper on the significance of fatigue crack closure - damage
tolerance in aircraft structures, published as ASTM- STP- 486 had a very high citation of
240, I think. That’s what I remember, 240 citations. And it is discussed as a citation classic
which was originally rejected. It became a citation classic. And we will further see, what the
crack closure concept is all about.
So, you look at, what is the effective delta K rather than the actual delta K. So, you have to
find out, how to get delta K effective? Several models have been proposed. People have
done experimentation and calculated it. And you will also have to bring in, the effect of
stress ratio R. As a function of R, how does delta K effective changes. So, this is how
research proceeded. And we will see, how they developed delta K effective. So, delta K
effective is K max minus K opening where K op is the value of KI when the crack opens
completely during the cycle.
And you have to note, unlike the fracture toughness, K opening is not a material constant
but depends on a number of factors. So, that makes the problem difficult. Different alloys
exhibit different closure behaviors. So, this is one observation. So, you have to do a lot of
tests, to find out. Even for a given alloy, the closure behavior is different in different loading
regimes. So, that makes the problem much more complex. And I think, you have the paper
by Elber. This is the paper published in 1970, ‘Fatigue crack growth under cyclic tension’.
This was published in Engineering Fracture Mechanics. This is volume number 2 between
37 to 45. You can go and have a look at it, how he has presented the work.
And what is the main difficulty in the experiment? One of the main difficulties in experiments
is obtaining the information of displacement histories at mid-section in a thick specimen.
See, I have already mentioned, the crack opening is not uniform along the front. So, you
have to ensure if I have a thick specimen, the in-between portion whether it has opened or
not, I have to have experimental measurement. Only then, it will be more realistic. That
poses a challenge. It is challenging as it is not easily accessible. I suppose, you have been
able to write these points. And the time is sufficient for you to write.
And before we move further, you know I would also like to share another note which came in
the citation classic which Elber wrote. He mentions like this. The time from the initial
discovery of any phenomenon to a profitable application is often long. In this case, which
means crack closure, the inclusion of crack closure in numerical crack growth calculations
adds significant cost and complexity for gains in accuracy. Only required in the space and
aeronautics industries. Many industries will continue to use simpler and less accurate
theories, leaving the continued work in crack closure as an area of basic research.
So, you go from 0 to maximum and then come down. And make neat sketches of this as
much as possible. So, I have this as the crack. I have the axis as r. This is the distance
measured. And in this axis you have, stress is marked. So, you have Tresca yield criteria. I
have marked this as sigma x. So, this will be horizontal. And there will be some variation of
this along the crack axis. And we have already seen, the plastic zone in the case of mode I
will be something like this. And what is shown in blue is the elastically deformed
neighborhood. The slight light brown color shows a material plastically deformed.
So, what you have to recognize is, even though your external loading is much smaller
because of the presence of a crack, when the load is increased gradually from to 0 to peak,
invariably you will have plastic deformation near the crack-tip. So, this happens during
loading. And what is our focus is, we want to see, what is a residual stress ahead of a crack
in a cycle? This also you have to note. We are just looking at a virgin material. We have
loaded it for the first time. And you have a plastic zone surrounded by an elastic region. And
when I reduce the load, what would happen? Unloading takes place. Whatever that has
happened to the elastic region, it will spring back to its original position. If there is no plastic
deformation at the crack-tip, the spring back would be uniform all throughout. But because
you have plastically deformed zone near the crack-tip, the elastic recovery will go and
compress this zone.
Video Lecture on Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 8
So, you will have a residual compressive stress and a residual tension. You know, if you
understand this, many other discussions, what happens when there is a overload? What
happens if there is a crack closure? For all of this, you have to recognize because the load
is increased and decreased, you have a residual stress formed ahead of the crack-tip. This
is the first knowledge you should get. So, what I will do is, I will replay this animation again.
You have carefully drawn this sketch as much as possible. And what we will do now is, we
will replay the animation where I am showing, what happens when load is increased from 0
to the peak value? So, you will have a plastic zone. And this is the elastic region. And this is
the approximate shape of the plastic zone at the crack-tip, surrounded by elastic region. And
this is schematic. Don’t think, only a circle around the crack is elastic. No, it is not so.
And you have a compression followed by residual tension. If you understand this, all our
future discussions, it becomes easier to discuss. Now, you have to see, if I have multiple
cycles, the crack will go through a plastic wake. We will see that also. I have very nice set of
animations and we will see through that. In a growing fatigue crack, behind the crack-tip, a
plastic wake is developed. You know, I have initial crack length. And what is shown here is,
this is indicated that you are having a cyclical loading. You are seeing, at the end of one
Video Lecture on Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 9
cycle what happens. After several cycles, what happens. You know, the crack is growing in
length.
Plastic wake
shown. Suppose, I reduce the load, what happens? When the load is reduced due to
permanent elongation of the crack lips, they close before the load is 0. So, that is what is
shown here. Ideally, only when the load point comes to this, the value of stress is 0.
But even at this stage, you find the crack is closed. So, the effective SIF has to be calculated
from this point to this. It cannot go from 0 to K max. So, that is the issue that is being
discussed. So, what you are really looking at is, because of cyclical loading, if the load is
increased and decreased, there is residual stress formation. If I have multiple cycles like
this, the crack has to go through the plastic wake. And the plastic wake makes the crack
faces to close before the load reaches 0. So that means, only part of the loading is really felt
by the crack. That is why we have K effective. And this was the model proposed by Elbert.
And later similar models have been proposed for various situations.
So, what you have here is, the crack is fully open when the load is at its peak. But the crack
is closed even before the load has reached 0. So, that is the issue that you have to keep in
mind. And this explains, how to understand the phenomena of crack closure. And you can
see the animation again. For this case, you have the plastic wake. And this explains, what is
the plastic wake? And this shows when the load is reduced. You find when the load is still
having some value, the crack is closed. And you also have the typical residual stress pattern
at zero load. And I think, I can magnify this for you.
appreciation of phenomena is very similar to plasticity induced case. Instead of the plastic
wake, here it would all be dictated by the phase transformation. Otherwise, there is
comparison between the two. And that is what is mentioned here. This is similar to the
plasticity induced crack closure.
Here again, you look at, after few cycles, at the peak load. At the peak load, the crack is
open. Just to distinguish it from plastic wake, here the shading is different. But the pictures
are essentially same. And this is because of phase transformation. And now you see, when
the load is reduced before it reaches 0, the crack is closed. It is because of phase
transformation. So, that is what is indicated here.
Because of the corrosive action, you have corrosion product shown. And when the load is
reduced, you know, because of corrosion products, it appears as if the crack is closed. It has
a similar effect of crack closure. And this is called oxide-induced closure. So, this is
observed in aggressive environment. In every case, discussing on crack closure, we show
the cyclical loading. You see, what happens at the peak load? And what happens when the
load is reduced? And when the crack faces are closed. So, that is the way you have to
interpret what is given on the left and what is given on the right. Left shows the loading. And
the green point shows in the loading history at which point we are really looking at the crack
faces. This is at the peak load. This is at a reduced load.
macroscopic pictures; highly magnified microscopic pictures. That’s the way you have to
look at it. And what is mentioned is, the displacement due to mode II can cause mismatch
between upper and lower crack faces contributing to crack closure phenomena.
And we will also see that as a picture. Here again, you see the load history. At the peak
load, you are looking at it. And at the reduced load, you have a picture like this. I think, I
could magnify it for you. And, this is called mode II induced closure. And this mode II loading
comes at the microscopic level. So, what you will have to keep in mind is, crack closure is
an accepted phenomena. Though it was not initially accepted, later people have recognized
its role. And many other mechanisms also, people have observed and categorized.
So, in all those cases, you should have a methodology, how to find out delta K effective. So,
you have to perform more tests and look at the literature and find out, how to get the delta K
effective. Only then, you will be able to use the crack closure model for finding out the da by
dN. See, there is also another important aspect that you have to keep in mind. Suppose, I
have an overload, is it beneficial from fracture mechanics point of view or not? See, if you
recall, in my early discussion, I have said, plasticity is a friend of fracture mechanics.
And let us see, how the crack growth for this case is? You also have some numbers given to
this. It is varying from 48 MPa to 113 MPa. And you find, the crack growth is something like
this. Suppose, after sometime, I have an overload which goes from positive to negative. It
goes to 188 MPa to minus 28 MPa for the purpose of this graph. And, how does the crack
growth looks like? So, definitely the rate at which crack grows after an overload going from
positive to negative is definitely smaller than what you see when you have constant
amplitude. But has not really benefited the structure. Let me take another case where I have
an overload only in the positive direction.
How does the crack growth rate changes? And what you find here is, when there is overload
only in the positive direction, there is definitely retardation in the crack growth. And I have
another overload here; another overload here. You have to know, why is this so?
Video Lecture on Engineering Fracture Mechanics, Prof. K. Ramesh, IIT Madras 13
Nevertheless, it is beneficial. So, the wisdom, people gained by sheer experience of periodic
proof testing of the structure has helped its life. You have an answer from fracture
mechanics point of view. What way we are going to look at is, the plastic zone would be
much larger. When I have a overload, the plastic zone would be much larger. That has
helped this retardation.
So, your modeling of plastic zone is very important. And recognizing, when you have a
cyclical load, you are going to have a residual stress ahead of the crack-tip. And, when I
have an occasional overload, I will have a very large plastic zone. And this crack has to
wade through that plastic zone. So that, in a sense, retards the crack growth. And you have
a model for that. And this model is proposed by Wheeler. The details of it, we would see in
the next class. Again, he will go back to the basic kernel of how Paris reported da by dN.
There would be modification to that which will accommodate the effect of overload. And this
is very important in the fracture literature - Influence of overload on crack growth.
So, in one graph, you see for constant amplitude, how is the crack growth? For a reversed
overload, how does it retardation take place? For overload in one direction, the retardation is
quite significant. So, in this class, we have essentially looked at concepts of crack closure
proposed by Elber. We also saw, how he arrived at crack closure. How the result was
initially accepted by the community. After sustained effort, he has been able to convenience
a scientific community to accept this phenomena. Now, it has become a routine, in
advanced life estimation calculations. People have embedded that. And the softwares like
NASGRO and such software use this as part of their life estimation calculation. Thank you.