Search NASA⌕ Search

SEARCH · Search NASA

Results for “crack growth”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Probabilistic Prognosis of Non-Planar Fatigue Crack Growth

Quantifying the uncertainty in model parameters for the purpose of damage prognosis can be accomplished utilizing Bayesian inference and damage diagnosis data from sources such as non-destructive evaluation or structural health monitoring. The number of samples required to solve the Bayesian inverse problem through common sampling techniques (e.g., Markov chain Monte Carlo) renders high-fidelity finite element-based damage growth models unusable due to prohibitive computation times. However, these types of models are often the only option when attempting to model complex damage growth in real-world structures. Here, a recently developed high-fidelity crack growth model is used which, when compared to finite element-based modeling, has demonstrated reductions in computation times of three orders of magnitude through the use of surrogate models and machine learning. The model is flexible in that only the expensive computation of the crack driving forces is replaced by the surrogate models, leaving the remaining parameters accessible for uncertainty quantification. A probabilistic prognosis framework incorporating this model is developed and demonstrated for non-planar crack growth in a modified, edge-notched, aluminum tensile specimen. Predictions of remaining useful life are made over time for five updates of the damage diagnosis data, and prognostic metrics are utilized to evaluate the performance of the prognostic framework. Challenges specific to the probabilistic prognosis of non-planar fatigue crack growth are highlighted and discussed in the context of the experimental results.

Leser, Patrick E.↗
DOE OSTI2025

Evaluating methods to reduce duration of near-threshold fatigue crack growth rate measurements for low-alloy steels in hydrogen gas

Measurement of the near-threshold fatigue crack growth rate (da/dN) vs. stress-intensity factor range (∆K) relationship in hydrogen gas is essential for maximizing the calculated design fatigue life of high-pressure hydrogen storage vessels. However, such measurements are rarely performed, since the low cyclic loading frequencies applied in standard practice lead to prohibitively protracted test durations. The objective of this study was to demonstrate two means for reducing test durations when measuring near-threshold da/dN vs. ΔK relationships under decreasing ΔK for low-alloy pressure vessel steels in hydrogen gas: 1) imposing steeper K-gradients relative to the recommended limits in standards such as ASTM E647, and 2) increasing cyclic loading frequency relative to typical values applied during fatigue crack growth testing of low-alloy steels in hydrogen gas. Recognizing that steeper K-gradients could amplify loading-history effects, test methods employing this approach were designed to mitigate such effects by either maintaining constant K max or gradually increasing the K-gradient as the threshold was approached. Although the varying K-gradient method was vulnerable to loading-history effects in the form of plasticity-induced crack closure, particularly at lower stress ratio (R) and higher starting K max values, these effects could be compensated by applying the adjusted compliance ratio (ACR) method. Here, it was demonstrated that steeper K-gradients in concert with increased cyclic loading frequency reduced the duration of near-threshold fatigue crack growth tests in hydrogen gas by more than 99% relative to standard practices.

Fatigue threshold↗
NASA NTRS1973

Quantitative observations of hydrogen-induced, slow crack growth in a low alloy steel

Hydrogen-induced slow crack growth, da/dt, was studied in AISI-SAE 4130 low alloy steel in gaseous hydrogen and distilled water environments as a function of applied stress intensity, K, at various temperatures, hydrogen pressures, and alloy strength levels. At low values of K, da/dt was found to exhibit a strong exponential K dependence (Stage 1 growth) in both hydrogen and water. At intermediate values of K, da/dt exhibited a small but finite K dependence (Stage 2), with the Stage 2 slope being greater in hydrogen than in water. In hydrogen, at a constant K, (da/dt) sub 2 varied inversely with alloy strength level and varied essentially in the same complex manner with temperature and hydrogen pressure as noted previously. The results of this study provide support for most of the qualitative predictions of the lattice decohesion theory as recently modified by Oriani. The lack of quantitative agreement between data and theory and the inability of theory to explain the observed pressure dependence of slow crack growth are mentioned and possible rationalizations to account for these differences are presented.

Nelson, H. G.↗
NASA NTRS2018

Quantification of Error Associated with Using Misaligned Meshes in Continuum Damage Mechanics Material Models for Matrix Crack Growth Predictions in Composites

The ability of a material model to capture in-plane matrix mode I and mode II crack growth is an essential component for modeling ply level damage evolution in composite structures. Previous studies using a continuum damage mechanics (CDM) approach have shown success in satisfying benchmark solutions for mode I and II crack growth. However, success was shown using a fiber-aligned meshing strategy, which encourages matrix cracks to propagate in a single band of elements, along the fiber direction. Generating a fiber-aligned mesh becomes a highly involved process for laminates including off-axis (non 0° or 90°) plies. The objective of this study is to quantify the effect of non-fiber aligned mesh discretization on predictions of in-plane matrix crack propagation. The approach taken incrementally varies the mesh orientation angle relative to the fiber orientation; more specifically, misaligned meshes are used to quantify the effect of element angle orientation relative to the initial crack orientation on the energy released during matrix crack propagation simulations using a CDM method. CDM solutions obtained with the misaligned meshes are evaluated against known benchmarks for mode I and II matrix crack growth. The CDM solutions reveal a near-polynomial trend of increased predicted failure stress with increased mesh misalignment angle; hence implying a potential relationship between element orientation angle and apparent fracture toughness.

Justusson, Brian↗
DOE OSTI2020

Crack Growth Rate and Fracture Toughness Tests on Irradiated Ex-Plant Materials

The performance of structural materials is critical for the safe and economic operation of light water reactors. Exposed to neutron irradiation during service, the reactor core internal materials can undergo significant microstructural and microchemical changes, leading to irradiation hardening and embrittlement. To ensure the structural integrity and functionality of nuclear reactor components during long-term operation, material degradation and damage mechanisms must be understood and managed adequately. In this work, irradiated materials harvested from the decommissioned Zorita reactor were studied for their cracking susceptibility and fracture resistance as a function of irradiation dose up to 47 displacement per atom (dpa). The material is a Type 304 stainless steel sectioned from the baffle plates of this pressurized water reactor with 38 years of service. Crack growth rate and fracture toughness J-resistance (J-R) curve tests were performed in low-corrosion-potential environments at ~315°C. All samples behaved similarly under cyclic loading, and no deteriorated corrosion-fatigue behavior was observed in the test environments. Under constant stress intensity factors, most samples did not show elevated crack growth rates, suggesting an adequate stress corrosion cracking resistance in the test environments. However, an unstable cracking behavior was observed in a 47-dpa sample, resulting in significantly higher crack growth rates than expected at high stress intensity factors. Crack instability was also observed in a 0.06-dpa sample but did not lead to a sustained high crack growth rate. The impact of neutron irradiation was more evident in the fracture toughness J-R curve tests. As the dose increased, the J-R curve declined considerably and became very shallow at high doses. A fully intergranular fracture morphology was also observed among the high-dose samples ruptured in an air atmosphere at room temperature. This brittle fracture mode in the absence of high temperature water environment confirmed a high degree of embrittlement of this material resulting from its service exposure to neutron irradiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1988

Accelerated fatigue crack growth behavior of PWA 1480 single crystal alloy and its dependence on the deformation mode

An investigation of the fatigue crack growth (FCG) behavior of PWA 1480 single crystal nickel base superalloy was conducted. Typical Paris region behavior was observed above a delta K of 8 MPa sq rt of m. However, below that stress intensity range, the alloy exhibited highly unusual behavior. This behavior consisted of a region where the crack growth rate became essentially independent of the applied stress intensity. The transition in the FCG behavior was related to a change in the observed crack growth mechanisms. In the Paris region, fatigue failure occurred along (111) facets; however, at the lower stress intensities, (001) fatigue failure was observed. A mechanism was proposed, based on barriers to dislocation motion, to explain the changes in the observed FCG behavior. The FCG data were also evaluated in terms of a recently proposed stress intensity parameter, K sub rss. This parameter, based on the resolved shear stresses on the slip planes, quantified the crack driving force as well as the mode I delta K, and at the same time was also able to predict the microscopic crack path under different stress states.

Telesman, Jack↗
NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗
NASA NTRS2020

Effects of Texture and Silica Content on Crack Growth in Boron Nitrides

Boron nitride is used in applications such as crucibles for melting and casting glasses and metals, insulators for furnaces, molds for hot pressing, and neutron absorbers. Historically, various grades of hot pressed hexagonal boron nitride (BN) have been used. This study investigates the fracture toughness and slow crack growth parameters of several commercially available BN grades. Prior work revealed that some grades of BN absorb water and change strength, thus presenting a philosophical conundrum on crack growth test methods. The grades selected for this study are of interest because their available billet size is sufficient for large components, or because they have heritage in specific applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses of components of interest. Boron nitrides exhibit limited slow crack growth in humidity, with an orientation dependence due to crystallographic texture: orientations with van der Waal bonds are insensitive to water whereas those with covalent bonds are sensitive. Fracture toughness is low, around that of glass, and is also a function of orientation (bond type), with fracture occurring more readily along van der Waal bonds between hexagonal BN platelets than at covalent bonds across platelets. Silica additions toughen BN, but increase slow crack growth susceptibility.

Salem, Jonathan A.↗
NASA NTRS1988

Automatic crack growth tracking of bimaterial interface cracks

The propagation process of an interfacial crack in composite material is studied using the modified maximum dilatational strain energy density criterion, NT-criterion. Some necessary assumptions have been adopted to facilitate the use of the NT-criterion in this case. The stress intensity factors at the crack tip are extracted from the complex displacement field and finite element results. A simple algorithm for automatic crack propagation is presented with an illustrative example.

Yehia, Nabil A. B.↗
DOE OSTI2022

Effect of Water Chemistry on Crack Growth Rate in Neutron Irradiated X-750 and XM-19

The Advanced Test Reactor (ATR) National Science User Facility (NSUF) was used to study the effect of neutron damage on crack growth rates (CGR) under simulated boiling water reactor (BWR) water chemistry conditions using a fast neutron spectrum to accelerate the damage process. Nickel based Alloy X-750 and XM-19 were irradiated in the ATR center flux trap (CFT), with this experiment marking the first civilian project to utilize this position within the reactor. 0.4T-CT specimens were used to study crack growth rates for two sample fluences (~1.9 x 1020 n/cm2 and ~9.5 x 1020 n/cm2, E > 1MeV)) in both normal water chemistry (NWC) at 2.5 ppm O2 and hydrogen water chemistry (HWC) at ~80 ppb H2. CGR testing was conducted at a temperature of 288 °C. A decrease in CGR was observed for both alloys with the average ratio (CGR in NWC/CGR in HWC) being a factor of 281 for the XM-19 samples and a factor of 27.8 for the X-750 samples. Observed CGRs in this study showed little difference compared to non-irradiated samples (the non-irradiated XM-19 was 20% cold worked), suggesting limited sensitivity of these susceptible alloys to irradiation effects. Detailed results of CGR response to varying environmental electrochemical potential (ECP) and water purity will be presented in the context of crack growth mitigation in different water chemistries and the change in material behavior relative to non-irradiated samples of the material.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fatigue crack growth resistance of a mesoscale composite microstructure Haynes 282 fabricated via electron beam melting additive manufacturing

Materials synthesis via additive manufacturing gives unprecedented control over the solidified microstructure. While a number of studies have demonstrated the ability to produce spatially varying microstructures, little work exists to understand the behavior of such “composite” materials. In this work, we utilized electron beam melting to process Ni-based superalloy Haynes 282 and produce compact tension samples with a spatially varying mesoscale structure. Fatigue crack growth experiments reveal that the crack growth rate is dependent on the degree of microstructural heterogeneity. This work demonstrates that the crack growth resistance can be tailored within a component using electron beam melting additive manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRS1976

A film-rupture model of hydrogen-induced, slow crack growth in acicular alpha-beta titanium

A study has been conducted of the terrace-like fracture morphology of gaseous hydrogen-induced crack growth in acicular alpha-beta titanium alloys in terms of specimen configuration, magnitude of applied stress intensity, test temperature, and hydrogen pressure. Although the overall appearance of the terrace structure remained essentially unchanged, a distinguishable variation is found in the size of the individual terrace steps, and step size is found to be inversely dependent upon the rate of hydrogen-induced slow crack growth. This inverse relationship is independent of all the variables investigated. These observations are quantitatively discussed in terms of the formation and growth of a thin hydride film along the alpha-beta boundaries and a qualitative model for hydrogen-induced slow crack growth is presented, based on the film-rupture model of stress corrosion cracking.

Nelson, H. G.↗
NASA NTRS2001

The Effect of O2, H2O, and N2 on the Fatigue Crack Growth Behavior of an Alpha + Beta Titanium Alloy at 24 C and 177 C

To study the effects of atmospheric species on the fatigue crack growth behavior of an a+B titanium alloy (Ti 6-2-2-2-2) at room temperature and 177 C, fatigue tests were performed in laboratory air, ultrahigh vacuum, and high purity water vapor, oxygen, nitrogen and helium at various partial pressures. Accelerated fatigue crack growth rates in laboratory air compared to ultrahigh vacuum are linked to the damaging effects of both water vapor and oxygen. Observations of the fatigue crack growth behavior in ultrahigh purity environments, along with surface film analysis using X-ray photoelectron spectroscopy (XPS), suggest that multiple crack-tip processes govern the damaging effects of air. Three possible mechanisms are proposed: 1) at low pressure (less than 10(exp -1) Pa), accelerated da/dN is likely due to monolayer adsorption on crack-tip surfaces presumably resulting in decreased bond strengths at the fatigue crack tip, 2) for pressures greater than 10(exp -1) Pa, accelerated da/dN in oxygen may result from oxidation at the crack tip limiting reversible slip, and 3) in water vapor, absorption of atomic hydrogen at the reactive crack tip resulting in process zone embrittlement.

Smith, Stephen W.↗
DOE OSTI2023

A617 Notch Effect and Crack Growth Testing Status

This is an update on the Alloy 617 notched specimen creep testing and crack growth rate testing performed in FY23. Long-term notch testing continues, with some new results on double V-notch specimens. Creep-fatigue crack growth rate testing has begun and some preliminary results are shown.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Sustained load crack growth design data for Ti-6Al-4V titanium alloy tanks containing hydrazine

Results are presented for an experimental study intended to provide sustained load crack growth (SLCG) data for Ti-6Al-4V titanium alloy tanks containing MIL-P-26536 hydrazine and refined hydrazine. Fracture mechanics data on crack growth threshold for heat-treated forgings, aged and unaged welds, and aged and unaged heat-affected zones (HAZ) are presented. All tests were made on uniaxially loaded fracture mechanics specimens involving part-through cracks, and an electrical discharge machined notch was used to start the crack. Fracture mechanics design curves of crack growth threshold stress intensity versus temperature are obtained for the temperature range 40-71 C. Major conclusions are that extreme susceptibility to SLCG in hydrazine is a universal property of unaged weld metal in Ti-6Al-4V titanium alloy of normal interstitial content, and that aging both weld metal and HAZ at 510 C for 4 hr after welding completely removes all susceptibility to SLCG induced by hydrazine, with less susceptibility to SLCG in refined hydrazine.

Lewis, J. C.↗
NASA NTRS1989

Stochastic modeling of crack initiation and short-crack growth under creep and creep-fatigue conditions

A simplified stochastic model is proposed for crack initiation and short-crack growth under creep and creep-fatigue conditions. Material inhomogeneity provides the random nature of crack initiation and early growth. In the model, the influence of microstructure is introduced by the variability of: (1) damage accumulation along grain boundaries, (2) critical damage required for crack initiation or growth, and (3) the grain-boundary length. The probabilities of crack initiation and growth are derived by using convolution integrals. The model is calibrated and used to predict the crack density and crack-growth rate of short cracks of 304 stainless steel under creep and creep-fatigue conditions. The mean-crack initiation lives are predicted to be within an average deviation of about 10 percent from the experimental results. The predicted cumulative distributions of crack-growth rate follow the experimental data closely. The applicability of the simplified stochastic model is discussed and the future research direction is outlined.

Kitamura, Takayuki↗
NASA NTRS1992

Stochastic modeling of crack initiation and short-crack growth under creep and creep-fatigue conditions

A simplified stochastic model is proposed for crack initiation and short-crack growth under creep and creep-fatigue conditions. Material inhomogeneity provides the random nature of crack initiation and early growth. In the model, the influence of microstructure is introduced by the variability of: (1) damage accumulation along grain boundaries, (2) critical damage required for crack initiation or growth, and (3) the grain-boundary length. The probabilities of crack initiation and growth are derived by using convolution integrals. The model is calibrated and used to predict the crack density and crack-growth rate of short cracks of 304 stainless steel under creep and creep-fatigue conditions. The mean-crack initiation lives are predicted to be within an average deviation of about 10 percent from the experimental results. The predicted comulative distributions of crack-growth rate follow the experimental data closely. The applicability of the simplified stochastic model is discussed and the future research direction is outlined.

Kitamura, Takayuki↗