Determination of Crack-Initiation in Fracture Toughness Testing Using an Experimental Key-Curve Methodology

A new approach was implemented to confirm the start of ductile tearing relative to assessments by other methods such as direct-current Electric Potential (d-c EP) method in coupon specimens. This approach was developed on the Key-Curve methodology by Ernst/Joyce and is similar to the ASTM E-1820 Load Normalization procedure used to determine J-R curves directly from load versus Load-Line Displacement (LLD) record of the test specimen. It is consistent with Deformation Plasticity relationships for fully plastic behavior. Using this Experimental Key-Curve method, crack initiation can be determined directly from load versus LLD data or load versus Crack-Mouth Opening Displacement (CMOD) obtained from a fracture test without the need for additional instrumentation required for crack initiation detection. It is based on the fact that plastic deformation of homogeneous metals at the crack tip follows a power-law function until the crack tearing initiates. Crack tearing initiation is determined at the point where the power-law fit to the load versus plastic part of CMOD or LLD curve deviates from the total experimental load versus plastic-CMOD or LLD curve. The procedure for fitting of the data requires some care to be exercised such that the fitted data is beyond the elastic region and early small-scale plastic region of the Load-CMOD or Load-LLD curve but include data before crack initiation. An iterative regression analysis was done to achieve this, which is shown in this paper. The iterative fitting in this region typically results with a coefficient of determination (R2) values that are greater than 0.990. This method can be either used in conjunction with other methods such as direct-current Electric Potential (d-c EP) or unloading-compliance methods as a secondary (or primary) confirmation of crack tearing initiation (and even for crack growth); or can be used alone when other methods cannot be used. Furthermore, when using instrumentation methods for determining crack-initiation such as d-c EP method in a fracture toughness test, it is good to have a secondary confirmation of the initiation point in case of instrumentation malfunction or high signal to noise ratio in the measured d-c EP signals. In addition, the Experimental Key-Curve procedure provides relatively smooth data for the fitting procedure, while unloading-compliance data when used to get small crack growth values frequently has significant variability, which is part of the reason that JIC by ASTM E1820 is determined using an offset with some growth past the very start of ductile tearing. In this work, the Experimental Key-Curve method had been successfully used to determine crack tearing initiation and demonstrate the applicability for different fracture toughness specimen geometries such as SEN(T), and C(T) specimens. In all the cases analyzed, the Experimental Key-Curve method gave consistent results that were in good agreement with other crack tearing initiation measuring method such as d-c EP but seemed to result in less scatter.

Crack Initiation and Propagation in Static Loaded Fracture Mechanics Tests in Steels Containing Atomic Hydrogen

Hydrogen is well known to have a detrimental influence on the ductility of low alloy steels, reducing the fracture toughness. Standard test methods to characterize fracture toughness of steels in terms of ductile tearing resistance curves have not been developed to account for any hydrogen-driven contribution to the crack extension, Δa. Simply plotting J or CTOD against Δa is not necessarily appropriate for defining the initiation fracture toughness for tests performed in a hydrogen-charging environment. This paper explores a method to further analyse experimental data collected during fracture toughness tests, which allows the contribution of plasticity (i.e. when blunting precedes ductile tearing) to be considered separately from the initiation of crack extension (which could be by stable tearing and/or by hydrogen-driven crack extension). The principle is based on the assumption that a crack growing by a hydrogen-driven mechanism in a quasi-static fracture mechanics test performed in environment may not be associated with significant ductility in the plastic zone (which would accompany crack growth by stable tearing). The analytical method presented in this paper compares the different points of deviation from linear behavior of the components of J, to isolate the effects of ductility within the plastic zone from pure crack extension. In this way, the point of crack initiation can be defined in order to determine the relevant initiation fracture toughness; whether by blunting and stable tearing, or by hydrogen-driven crack growth. This approach offers a screening method which is illustrated using examples of fracture mechanics specimens tested in environments of varying severity (air, seawater with cathodic protection, and sour service). This method can be used to identify the relevant definition of initiation fracture toughness while allowing for a combination of ductile tearing, hydrogen-driven crack extension, or both, to be present during the test.

Advanced Structural Integrity Assessment Tools for Safe Long Term Operation: ATLAS+ Project — Status of the Activities of the WP3 on Modelling in 2020

The main objective and mission of the ATLAS+ project is to develop advanced structural assessment tools to address the remaining technology gaps for the safe and long term operation of nuclear reactor pressure coolant boundary systems. ATLAS+ WP3 focuses mainly on ductile tearing prediction for large defect in piping and associated components: Several approaches have been developed to accurately model the ductile tearing process and to take into account phenomena such as triaxiality effects, or the ability to predict large tearing in industrial components. These advanced models include local approach coupled models or advanced energetic approaches. Unfortunately, the application of these tools is currently rather limited to R&D expertise. However, because of the continuous progress in the performance of calculation tools and accumulated knowledge, in particular by members of the ATLAS+ consortium, these models can now be considered as relevant for application in the context of engineering assessments. WP3 has been planned to: • Illustrate the implementation of these models for industrial applications through the interpretation of large scale mock-ups (with cracks in weld joints for some of them), • Make recommendations for the implementation of the advanced models in engineering assessments, • Correct data from the conventional engineering approach by developing a methodology to produce J-Δa curve suitable case by case, based on local approach models, • Improve the tools, guidance and procedures for undertaking leak-before-break (LBB) assessments of piping components, particularly in relation to representing structural representative fracture toughness J-Resistance curves and the influence of weld residual stresses. To achieve these goals, WP3 is divided into 4 sub-WPs and this paper presents the progress of the work performed in each sub-WP after 36 months of activities.