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CH10
CH10
CH10
FAILURE
Chapter 3 - 502
Failure of Engineering Materials
• Almost always an undesirable event:
– Putting human lives in jeopardy
– Causing economic losses
– Interfering with availability of “Products &
Services”
Chapter 3 - 508
Generally, for a “DUCTILE” Fracture
• A characteristic extensive “Plastic
Deformation” is encountered in the vicinity
of the advancing crack [Specifically, ahead
of the “Crack Tip”]
• Hence, propagation proceeds relatively
slowly as crack length is extended (allowing
sufficient time for the deformation ahead of
the crack to pick favorably oriented “Slip
Systems”)
• Such a crack is often said to be “Stable”
• i.e. it resists any further EXTENSION unless
there is an increase in the applied stress
Chapter 3 - 509
Fractography
Chapter 3 - 510
For Brittle Mode of Fracture . . .
• Postmortem to failure
• Inference on:
– Mechanism of fracture
– Fracture mode [Ductile or Brittle]
– Stress State [static or dynamic* , sudden
or gradual+]
– Crack nucleation/initiation site [Ductility in
remaining ligament$]
Chapter 3 - 519
Forensic Investigation ➔ Fractography
• Using “Scanning Electron Microscopy”
• Why??:
– Improved Resolution
Chapter 3 - 524
Chapter 3 - 525
On a MICRO-scopic scale . . .
• NO SIGNS of features indicative of gross
“Plastic Deformation” ➔ NO “Micro-void
Coalescence” ➔ NO “Dimples”
• Instead’
– A series of “V-shaped Chevron” markings form
near CENTER of fracture surface ➔ Pointing
BACK towards “Crack Initiation” site ➔ (as crack
initiates as a point and spreads out radially in
successive cleavage outwards to form an ARCH)
– Lines/Ridges radiate from ORIGIN of crack in a
“Fan-like pattern”
Chapter 3 - 526
V-shaped Chevron Markings
Chapter 3 - 527
Fan-like Patterns
Chapter 3 - 528
These features are visible . . .
• To the “naked-eye”
For coarse-grained metals
• Only under an “SEM”
For very hard and fine-grained metals
• Nearly nonexistent [relatively
smooth/shiny fracture surface]
For amorphous materials (e.g. ceramic
glasses)
Chapter 3 - 529
Trans-granular (or -crystalline) BRITTLE
fracture
Chapter 3 - 536
Chapter 3 - 537
A Brittle Fracture of Normally Ductile Materials
– Stress Level
Chapter 3 - 540
Stress Concentration
• For MOST materials
– σf [Exp. Measured] < < σf [Theorit. Calc. based on
“Atomic Bonding Energies”]
– This is intimately related to geometrical
factors. BUT of WHAT?
– Ans.: of MICRO-scopic FLAWs/CRACKs
– These are ALWAYs present [under
NORMAL conditions]
• At the “Surface”
• Within the “Interior”
of a body of materials
Chapter 3 - 541
Flaws are a detriment to σf . . .
Chapter 3 - 542
Stress Distribution in Vicinity of Surface
(a) and Interior (2a) Cracks
Chapter 3 - 543
Observations . . .
Chapter 3 - 545
A Mathematical Expression for “Crack-
Tip Stress”
• Assume,
– Crack resembling an “elliptical hole” through a
plate
– The ellipse is oriented perpendicular to applied
stress
• Then MAX. Stress (or that is at “Crack-Tip)”
is given as,
1Τ2
𝑎
σ𝑚 = 2σ°
𝜌𝑡
Chapter 3 - 546
1Τ2
𝑎
σ𝑚 = 2σ°
𝜌𝑡
where,
σm is magnitude of nominal applied
tensile stress
ρt is radius of curvature of crack-tip
a is length of a “surface crack” or
half the length of an “internal crack”
Chapter 3 - 547
For a relatively LONG “micro-crack” that
has a SMALL “tip-radius of curvature” . .
1Τ2
σ𝑚 𝑎
𝐾𝑡 = =2
σ𝑜 𝜌𝑡
i.e. SIMPLY this is a measure of the
“DEGREE to which an external stress is
AMPLIFIED at the tip of a crack”
Chapter 3 - 549
“Stress Concentration” is NOT EXCLUSIVE
to MICRO-scopic DEFECTS . . .
Chapter 3 - 550
How does all this play out for “Ductile-
& Brittle-modes of Fracture”?
• With Ductile Fracture
“Stress Raiser” or “MICRO-crack”
increases stress at “Crack-tip” ➔ By
virtue of the ductile nature at hand [σy] is
relatively LOW and easily reachable by
ENHANCED “Crack-tip” stresses as
oppose to “threshold stress required for
crack propagation” ➔ Hence, “Plastic
deformation” is triggered
PREFERENTIALLY Chapter 3 - 551
How does all this play out for “Ductile-
& Brittle-modes of Fracture”?
• With Ductile Fracture
So material “Plastically deforms” INSTEAD of
propagating the crack at the “Crack-tip” ➔ i.e.
a “plastically deformed” zone forms ahead of
the “crack-tip” ➔ As such, this zone
experiences frequent incidences of disordering
processes* ➔ this distorts/BLUNTS the
inherently SHARP crack-tip ➔ thereby
stripping it from its “stress-raising” potential ➔
i.e. a more uniform distribution of stress is now
in effect around the BLUNTED crack-tip Chapter 3 - 552
How does all this play out for “Ductile-
& Brittle-modes of Fracture”?
• With Ductile Fracture
This is effectively an “auto-catalytic” process ➔
in that the easily reachable σy ➔ has now
naturally formed a situation where (ρt) is
progressively larger ➔ from the definition of
(σm) this further lowers (σm) to effectively
lower values that would initially be anticipated
as we go along or lowers (Kt) ➔ this in turn
further damps “crack propagation” ➔ hence,
the renowned “Stability” of a ductile crack.
Chapter 3 - 553
For Brittle mode of fracture . . .
1Τ2
2𝐸𝛾𝑠
σ𝑐 =
𝜋𝑎
Chapter 3 - 555
Where,
Chapter 3 - 556
Fracture Toughness
Chapter 3 - 559
You will eventually
reach a point where the
The more stress you
stress applied exceeds
apply the further the This σc
mean that now
for brittle crack rapid
plastic zone grows the crack is able to
propagation
ahead of the crack tip propagate into the
plastic zone
Chapter 3 - 560
As the crack propagates it
is preceded by a plastic
zone and it leaves behind
a wake of previously
deformed plastic material Chapter 3 - 561
The stress state ahead of the crack
tip
Chapter 3 - 562
Plane Strain ➔ Lets start by working
with a PURELY BRITTLE MATERIAL
A very small
distance ahead of
the crack tip BUT
a LONG WAY
comparatively
form the edge
(external/free
surface) of the
specimen Provided that the
sample is
reasonably
THICK Chapter 3 - 564
The POINT defined is said to be in
“Plane Strain”
Meaning that the
distance along the
crack front between
the specimen edges
(or free surfaces) [i.e.
sample THICKNESS]
is MUCH GREATER
than the distance of
the POINT defined
from the crack tip
Chapter 3 - 565
In plane strain this
is now strain
parallel to the
crack front
Chapter 3 - 566
i.e. the contractions are
effectively constrained by
the large amount of
surrounding material ➔
rememberratio
Poisson’s sample is
isassumed
then valid thick here
Although
here andlocally
an
adjacent
accompanyingto the
crack front there
COTRACTIVE
exist
strainTENSILE
extends
strains [ONLY in
along/parallel to
direction
the crack of front In which case a state of strain
The
nominal absence
This of a strain
is automatically
externally HENCE,results
imbalance no netinstrain
a shear
parallel to crack front
appliednullified/counteracted
stress ONLY bycomponent
theparallel tobetween
crack front
nominal
applies
[MAX] in INTERIOR
opposing
and along tensile[LONG
strains of
And given stress
that the direction
material is and crack-front
way from
crack EDGE] but NOT
the ACCUMULATIVE
propagation BRITTLE ONLYparallel
allowingstrains that points 45°
for elastic
near FREE
direction THICKNESS
[MIN]Surfaceof the
deformation [Noupwards
plasticity there] Chapter 3 - 567
materials
The counteracting tensile
effect assumed by the
surrounding material
thickness that nullifies
the crack-front Poisson's
principle induced elastic
contraction ➔ renders a
state of “Triaxial tension”
at the crack tip ➔ a
balanced state
characteristic of “Plane
Strain”
Near the
center of the
specimen we
can still identify
points that are
relatively far
from the “free
surface”
compared to
the distance
from
i.e. the crack
where a state of
tip Strain” exists
“Plane
Chapter 3 - 570
Whilst STILL
close to the
specimen center
(i.e. away from
the free
surfaces) EVEN
if the plastic
zone lies within
the region of The fracture STILL
Any fracture will still feel the constrains of “Plain Strain” ➔ i.e.
“Plane Strain” generates an overall
you are STILL avoiding the presence of strain parallel to the
FLAT surface
crack-front ➔ hence, NO 45° components formed with the
Chapter 3 - 571
MAJOR strain in direction of nominal applied stress
What would happen
The latter strain component
then is that points
HOWEVER,
would form with the strain
towards the center
consider
directed what
along the nominal
would still fracture in
happens
applied stressasawe
45°
accordance with
move NEARER
component to
that is now
“Plane Strain” ➔
the “Free Surface”
OPERABLE
giving Flat
Since
As we we
before are must
at this stage “Cleavage” Surfaces
within the
MOVE PLASTIC
CLOSER Zone
to the
crack-front to STAY in a Meanwhile, material near
state of “Plane Strain” the free-surface would
RECALL that less
experience MINIMUM
restriction σ
[i.e. to maintain the There is ONLY
required to a certain
cause extent
yield favors in
highly packed material from minimal packed
φ*column
which weλ can
= = 45°
of
minimize
which
material isthe
at
and σdist.
y = 2.
Up to a particular
backing with distance point we
By this stagebewe wouldcloser
be well τCRSS
Towithin ➔ eventually
crack-front
the
would ourtopresence
plasticadhere
zone towithin
allow
the
for a
would
form free-surface getting to
whilst“Free-surface”
unable to satisfy the
to ratioratio
(this “Plastic
that STILL
close Zone” would
puts tip)
to crack us within only
relative to dist. To crack without NET strain component that
that facilitates “Plane Strain” “Plane Strain”
promote whilst
shear alarmingly
along the 45°
tip] being able to reduced dist. acts parallel to the crack
getting closer to➔the
component “Shear Lip”
free-surface
front to come intoChapter
action
With crack-tip 3 - 572
To Summarize ➔ Fracture Near Center
No NET stress
MAX of THICK specimenallowed along
stresses crack front ➔
[nominal Due to column
applied of constraining
tensile material
stressed]
For simplicity
we’re going to
omit overlookSo 45° strain MINof
If any extent stress [Opens up
plastic
drawing the
components might only should
deformation crack during
occur (it
plastic strain
be a result
wouldofshear
the along propagation]
these favored
fields BASAL tensile stresses
45° components) Chapter 3 - 573
When Failure Occurs it’ll be in the Same
Plane as the Original Crack
Chapter 3 - 574
To Summarize ➔ For an Ultra-thin
specimen ➔ We’re very close to Free-
surface ➔ Well within a relatively large
“Plastic Zone*”
Chapter 3 - 575
However, this time
these are NO
CONSTRAINS
from column of
material above ➔
so there exists a
stress acting along
the crack-front
[MIN though]
The result are
45°components
but
MAXpointing
Stress [as in case
upwards
of thick specimens] is
favored by of nominal
in direction
plastic applied
shear stress
Chapter 3 - 576
As soon as the crack starts to propagate it would do
so through a material that has suffered extensive
“plastic shear” at 45° to surface.
The crack being free of “Plane Strain” restrictions
turns through 45° into one or other of planes of
shear
Chapter 3 - 577
In a very THIN specimen this is
referred to as
“Plane Stress”
&
The fracture face will be at 45° to
the surface
Chapter 3 - 578
In THICKER specimens . . .
Chapter 3 - 581
Chapter 3 - 582
Chapter 3 - 583
Sometimes “Plane Strain Fracture
Toughness” is expressed as (KIc)
Chapter 3 - 584
Three Modes of Crack Displacement
Chapter 3 - 585
Another Perspective . . .
Chapter 3 - 586
Or . . .
Chapter 3 - 587
Contrast between Brittle & Ductile . . .
Chapter 3 - 588