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NASA NTRS2003

Test-Free Fracture Toughness

Computational simulation results can give the prediction of damage growth and progression and fracture toughness of composite structures. The experimental data from literature provide environmental effects on the fracture behavior of metallic or fiber composite structures. However, the traditional experimental methods to analyze the influence of the imposed conditions are expensive and time consuming. This research used the CODSTRAN code to model the temperature effects, scaling effects and the loading effects of fiber/braided composite specimens with and without fiber-optic sensors on the damage initiation and energy release rates. The load-displacement relationship and fracture toughness assessment approach is compared with the test results from literature and it is verified that the computational simulation, with the use of established material modeling and finite element modules, adequately tracks the changes of fracture toughness and subsequent fracture propagation for any fiber/braided composite structure due to the change of fiber orientations, presence of large diameter optical fibers, and any loading conditions.

Minnetyan, Levon↗

NASA NTRS1989

Indentation fracture toughness of sintered silicon carbide in the Palmqvist crack regime

The fracture toughness of a sintered dense alpha-SiC was estimated by the Vickers indentation microfracture method in the low-load Palmqvist crack regime. It was observed that the use of simultaneously obtained Vickers hardnesses does not yield reliable fracture toughness values, nor does application of the median-crack-derived equations. It is necessary to utilize a load-independent, crack-free hardness value with this toughness estimation method. Although several of the curve-fitting equations yield similar toughnesses, it is concluded for the Palmqvist crack system in this alpha-SiC that the Niihara-Morena-Hasselman (1982) equation is the only one which yields fracture toughness values in agreement with conventional measurement techniques.

Li, Zhuang↗

NASA NTRS1984

Fracture toughness of fibrous composite materials

Laminates with various proportions of 0 deg, 45 deg, and 90 deg plies were fabricated from T300/5208 and T300/BP-907 graphite/epoxy prepreg tape material. The fracture toughness of each laminate orientation or lay-up was determined by testing center-cracked specimens, and it was also predicted with the general fracture-toughness parameter. The predictions were good except when crack-tip splitting was large, at which time the toughness and strengths tended to be underpredicted. By using predictions, a parametric study was also made of factors that influence fracture toughness. Fiber and matrix properties as well as lay-up were investigated. Without crack-tip splitting, fracture toughness increases in proportion to fiber strength and fiber volume fraction, increases linearly with E(22)/E(11), is largest when the modulus for non-0 deg fibers is greater than that of 0 deg fibers, and is smallest for 0(m)/90(p)(s) lay-ups. (The E(11) and E(22) are Young's moduli of the lamina parallel to and normal to the direction of the fibers, respectively). For a given proportion of 0 deg plies, the most notch-sensitive lay-ups are 0(m)/90(p)(s) and the least sensitive are 0(m)/45(n)(s) and alpha(s). Notch sensitivity increases with the proportion of 0 deg plies and decreases with alpha. Strong, tough matrix materials, which inhibit crack-tip splitting, generally lead to minimum fracture toughness.

Poe, C. C., Jr.↗

NASA NTRS2010

Mode II Interlaminar Fracture Toughness and Fatigue Characterization of a Graphite Epoxy Composite Material

Mode II interlaminar fracture toughness and delamination onset and growth characterization data were generated for IM7/8552 graphite epoxy composite materials from two suppliers for use in fracture mechanics analyses. Both the fracture toughness testing and the fatigue testing were conducted using the End-notched Flexure (ENF) test. The ENF test for mode II fracture toughness is currently under review by ASTM as a potential standard test method. This current draft ASTM protocol was used as a guide to conduct the tests on the IM7/8552 material. This report summarizes the test approach, methods, procedures and results of this characterization effort.

O'Brien, T. Kevin↗

NASA NTRS2006

Slow Crack Growth and Fracture Toughness of Sapphire for the International Space Station Fluids and Combustion Facility

The fracture toughness, inert flexural strength, and slow crack growth parameters of the r- and a-planes of sapphire grown by the Heat Exchange Method were measured to qualify sapphire for structural use in the International Space Station. The fracture toughness in dry nitrogen, K(sub Ipb), was 2.31 +/- 0.12 MPa(square root of)m and 2.47 +/- 0.15 MPa(squre root of)m for the a- and r-planes, respectively. Fracture toughness measured in water via the operational procedure in ASTM C1421 was significantly lower, K(sub Ivb) = 1.95+/- 0.03 MPa(square root of)m, 1.94 +/- 0.07 and 1.77 +/- 0.13 MPa(square root of)m for the a- , m- and r-planes, respectively. The mean inert flexural strength in dry nitrogen was 1085 +/- 127 MPa for the r-plane and 1255 +/- 547 MPa for the a-plane. The power law slow crack growth exponent for testing in water was n = 21 +/- 4 for the r-plane and n (greater than or equal to) 31 for the a-plane. The power law slow crack growth coefficient was A = 2.81 x 10(exp -14) m/s x (MPa(squre root of)m)/n for the r-plane and A (approx. equals)2.06 x 10(exp -15) m/s x (MPa(square root of)m)/n for the a-plane. The r- and a-planes of sapphire are relatively susceptible to stress corrosion induced slow crack growth in water. However, failure occurs by competing modes of slow crack growth at long failure times and twinning for short failure time and inert environments. Slow crack growth testing needs to be performed at low failure stress levels and long failure times so that twinning does not affect the results. Some difficulty was encountered in measuring the slow crack growth parameters for the a-plane due to a short finish (i.e., insufficient material removal for elimination of the damage generated in the early grinding stages). A consistent preparation method that increases the Weibull modulus of sapphire test specimens and components is needed. This would impart higher component reliability, even if higher Weibull modulus is gained at the sacrifice of absolute strength of the component. The current specification frequently used for the preparation of sapphire test specimens and components (e.g., a "60/40" scratch-dig finish) is inadequate to avoid a short finish.

Salem, Jonathan A.↗

NASA NTRS1973

Effect of specimen thickness of fatigue-crack-growth behavior and fracture toughness of 7075-T6 and 7178-T6 aluminum alloys

A study was made to determine the effects of specimen thickness on fatigue crack growth and fracture behavior of 7075-T6 and 7178-T6 aluminum alloy sheet and plate. Specimen thicknesses ranged from 5.1 to 12.7 mm (0.20 to 0.50 in.) for 7075-T6 and from 1.3 to 6.4 mm (0.05 to 0.25 in.) for 7178-T6. The stress ratios R used in the crack growth experiments were 0.02 and 0.50. For 7075-T6, specimen thickness had relatively little effect on fatigue-crack growth. However, the fracture toughness of the thickness of the thickest gage of 7075-T6 was about two-thirds of the fracture toughness of the thinner gages of 7075-T6. For 7178-T6, fatigue cracks generally grew somewhat faster in the thicker gages than in the thinnest gage. The fracture toughness of the thickest gage of 7178-T6 was about two-thirds of the fracture toughness of the thinner gages of 7178-T6. Stress intensity methods were used to analyze the experimental results. For a given thickness and value of R, the rate of fatigue crack growth was essentially a single-valued function of the stress intensity range for 7075-T6 and 7178-T6. An empirical equation developed by Forman, Kearney, and Engle fit the 7075-T6 and 7178-T6 crack growth data reasonably well.

Hudson, C. M.↗

NASA NTRS1981

A single fracture toughness parameter for fibrous composite laminates

A general fracture toughness parameter Qc was previously derived and verified to be a material constant, independent of layup, for centrally cracked boron aluminum composite specimens. The specimens were made with various proportions of 0 and + or - 45 degree plies. A limited amount of data indicated that the ratio Qc/epsilon tuf' where epsilon tuf is the ultimate tensile strain of the fibers, might be a constant for all composite laminates, regardless of material and layup. In that case, a single value of Qc/epsilon tuf could be used to predict the fracture toughness of all fibrous composite laminates from only the elastic constants and epsilon tuf. Values of Qc/epsilon tuf were calculated for centrally cracked specimens made from graphite/polyimide, graphite/epoxy, E glass/epoxy, boron/epoxy, and S glass graphite/epoxy materials with numerous layups. Within ordinary scatter, the data indicate that Qc/epsilon tuf is a constant for all laminates that did not split extensively at the crack tips or have other deviate failure modes.

Poe, C. C., Jr.↗

NASA NTRS2003

Strength, Fracture Toughness, Fatigue, and Standardization Issues of Free-standing Thermal Barrier Coatings

Strength, fracture toughness and fatigue behavior of free-standing thick thermal barrier coatings of plasma-sprayed ZrO2-8wt % Y2O3 were determined at ambient and elevated temperatures in an attempt to establish a database for design. Strength, in conjunction with deformation (stress-strain behavior), was evaluated in tension (uniaxial and trans-thickness), compression, and uniaxial and biaxial flexure; fracture toughness was determined in various load conditions including mode I, mode II, and mixed modes I and II; fatigue or slow crack growth behavior was estimated in cyclic tension and dynamic flexure loading. Effect of sintering was quantified through approaches using strength, fracture toughness, and modulus (constitutive relations) measurements. Standardization issues on test methodology also was presented with a special regard to material's unique constitutive relations.

Choi, Sung R.↗

NASA NTRS1989

Fracture toughness of SiC/Al metal matrix composite

An experimental study was conducted to evaluate fracture toughness of SiC/Al metal matrix composite (MMC). The material was a 12.7 mm thick extrusion of 6061-T6 aluminum alloy with 40 v/o SiC particulates. Specimen configuration and test procedure conformed to ASTM E399 Standard for compact specimens. It was found that special procedures were necessary to obtain fatigue cracks of controlled lengths in the preparation of precracked specimens for the MMC material. Fatigue loading with both minimum and maximum loads in compression was used to start the precrack. The initial precracking would stop by self-arrest. Afterwards, the precrack could be safely extended to the desired length by additional cyclic tensile loading. Test results met practically all the E399 criteria for the calculation of plane strain fracture toughness of the material. A valid K sub IC value of the SiC/Al composite was established as K sub IC = 8.9 MPa square root of m. The threshold stress intensity under which crack would cease to grow in the material was estimated as delta K sub th = 2MPa square root of m for R = 0.09 using the fatigue precracking data. Fractographic examinations show that failure occurred by the micromechanism involved with plastic deformation although the specimens broke by brittle fracture. The effect of precracking by cyclic loading in compression on fracture toughness is included in the discussion.

Flom, Yury↗

NASA NTRS1989

Fracture toughness of SiC/Al metal matrix composite

Flom, Yury↗

NASA NTRS1979

Comparison tests and experimental compliance calibration of the proposed standard round compact plane strain fracture toughness specimen

Standard round specimen fracture test results compared satisfactorily with results from standard rectangular compact specimens machined from the same material. The location of the loading pin holes was found to provide adequate strength in the load bearing region for plane strain fracture toughness testing. Excellent agreement was found between the stress intensity coefficient values obtained from compliance measurements and the analytic solution proposed for inclusion in the standard test method. Load displacement measurements were made using long armed displacement gages and hollow loading cylinders. Gage points registered on the loading hole surfaces through small holes in the walls of the loading cylinders.

Fisher, D. M.↗

NASA NTRS1989

Fracture toughness of polycrystalline ceramics in combined mode I and mode II loading

The present investigation of the fracture of alumina and zirconia polycrystalline ceramic specimens of precracked-disk type, in diametral compression, evaluated fracture toughness in pure mode I, combined mode I/mode II, and pure mode II, depending on the alignment of the center crack relative to the loading diameter. The mixed-mode fracture-toughness envelope thus obtained exhibits significant deviation to higher fracture toughness in mode II, relative to the predictions of linear elastic fracture mechanics theory. Crack-surface resistance due to grain-interlocking and abrasion are identified as the primary sources of increased fracture resistance in mode II loading of the polycrystalline ceramics.

Singh, Dileep↗

NASA NTRS1975

The feasibility of ranking material fracture toughness by ultrasonic attenuation measurements

A preliminary study was conducted to assess the feasibility of ultrasonically ranking material fracture toughness. Specimens of two grades of maraging steel for which fracture toughness values were measured were subjected to ultrasonic probing. The slope of the attenuation coefficient versus frequency curve was empirically correlated with the plane strain fracture toughness value for each grade of steel.

Vary, A.↗

NASA NTRS1975

The feasibility of ranking material fracture toughness by ultrasonic attenuation measurements

A preliminary study was conducted to assess the feasibility of ultrasonically ranking material fracture toughness. Specimens of two grades of maraging steel for which fracture toughness values were measured were subjected to ultrasonic probing. The slope of the attenuation coefficient vs frequency curve was empirically correlated with the plane strain fracture toughness value for each grade of steel.

Vary, A.↗

NASA NTRS2002

Strength and Fracture Toughness of Solid Oxide Fuel Cell Electrolyte Material Improved

Solid oxide fuel cells (SOFC) are being developed for various applications in the automobile, power-generation, and aeronautics industries. Recently, the NASA Glenn Research Center has been exploring the possibility of using SOFC's for aeropropulsion under its Zero Carbon Dioxide Emission Technology (ZCET) Program. 10-mol% yttriastabilized zirconia (10YSZ) is a very good anionic conductor at high temperatures and is, therefore, used as an oxygen solid electrolyte in SOFC. However, it has a high thermal expansion coefficient, low thermal shock resistance, low fracture toughness, and poor mechanical strength. For aeronautic applications, the thin ceramic electrolyte membrane of the SOFC needs to be strong and tough. Therefore, we have been investigating the possibility of enhancing the strength and fracture toughness of the 10YSZ electrolyte without degrading its electrical conductivity to an appreciable extent. We recently demonstrated that the addition of alumina to zirconia electrolyte increases its strength as well as its fracture toughness. Zirconia-alumina composites containing 0 to 30 mol% of alumina were fabricated by hot pressing. The hot pressing procedure was developed and various hot pressing parameters were optimized, resulting in dense, crackfree panels of composite materials. Cubic zirconia and a-alumina were the only phases detected, indicating that there was no chemical reaction between the constituents during hot pressing at elevated temperatures. Flexure strength sf and fracture toughness K(sub IC) of the various zirconia-alumina composites were measured at room temperature as well as at 1000 C in air. Both properties showed systematic improvement with increased alumina addition at room temperature and at 1000 C. Use of these modified electrolytes with improved strength and fracture toughness should prolong the life and enhance the performance of SOFC in aeronautics and other applications.

Bansal, Narottam P.↗

NASA NTRS1993

Effect of environment on fracture toughness of 96 wt pct alumina

An effort is made to deepen understanding of environmental effects on the fracture toughness of an alumina composition that contains a residual glassy phase, by ascertaining the fracture toughness under atmospheric conditions in such varied environments as air distilled water, silicone oil, and liquid nitrogen. Fracture toughness was determined via the single-edge-precracked beam technique. Weibull strength parameters are compared for polished specimens tested both in air and silicone environments.

Choi, Sung R.↗

NASA NTRS1993

Evaluation of the Fracture Toughness of Nb-40Al-8Cr-1W-1Y-0.05B Intermetallic Material by Indentation Techniques

The fracture toughness of an Nb-40Al-8Cr - 1W-1Y-0.05B intermetallic material was evaluated by indentation techniques at room temperature. Two widely used indentation methods, crack size measurement and indent strength, yielded excellent agreement with a conventional fracture toughness technique using straight-through precracked specimens, despite the occasional formation of poorly configured cracks. However, the modified indentation technique, using dummy indent flaws, resulted in a low fracture toughness compared to that evaluated by the other methods. The material did not exhibit rising R-curve behavior, as evaluated from the indentation strength data. These results indicate that indentation fracture principles are applicable to this brittle intermetallic material without modification of the residual contact stress term originally calibrated for ceramic materials.

Choi, S. R.↗

NASA NTRSDate not supplied

Computational Assessment of the Opening Mode Facesheet-to-Core Fracture Toughness of a Thin-Gage Facesheet Sandwich Structure

The single-cantilevered beam test (SCB) is currently being considered for standardization for measuring the opening mode fracture toughness of sandwich structures subjected to facesheet-to-core separation. At present, the Area method is considered the benchmark method for determining energy required to propagate the crack. This method is problematic since it requires periodic unloading and cannot be evaluated instantaneously. Therefore, a method is needed to accurately and instantaneously calculate opening mode fracture toughness. In previous work, SCB tests with thin-gauge facesheets were performed to compare the J-integral approach to data reduction methods including the Modified Beam Theory (MBT) and the Area method. Large deviations (over 10%) in the calculated fracture toughness were observed between the J-integral and MBT for large displacements. In this study, a simulated SCB experiment using a virtual crackclosure technique was performed to assess the previously observed discrepancies. The predicted load displacement response, the predicted angle at the load application point, and the predicted crack growth results are in good agreement (within 5%) with the corresponding experimental data. Using the predicted load and angles, the predicted J-integral is in good agreement (within 10%) with the experimentally obtained solution. Using the MBT approach, the previously observed deviations in the fracture toughness were determined to be associated with the empirical extrapolation procedure to estimate the crack-root rotation correction from nonlinear compliance curves. The nonlinear compliance is determined to be associated with large displacement effects observed within the predicted and experimental results.

Sandwich Composite↗