Fracture behavior of two new high-strength aluminum alloys.
Al alloys properties evaluated to determine tensile and static fracture behavior
Keys, R. D.↗
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Fracture characteristics and heat treatment of laser powder bed fusion additively manufactured GRCop-84 copper
Laser Powder Bed Fusion (LPBF) of Glenn Research Copper 84 (GRCop-84), a Cr 2 Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, produces a fully dense high conductivity alloy with a yield strength of 500 MPa and ultimate tensile strength (UTS) of 740 MPa, superior to other competing copper alloys, and 20% elongation at fracture for material stressed perpendicular to the build direction. The high thermal stability of the Cr 2 Nb precipitate in the copper matrix reduces coarsening and maintains a 300 MPa yield, 520 MPa UTS and 26% elongation after a 900 °C, 5-h heat treatment, while a 3 h 450 °C heat treatment increases yield to 810 MPa, UTS to 970 MPa with 9% elongation at fracture, for samples stressed perpendicular to the build direction. Tensile strength anisotropy based on print direction was attributed to internal stress and columnar grain formation. Void nucleation during tensile fracture was initiated by brittle fracture of precipitate particles within the copper matrix. Fracture cusps contain matching precipitate fragment geometry on opposing sides located near the cusp center in at least 80% of fracture cusps. An optimal precipitate size of 100 nm is predicted for maximum tensile strength from precipitates on fracture surfaces, while tensile testing with varying heat treatments shows maximum strength with 100 nm and smaller precipitates. Cr2Nb precipitates are shown to transition between polycrystalline and monocrystalline structures at high temperature.
36 MATERIALS SCIENCE↗
Deformation and failure of the CrCoNi medium-entropy alloy subjected to extreme shock loading
The extraordinary work hardening ability and fracture toughness of the face-centered cubic (fcc) high-entropy alloys render them ideal candidates for many structural applications. Here, the deformation and failure mechanisms of an equiatomic CrCoNi medium-entropyalloy (MEA) were investigated by powerful laser-driven shock experiments. Multiscale characterization demonstrates that profuse planar defects including stacking faults, nanotwins, and hexagonal nanolamella were generated during shock compression, forming a three-dimensional network. During shock release, the MEA fractured by strong tensile deformation and numerous voids was observed in the vicinity of the fracture plane. High defect populations, nanorecrystallization, and amorphization were found adjacent to these areas of localized deformation. Molecular dynamics simulations corroborate the experimental results and suggest that deformation-induced defects formed before void nucleation govern the geometry of void growth and delay their coalescence. Our results indicate that the CrCoNi-based alloys are impact resistant, damage tolerant, and potentially suitable in applications under extreme conditions.
36 MATERIALS SCIENCE↗
Effects of temperature and hold times on low cycle fatigue of Astroloy
Low cycle fatigue (LCF) and creep-fatigue-environment interactions of HIP Astroloy were studied at 650 C and 725 C. The results showed that the model proposed by Kaisand and Mowbray (1979) was successful in predicting the magnitude and trend of the fatigue crack growth rate from LCF data. Raising the temperature from 650 C to 725 C did not change the fracture mode, while employing tensile hold caused a change in fracture mode and was more damaging than raising the temperature by 75 C. All samples displayed multiple fracture origins, which is initiated transgranularly in continuous cycling tests and intergranularly in hold time tests. An examination of the secondary crack showed no apparent creep damage. Oxidation in high purity argon appeared to be the major factor in LCF life degradation due to hold time.
Choe, S. J.↗
Fatigue fracture in thin plates subjected to tensile and shearing loads - Crack tip fields, J integral and preliminary experimental results
In one scenario of a crack in an airplane fuselage, the crack is subjected to cyclic tensile and out of plane shearing loads. To predict the fatigue crack growth in such a situation, experiments are being performed to measure the crack growth rate in laboratory specimens subjected to similar loadings. The mechanics of this problem are reviewed, the energy release rate is calculated and designs for an experiment are discussed along with some preliminary experimental observations.
Zehnder, Alan T.↗
The effect of hydrogen on the deformation and fracture of PWA 1480
The effect of internal hydrogen on mechanical properties and fracture behavior is studied in the single-crystal nickel-base superalloy PWA 1480. In particular, plane strain fracture toughness and tensile tests have been performed in hydrogen-free samples and hydrogen-gas phase-charged samples in two different sample orientations. The mechanical properties, as well as the fracture process, were found to be very dependent on orientation. Hydrogen did not affect the yield strength but reduced the uniform tensile elongation more than 75 percent. However, hydrogen reduced the tensile reduction-in-area and the fracture toughness by only 10 percent. Cleavage of the eutectic gamma-prime, as well as the role of hydrogen trapping, will be discussed. These results will be analyzed in terms of the effects that orientation, microstructure, and hydrogen have on the fracture process.
Walston, W. S.↗
Behavior of plasma-sprayed coatings
The microstructural development of plasma sprayed oxide coatings is described with particualr reference to aluminum oxide coatings and thermal barrier coatings of yttria stabilized zirconia (YSZ). The microstructural features of these coatings, observed by optical and electron microscopy, are related to their mechanical behavior. The adhesion of the coatings is also investigated using fracture toughness and tensile tests. It is noted that acoustic emission is valuable in formulating possible fracture mechanisms for YSZ coatings.
Berndt, Christopher C.↗
Fracture of thick graphite/epoxy laminates with part-through surface flaws
Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of facture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.
Morris, D. H.↗
Fracture of thick graphite/epoxy laminates with part-through surface flaws
Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of fracture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.
Harris, C. E.↗
Fracture Test Results for 0.5, 0.7 and 0.9 Inch Thick 2324-T39 Aluminum Alloy Material
A summary of experimental data is presented for a series of fracture tests and tensile tests that were conducted on a 2324-T39 aluminum alloy material. Static tensile tests were performed to determine the stress-strain response for the material. For the fracture tests three thicknesses (B = 0.5, 0.7, and 0.9-inches) and two specimen types (middle crack tension and compact tension specimens) were used. The middle crack tension specimens were 12-inches wide, and the compact tension specimens were 2, 4, and 6-inches wide. The fracture tests were conducted in the L-T orientation (crack perpendicular to the rolling direction and load parallel to the rolling direction).
Johnston, William M.↗
Epoxy hydantoins as matrix resins
Tensile strength and fracture toughness of castings of the hydantoin resins cured with methylenedianiline are significantly higher than MY 720 control castings. Water absorption of an ethyl, amyl hydantoin formulation is 2.1 percent at equilibrium and Tg's are about 160 C, approximately 15 deg below the final cure temperature. Two series of urethane and ester-extended hydantoin epoxy resins were synthesized to determine the effect of crosslink density and functional groups on properties. Castings cured with methylenedianiline or with hexahydrophthalic anhydride were made from these compounds and evaluated. The glass transition temperatures, tensile strengths and moduli, and fracture toughness values were all much lower than that of the simple hydantoin epoxy resins. Using a methylene bishydantoin epoxy with a more rigid structure gave brittle, low-energy fractures, while a more flexible, ethoxy-extended hydantoin epoxy resin gave a very low Tg.
Weiss, J.↗
Evaluation of the Mechanical Properties of Electroslag Refined Fe-12Ni Alloys
Three Fe-12Ni alloys, individually alloyed with small amounts of V, Ti, and Al, were manufactured through different melting techniques, with special emphasis on electroslag remelting, in order to achieve different levels of metal purity and associated costs. The relative effectiveness of these melting techniques was evaluated from tensile and slow bend fracture toughness behavior at 25 C and -196 C after tempering the test specimens at various temperatures. The best melting procedure was vacuum induction melting (VIM) with or without electroslag remelting (ESR). VIM+ESR is the recommended procedure since ESR provides increased yield of plate product, a reduction of overall manufacturing costs and, depending on the alloy composition, improved tensile and fracture toughness properties.
Bhat, G. K.↗
Elevated temperature crack growth in advanced powder metallurgy aluminum alloys
Rapidly solidified Al-Fe-V-Si powder metallurgy alloy FVS0812 is among the most promising of the elevated temperature aluminum alloys developed in recent years. The ultra fine grain size and high volume fraction of thermally stable dispersoids enable the alloy to maintain tensile properties at elevated temperatures. In contrast, this alloy displays complex and potentially deleterious damage tolerant and time dependent fracture behavior that varies with temperature. J-Integral fracture mechanics were used to determine fracture toughness (K sub IC) and crack growth resistance (tearing modulus, T) of extruded FVS0812 as a function of temperature. The alloy exhibits high fracture properties at room temperature when tested in the LT orientation, due to extensive delamination of prior ribbon particle boundaries perpendicular to the crack front. Delamination results in a loss of through thickness constraint along the crack front, raising the critical stress intensity necessary for precrack initiation. The fracture toughness and tensile ductility of this alloy decrease with increasing temperature, with minima observed at 200 C. This behavior results from minima in the intrinsic toughness of the material, due to dynamic strain aging, and in the extent of prior particle boundary delaminations. At 200 C FVS0812 fails at K levels that are insufficient to cause through thickness delamination. As temperature increases beyond the minimum, strain aging is reduced and delamination returns. For the TL orientation, K (sub IC) decreased and T increased slightly with increasing temperature from 25 to 316 C. Fracture in the TL orientation is governed by prior particle boundary toughness; increased strain localization at these boundaries may result in lower toughness with increasing temperature. Preliminary results demonstrate a complex effect of loading rate on K (sub IC) and T at 175 C, and indicate that the combined effects of time dependent deformation, environment, and strain aging may play a role. Fractography showed that microvoid coalescence was the microscopic mode of fracture in FVS0812 under all testing conditions. However, the nature of the microvoids varied with test temperature and loading rate, and is complex for the fine grain and dipersoid sizes of FVS0812.
Porr, William C., Jr.↗
Fracture toughness evaluations for spent nuclear fuel dry storage canister welds and spent nuclear fuel clad-pellet structures
Integrity of spent nuclear fuel (SNF) interim storage canisters is very important to the safety of the back-end nuclear fuel cycle. Stress corrosion cracking (SCC) potential of interim storage canister has been considered as a high priority. Because no post-weld heat treatment was required for forming these canisters, the high tensile residual stress existed within these canister welds. This can change the fracture resistance capacity significantly as well as increase SCC potential. Due to relative thin shell thickness of a canister weldment, the spiral notch torsion test (SNTT) method was used to estimate the canister weldment fracture toughness. SNTT was developed to measure the intrinsic fracture toughness of structural materials using small specimens. The SNTT method has been applied to a wide variety of structural materials, such as low-alloy steels, stainless steel, aluminum alloy, ceramics, concrete, and composites. The SNTT system operates by applying pure torsion to cylindrical specimens with a notch line that spirals around the specimen at a 45° pitch. In order to carry out pure torsion load mode, biaxial tension/torsion tester was developed accordingly to perform SNTT protocol. Moreover, applying fracture mechanics approach to SNF system reliability investigation is warranted due to the inherent flaws and hydride structures existed in a SNF system after nuclear reactor operation. However, none of the existing fracture toughness data deal with fuel cladding specific geometry or spent fuel material conditions, such as cladding structure with the pellet-inserts and the associated pellet clad mechanical interactions induced mixed-mode damage mechanisms. Thus, the development of an intrinsic fracture mechanics approach that is suitable for SNF materials is needed. Furthermore, due to thin wall and small dimension of clad tubing structure, the SNTT method was used to estimate the clad tubing structure fracture toughness. Fracture testing were performed on the received stainless steel canister weldment, most SNTT weld samples fracture initiation sites are at heat-affected zone (HAZ) regions. The estimated fracture toughness J Q ’ for the baseline SS304 steel is at 283 kJ/m². The estimated JQ’ for the SS304/308 weld and baseline metals are 148 kJ/m 2 and 459 kJ/m 2 , respectively. Out of cell fracture testing for spent fuel structure were carried out on the surrogate rods made of Zr-4 clad and alumina inserts, the estimated fracture toughness values for baseline Zr-4 cladding with alumina-pellet inserts are: (1) For SNTT samples with a short or medium crack length, between 5.4-mm and 8-mm, the estimate J IQ upon fracture initiation for the baseline Zr-4 cladding is at 50 kJ/m 2 with 2-sigma uncertainty of 3.26 kJ/m 2 , and the associated K IQ is at 67.46 MPa$\sqrt{m}$; and (2) For SNTT samples with a long crack length, around 13-mm, the crack initialization is deviated from that of the Mode-I tensile fracture and appears to be a mixed-mode fracture of Mode I - tensile stress and Mode III - out of plane shear stress; the estimated J MQ is at 18.9 kJ/m 2 , the associated K MQ is at 41.4 MPa$\sqrt{m}$.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Comparison of fracture mechanisms for carbon-epoxy composites under tensile loading
The effects of oxidative surface treatments and differences in resin crack sensitivity on the tensile properties of carbon-epoxy composites have been investigated. A comparison of the fracture mechanisms for two different fiber batches was made in both model and engineering composites, using unmodified and modified epoxy resin. It has been observed that two distinct characteristics occur in the fracture surfaces of most engineering composites; first, fibers which fracture at the surface result in cleavage failure and, second, those which have fractured elsewhere and pulled out. A detailed discussion of these observations is contained in this paper.
Mazzio, V. F.↗
B218 Weld Filler Wire Characterization for Al-Li Alloy 2195
NASA Marshall Space Flight Center, Lockheed Martin Space Systems- Michoud Operations, and McCook Metals have developed an aluminum-copper weld filler wire for fusion welding aluminum lithium alloy 2195. The aluminum-copper based weld filler wire has been identified as B218, a McCook Metals designation. B218 is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties over the 4043 aluminum-silicon weld filler wire, which is currently used to weld 2195 on the Super Lightweight External Tank for the NASA Space Shuttle Program. An initial characterization was performed consisting of a repair weld evaluation using B218 and 4043 weld filler wires. The testing involved room temperature and cryogenic repair weld tensile testing along with fracture toughness testing. From the testing, B218 weld filler wire produce enhanced repair weld tensile strength, ductility, and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding aluminum lithium alloy 2195 over 4043.
Bjorkman, Gerry↗
Gas tungsten arc welding and post weld heat treatment effects on microstructure and mechanical property of castable nanostructured alloy steel
Here, this paper details the first study of castable nanostructured alloy (CNA) steel gas tungsten arc weldability and the post-weld heat treatment (PWHT) effects. Effects of welding heat input, thermal cycles, and PWHT on microstructures, microhardness distributions, room temperature tensile properties, and fracture characteristics are discussed. Results show that CNA steel exhibits excellent weldability (i.e., no indication of welding defects and reasonable tensile properties). The welded joint exhibited heterogeneous microstructures with δ-ferrite as well as large microhardness variation and fluctuation. The welded joint yield and ultimate tensile strengths were similar to those of the base metal, but the elongations decreased by 30 %. However, with normalization and tempering PWHT, the δ-ferrite was eliminated, microstructure was modified, hardness was unified, and joint ductility was restored. The study indicated that the CNA reduced-activation ferritic-martensitic steel owns excellent weldability, and PWHT is needed for the industrial application of welded structures.
36 MATERIALS SCIENCE↗
AMMT FY23 HFIR Irradiation Test Matrix – Supported by the Design of a Miniature Bend Bar Irradiation Vehicle
With the continued advancement of additive manufacturing (AM) techniques, interest has grown in the development and qualification of steels produced via these methods for use in the structural components of advanced nuclear reactors. Therefore, it is crucial that the properties of these materials such as the tensile strength and fracture toughness be investigated following neutron irradiation to support their use in industry. To that end, a test plan to irradiate several tensile and bend bar specimens in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory was proposed, along with the development of a new “MINBEN” capsule design that features MBS-1 bend bar specimens that have a larger cross-sectional area than those of previous designs, which allows for higher temperature out-of-pile testing. The specimens include AM 316H stainless steel with wrought 316H and A709 stainless steels for reference, and they will be irradiated at 2 dpa and 10 dpa—corresponding to roughly 1 and 5 cycles at the HFIR midplane—at temperatures of 400°C and 600°C. The MINBEN design was found to be capable of providing specimen test plane average temperatures in the range of 220–660°C for six specimens, with a min-max spread in this temperature of ~40°C and a 95% confidence interval of ~24°C. This analysis shows that the capsule provides an effective vehicle for gathering needed high-temperature fracture toughness data.
36 MATERIALS SCIENCE↗