Journal of ASTM International Selected Technical Papers STP 1526 Fatigue and Fracture Mechanics: 37th Volume JAI Guest Editors: Sreeramesh Kalluri MichaelA. McGaw Andrzej Neimitz ASTM International 100 Barr Harbor Drive PO Box C700 West Conshohocken, PA19428-2959 Printed in the U.S.A. ASTM Stock #: STP1526 LibraryofCongressCataloging-in-PublicationData ISBN:978-0-8031-7512-9 ISSN:1040-3094 Copyright©2011ASTMINTERNATIONAL,WestConshohocken,PA.Allrights reserved.Thismaterialmaynotbereproducedorcopied,inwholeorinpart,inanyprinted, mechanical,electronic,film,orotherdistributionandstoragemedia,withoutthe writtenconsentofthepublisher. JournalofASTMInternational„JAI…Scope TheJAIisamulti-disciplinaryforumtoservetheinternationalscientificandengineering communitythroughthetimelypublicationoftheresultsoforiginalresearchand criticalreviewarticlesinthephysicalandlifesciencesandengineeringtechnologies. Thesepeer-reviewedpaperscoverdiversetopicsrelevanttothescienceandresearchthat establishthefoundationforstandardsdevelopmentwithinASTMInternational. PhotocopyRights Authorizationtophotocopyitemsforinternal,personal,oreducationalclassroomuse,or theinternal,personal,oreducationalclassroomuseofspecificclients,isgrantedby ASTMInternationalprovidedthattheappropriatefeeispaidtoASTMInternational,100 BarrHarborDrive,P.O.BoxC700,WestConshohocken,PA19428-2959,Tel: 610-832-9634;online:http://www.astm.org/copyright. TheSocietyisnotresponsible,asabody,forthestatementsandopinionsexpressedin thispublication.ASTMInternationaldoesnotendorseanyproductsrepresentedinthis publication. PeerReviewPolicy Eachpaperpublishedinthisvolumewasevaluatedbytwopeerreviewersandatleast oneeditor.Theauthorsaddressedallofthereviewers’commentstothesatisfactionofboth thetechnicaleditor(s)andtheASTMInternationalCommitteeonPublications. Thequalityofthepapersinthispublicationreflectsnotonlytheobviouseffortsofthe authorsandthetechnicaleditor(s),butalsotheworkofthepeerreviewers.Inkeepingwith long-standingpublicationpractices,ASTMInternationalmaintainstheanonymityof thepeerreviewers.TheASTMInternationalCommitteeonPublicationsacknowledges withappreciationtheirdedicationandcontributionoftimeandeffortonbehalfof ASTMInternational. CitationofPapers Whencitingpapersfromthispublication,theappropriatecitationincludesthepaper authors,“papertitle”,J.ASTMIntl.,volumeandnumber,Paperdoi,ASTMInternational, WestConshohocken,PA,Paper,yearlistedinthefootnoteofthepaper.Acitationis providedasafootnoteonpageoneofeachpaper. PrintedinBaltimore,MD February,2011 Overview Thisspecialtechnicalpublication(STP1526)isacompilationofpaperspre- sented by several authors at the Ninth InternationalASTM/ESIS Sympo- siumonFatigueandFractureMechanics(37thNationalSymposiumonFa- tigue and Fracture Mechanics) and published in the Journal of ASTM International(JAI)aftersuccessfulpeerreviews.TheInternationalSympo- siumwasjointlysponsoredbyASTMCommitteeE08onFatigueandFrac- ture and the European Structural Integrity Society. The Symposium was held during May 20–22, 2009 in Vancouver, British Columbia, Canada, in conjunction with the May 18–19, 2009 standards development meetings of ASTMCommitteeE08. The opening Jerold L. Swedlow memorial lecture was delivered at the SymposiumbyProfessorDr.-Ing.Karl-HeinzSchwalbeonanalyticalmodels forfatiguecrackpropagationandfracture.Thesymposiumfocusedonthree major tracks of fatigue and fracture of structures and materials under 1) thermomechanicalconditions,2)multiaxialloadingconditions,and3)appli- cationofcohesivezonemodelstofractureproblems.Inaddition,severalpa- pers were presented at the Symposium in the traditional areas of fatigue behavior, fracture mechanics and mechanisms, fatigue crack propagation, andeffectsofresidualstressesonfatigueandfracture. In the last decade, physics- and mechanics-based approaches gained prominence in assessing fatigue and fracture related design lives of struc- turesusedinaerospace,surfacetransportation,powergeneration,biomedi- cal,andpetroleumindustries.Advancedstructuresintheseindustriesuti- lize specially engineered materials with heterogeneous properties (for example,materialswithcoatingsasthermalbarriersortoresistwearand corrosion)thatservemultiplepurposesandrequireapplicationofmechan- icsatbothmicro-andmacro-scalestoestimatethedamagesassociatedwith fatigue and fracture. In particular, estimating the remaining lives of such structures under prototypical loading conditions poses significant chal- lenges during the operation of those structures. Complexities associated withthechallengesincreasesignificantlywhentheadvancedstructuresare subjected to loads in multiple directions and nonisothermal loading condi- tions. Papers presented at the Symposium and compiled in this STP(after publicationinJAI)addresssomeofthesechallengingareas. Atotal of 33 papers, including the Jerold L. Swedlow memorial lecture paper,arecompiledinthisSTP.Theremaining32papersaregroupedinto thefollowingcategories:1)elastic—plasticfracturemechanicsandfracture mechanisms, 2) fatigue behavior and life estimation, 3) fatigue crack growth, 4) multiaxial fatigue and fracture, 5) residual stress effects on fa- tigue and fracture, 6) fatigue and fracture under thermomechanical condi- tions,and7)applicationoffracturemechanicsandcohesivezonemodels.It is our sincere hope that papers compiled in this STP advance the state-of- ix the-artinanalyticalmethodsandtestingtechniquesforfatigueandfracture mechanics.Inaddition,someofthepapersdocumentedinthisSTPareex- pectedtopromotethedevelopmentoffatigueandfracturerelatedstandards withinASTMCommitteeE08. Wewouldliketothankalltheauthorsfortheirvaluablecontributionsto the STP and all the reviewers for their thorough reviews, which substan- tiallyimprovedthequalityofpublishedpapers.WearegratefultoMs.Dor- othy Fitzpatrick and Ms. Hannah Sparks atASTM International for their meticulous organization of the Symposium, Ms. Susan Reilly atASTM In- ternationalforherhelpwiththeSTP,andMs.LindaBonielloattheAmeri- canInstituteofPhysics(AIP)forherexcellentcoordinationofpeerreviews forallthepapersandpublicationofthemanuscriptsinJAI. Dr.SreerameshKalluri OhioAerospaceInstitute NASAGlennResearchCenter BrookPark,Ohio,USA SymposiumCo-ChairmanandJAIGuestEditor Dr.MichaelA.McGaw McGawTechnology,Inc. FairviewPark,Ohio,USA SymposiumCo-ChairmanandJAIGuestEditor Prof.AndrzejNeimitz KielceUniversityofTechnology Kielce,Poland SymposiumCo-ChairmanandJAIGuestEditor x Contents ........................................................................ Overview ix TheJeroldL.SwedlowMemorialLecture OntheBeautyofAnalyticalModelsforFatigueCrackPropagationandFracture—A PersonalHistoricalReview ....................................................... K.-H.Schwalbe 3 Elastic-PlasticFractureMechanicsandFractureMechanisms InvestigationofTransitionFractureToughnessVariationwithintheThicknessof ReactorPressureVesselForgings ....................... E.Lucon,A.Leenaers,W.Vandermeulen,andM.Scibetta 77 MoreAccurateApproximationofJ-IntegralEquationforEvaluatingFractureResistance Curves ............................................... X.-K.ZhuandJ.A.Joyce 90 ApplicationofAdvancedMasterCurveApproachestotheEUROFractureToughness DataSet ................................................ E.LuconandM.Scibetta 116 RevisitofASTMRound-RobinTestDataforDeterminingRCurvesofThin-Sheet Materials ................................................. X.-K.ZhuandB.N.Leis 130 TheAnalysisofFractureMechanismsofFerriticSteel13HMFatLowTemperatures ............................................. A.NeimitzandJ.Galkiewicz 159 AWeibullStressModeltoPredictEffectsofWeldStrengthMismatchonCleavage FractureToughness ........................................................... C.Ruggieri 178 FatigueBehaviorandLifeEstimation FatigueInitiationModelingof316LNSteelBasedonNonlocalPlasticityTheory ....................................... J.Schwartz,O.Fandeur,andC.Rey 197 MechanicalConditioningofSuperelasticNitinolWireforImprovedFatigue Resistance ......................................................... J.E.Schaffer 217 Creep-FatigueRelationshipsinElectroactivePolymerSystemsandPredictedEffectsin anActuatorDesign ............................... A.M.Vinogradov,C.M.Ihlefeld,andI.Henslee 227 EffectsofMicrostructureontheIncipientFatigueandFrettingCrackProcessesin Al-Cu-LiAlloys .......................... J.Delacroix,J.-Y.Buffiere,S.Fouvry,andA.Danielou 241 DevelopmentofaSliding-RollingContactFatigueTester ........................................ G.Dvorak,M.Zahui,andB.Mitton 254 FatigueCrackGrowth DeterminationofΔK byCompressionPre-CrackinginaStructuralSteel th .................................... M.Carboni,L.Patriarca,andD.Regazzi 279 Crack-ClosureBehaviorof7050AluminumAlloynearThresholdConditionsforWide RangeinLoadRatiosandConstantK Tests max ............................. J.C.Newman,Jr.,Y.Yamada,andJ.A.Newman 297 DefinitionoftheInfluenceofPoreSizeontheFatigueLimitUsingShortCrack PropagationExperiments ................................ C.Oberwinkler,H.Leitner,andW.Eichlseder 320 FatigueCrackPropagationBehaviorofanInertiaFrictionWelded(cid:2)/(cid:3)Titanium Alloy ..................... Y.Pardhi,C.Dungey,G.Baxter,P.Bowen,andT.P.Halford 336 FatigueCrackPropagationinSAWSeamWeldsofAPI5LX42SteelPipeintheRadial ShortDirection ........ D.AngelesHerrera,J.L.GonzálezVelázquez,andA.deJ.MoralesRamírez 355 MultiaxialFatigueandFracture FatiguefromanInducedDefect:ExperimentsandApplicationofDifferentMultiaxial FatigueApproaches ................................................ G.LeopoldandY.Nadot 371 EffectofCladdingonBiaxiallyLoadedUndercladPart-ThroughCracks ...................................... M.Scibetta,E.Lucon,andT.Houben 394 AnAssessmentofCumulativeAxialandTorsionalFatigueinaCobalt-Base Superalloy ............................................. S.KalluriandP.J.Bonacuse 421 ANonLocalMultiaxialFatigueApproachtoAccountforStressGradientEffectApplied toCrackInitiationinFretting ........................... R.Amargier,S.Fouvry,C.Poupon,andL.Chambon 441 ExperimentalandNumericalAnalysesofFatigueBehaviorofWeldedCruciform Joints ............................ C.Erny,D.Thévenet,J.Y.Cognard,andM.Korner 466 ResidualStressEffectsonFatigueandFracture ImportanceofResidualStressesandSurfaceRoughnessregardingFatigueof TitaniumForgings ................................ B.Oberwinkler,M.Riedler,andW.Eichlseder 489 FatigueAssessmentofBrazedT-JointsBasedonDamageToleranceIncluding ResidualStressEffects ......................................... H.-J.SchindlerandC.Leinenbach 504 ResidualStrainEffectsonBridgingStressofCrackedandDelaminatedFiberMetal Laminates .............................................. J.T.WangandS.W.Smith 520 Elastic-PlasticStressAnalysisofCold-WorkedPin-LoadedHoles ........................... S.Ismonov,S.R.Daniewicz,andJ.C.Newman,Jr. 553 TheInfluenceofElasticFollow-UpontheIntegrityofStructures ........................................... S.Hadidi-MoudandD.J.Smith 570 FatigueandFractureUnderThermomechanicalConditions LifetimeCalculationofThermo-MechanicallyLoadedMaterials„Al,Cu,Ni,andFe Alloys…BasedonEmpiricalMethods .................................... H.Koeberl,G.Winter,andW.Eichlseder 589 Mesh-FreeSolutionofTwo-DimensionalEdgeCrackProblemsunderThermo- MechanicalLoad ............. M.Pant,I.V.Singh,B.K.Mishra,V.Bhasin,K.Sharma,andI.A.Khan 604 TemperatureCalibrationTechniquesforTMFTesting ................................. D.C.Dudzinski,W.Beres,andR.K.Kersey 620 ApplicationofFractureMechanicsandCohesiveZoneModels FatigueCrackGrowthSimulationinComponentswithRandomDefects ............................................. M.ShiraniandG.Härkegård 631 CohesiveZoneModelingofInitiationandPropagationofMultipleCracksinHardThin SurfaceCoatings ........................ A.Laukkanen,K.Homberg,H.Ronkainen,andK.Wallin 646 ModelingofCrackPropagationinWeldBeam-to-ColumnConnectionsSubmittedto CyclicLoadingwithaCohesiveZoneModel ...................... C.Lequesne,A.Plumier,L.Duchêne,andA.M.Habraken 675 ..................................................................... AuthorIndex 697 .................................................................... SubjectIndex 699 THE JEROLD L. SWEDLOW MEMORIAL LECTURE ReprintedfromJAI,Vol.7,No.8 doi:10.1520/JAI102713 Availableonlineatwww.astm.org/JAI Karl-Heinz Schwalbe1 On the Beauty of Analytical Models for Fatigue Crack Propagation and Fracture—A Personal Historical Review ABSTRACT: Starting from James Rice’s classical work on cyclic plastic stresses and deformations in the plastic zone of a Mode III loaded crack, it willbeshownthatthecracktipopeningdisplacementofaModeIcrackina work hardening material can be written in analytical form. This result was thenusedtoformulatethebluntinglineforJ-integraltestingandtoestimate the fatigue crack propagation rate of a number of materials. In a similar manner—based on the strain distribution within the plastic zone of a work hardeningmaterial—theinitiationofcrackextensionunderstaticloadingwas estimated. The stress distribution ahead of a crack and the Ritchie, Knott. and Rice model were applied to the ductile-to-brittle transition of ferritic steels as well as the transition temperature shift due to neutron irradiation. InspiredbyFongShih’scontributiontotheElectricPowerResearchInstitute Handbook, a simple but straightforward method for expressing the (cid:2) crack 5 openingdisplacementasacrackdrivingforceforfullyplasticconditionswas developed, finally ending up in a comprehensive assessment method for crackedcomponents.Theapplicationtomismatchedweldedjointswasdem- onstratedtobepossibleiftheyieldloadformismatchisavailable;thislatter taskwasperformedusingbothsliplinetheoryandfiniteelement(cid:2)FE(cid:3)analy- ses.Applicationexamplesofthesemodelswillbeshown,anditwillbeseen thatestimatesusingthesemodelsareinreasonableagreementwithexperi- mental results and FE analyses. Several elements of these models have madetheirwaytointernationalcodesandstandards. Manuscript received September 2, 2009; accepted for publication June 21, 2010; pub- lishedonlineAugust2010. 1Consultant,TechnischeUniversitätHamburg-Harburg;Ruhr-UniversitätBochum;and Anemonenweg32,21360Vögelsen(cid:2)Lüneburg(cid:3),Germany. Cite as: Schwalbe, K.-H., ‘‘On the Beauty of Analytical Models for Fatigue Crack Propagation and Fracture—A Personal Historical Review,’’ J. ASTM Intl., Vol. 7, No. 8. doi:10.1520/JAI102713. Copyright © 2010 by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken,PA19428-2959. 3 4 JAI•STP1526ONFATIGUEANDFRACTUREMECHANICS KEYWORDS: fatigue crack propagation, crack tip blunting, structural assessment, ductile-to-brittle transition, crack opening displacement, ductiletearing Nomenclature Roman Symbols a (cid:3) crack size B (cid:3) thickness of test piece or component d (cid:3) distance between inclusions dN (cid:3) factor quantifying the effect of strain hardening on crack tip opening displacement; see Eq 31 E (cid:3) Young’s modulus F (cid:3) force J (cid:3) J-integral K (cid:3) stress intensity factor Kc (cid:3) fracture toughness in terms of stress intensity factor Ki (cid:3) stress intensity factor at initiation of ductile tearing Kmax (cid:3) maximum stress intensity facture during cyclic loading (cid:4)Kth (cid:3) threshold value of cyclic stress intensity factor M (cid:3) mismatch factor; see Eq 58 N (cid:3) number of load cycles N (cid:3) strain hardening exponent as defined in Eq 4 n (cid:3) strain hardening exponent used in the Ramberg-Osgood formulation of a stress-strain curve r (cid:3) radius from crack tip to point under consideration R (cid:3) stress ratio under cyclic loading R (cid:3) radius as defined in Figs. 2 and 3 Rm (cid:3) fracture strength Rp0.2 (cid:3) yield strength defined at 0.2% plastic strain s (cid:3) load point displacement u (cid:3) crack displacement in x direction W (cid:3) width of test piece Greek Symbols (cid:5)(cid:3) shear strain (cid:2)(cid:3) crack tip opening displacement (cid:2)45 (cid:3) crack tip opening displacement defined in Fig. 1(cid:2)c(cid:3) (cid:2)x (cid:3) crack tip advance displacement defined in Fig. 1(cid:2)a(cid:3) (cid:2)5 (cid:3) crack tip opening displacement defined in Fig. 28