Analysis of crack-tip constraint due to V- and U- side grooves in C(T) specimens

Mechanical testing of A285 carbon steel, a storage tank material, was performed to develop fracture properties based on the constraint theory of fracture mechanics. A series of single edge-notched bend (SENB) specimen designs with various levels of crack tip constraint were used. The variation of crack tip constraint was achieved by changing the ratio of the initial crack length to the specimen depth. The test data show that the J-R curves are specimen-design-dependent, which is known as the constraint effect. A two-parameter fracture methodology is adopted to construct a constraint-modified J-R curve, which is a function of the constraint parameter, A2, while J remains the loading parameter. This additional fracture parameter is derived from a closed form solution and can be extracted from the finite element analysis for a specific crack configuration. Using this set of SENB test data, a mathematical expression representing a family of the J-R curves for A285 carbon steel can be developed. It is shown that the predicted J-R curves match well with the SENB data over an extensive amount of crack growth. In addition, this expression is used to predict the J-R curve of a compact tension specimen (CT), and reasonable agreement to the actual test data is achieved. To demonstrate its application in a flaw stability evaluation, a generic A285 storage tank with a postulated axial flaw is used. For a flaw length of 10% of the tank height, the predicted J-R curve is found to be similar to that for a SENB specimen with a short notch, which is in a state of low constraint. This implies that the use of a J-R curve from the ASTM (American Society for Testing and Materials) standard designs, which typically are high constraint specimens, may be overly conservative for analysis of fracture resistance of large structures.

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Features Testing of Stud Material Under Low Constraint Ductile Tearing

Volume 6A: Materials and Fabrication ◽

10.1115/pvp2017-65351 ◽

2017 ◽

Author(s):

P. James ◽

M. Jackson ◽

P. Birkett ◽

C. Madew

Keyword(s):

Structural Integrity ◽

High Stress ◽

Crack Tip ◽

Pressure Vessels ◽

Materials Testing ◽

Screw Thread ◽

Surface Point ◽

Defect Tolerance ◽

Material Response ◽

Crack Tip Constraint

Defect tolerance assessments are carried out to support the demonstration of structural integrity for high integrity components such as nuclear reactor pressure vessels. These assessments often consider surface-breaking defects and assess Stress Intensity Factors (SIFs) at both the surface and deepest points. This can be problematic when there is a high stress at the surface, for example due to the stress concentration at the root of a screw thread. In the past this has led to the development of complex and costly 3D finite element analyses to calculate more accurate SIFs, and still resulting in small apparent limiting defect sizes based on initiation at the surface point. Analysis has been carried out along with supporting materials testing, to demonstrate that the increased SIF at the surface point is offset by a reduction in crack-tip constraint, such that the material exhibits a higher apparent fracture toughness. This enables a more simplistic assessment which reduces the effective SIF at the surface such that only the SIF at the deepest point needs to be considered. This then leads to larger calculated limiting defect sizes. This in turn leads to a more robust demonstration of structural integrity, as the limiting defect sizes are consistent with the capability of non-destructive examination techniques. The high SIF at the surface location, and the concomitant reduction in crack-tip constraint, meant that it was not possible to demonstrate the material response with conventional tests, such as those using shallow-notched bend specimens. Instead it was necessary to develop modified specimens in which semielliptical defects were introduced into a geometry which replicated the notch acuity at the root of a screw thread. These feature tests were used to demonstrate the principle, prior to testing with more conventional specimens to fit more accurately the parameters required to represent the material response in a defect tolerance assessment. Margins in defect tolerance assessments are usually measured against the initiation of tearing, even though the final failure for the material may occur at a higher load following stable crack extension. This work measured and assessed the benefit of reduced crack-tip constraint on both the point of initiation and on the development of the tearing resistance curve. This demonstrated that the effect of constraint was valid with tearing for this material and that there was additional margin available beyond the onset of tearing. The feature test geometry also provided evidence of the tearing behaviour at the surface and deepest points of a surrogate component under representative loading. This paper provides an overview of the range of tests performed and the post-test interpretation performed in order to provide the R6 α and k constraint parameters.

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