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NASA NTRS1995

Calculating 3-D Crack-Opening Behavior Of A Fatigue Crack

Method for calculating through-the-thickness, three-dimensional (3-D) crack-opening behavior in standard fatigue-crack-growth test specimens devised. Involves determination of crack-opening loads from crack-propagation data and finite-element analyses. In method, one considers variation in rate of crack growth along crack front, relationship between rate of crack growth and effective stress intensity factor, and variation in three-dimensional stress-intensity factor along crack front. Developed to provide simpler means for obtaining fatigue-crack-opening behavior loads.

Newman, J. C., Jr.↗

NASA NTRS2001

Skin, Stringer, and Fastener Loads in Buckled Fuselage Panels

The results of a numerical study to assess the effect of skin buckling on the internal load distribution in a stiffened fuselage panel, with and without longitudinal cracks, are presented. In addition, the impact of changes in the internal loads on the fatigue life and residual strength of a fuselage panel is assessed. A generic narrow-body fuselage panel is considered. The entire panel is modeled using shell elements and considerable detail is included to represent the geometric-nonlinear response of the buckled skin, cross section deformation of the stiffening components, and details of the skin-string attachment with discrete fasteners. Results are presented for a fixed internal pressure and various combinations of axial tension or compression loads. Results illustrating the effect of skin buckling on the stress distribution in the skin and stringer, and fastener loads are presented. Results are presented for the pristine structure, and for cases where damage is introduced in the form of a longitudinal crack adjacent to the stringer, or failed fastener elements. The results indicate that axial compression loads and skin buckling can have a significant effect on the circumferential stress in the skin, and fastener loads, which will influence damage initiation, and a comparable effect on stress intensity factors for cases with cracks. The effects on stress intensity factors will influence damage propagation rates and the residual strength of the panel.

Young, Richard D.↗

NASA NTRS1988

Cracking of a layered medium on an elastic foundation under thermal shock

The cladded pressure vessel under thermal shock conditions which is simulated by using two simpler models was studied. The first model (Model 1) assumes that, if the crack size is very small compared to the vessel thickness, the problem can be treated as a semi-infinite elastic medium bonded to a very thin layer of different material. However, if the crack size is of the same order as the vessel thickness, the curvature effects may not be negligible. In this case it is assumed that the relatively thin walled hollow cylinder with cladding can be treated as a composite beam on an elastic foundation (Model 2). In both models, the effect of surface cooling rate is studied by assuming the temperature boundary condition to be a ramp function. The calculated results include the transient temperature, thermal stresses in the uncracked medium and stress intensity factors which are presented as a function of time, and the duration of cooling ramp. The stress intensity factors are also presented as a function of the size and the location of the crack. The problem is solved for two bonded materials of different thermal and mechanical properties. The mathematical formulation results in two singular integral equations which are solved numerically. The results are given for two material pairs, namely an austenitic steel layer welded on a ferritic steel substrate, and a ceramic coating on ferritic steel. In the case of the yielded clad, the stress intensity factors for a crack under the clad are determined by using a plastic strip model and are compared with elastic clad results.

Rizk, Abd El-Fattah A.↗

NASA NTRS1989

Strain intensity factor approach for predicting the strength of continuously reinforced metal matrix composites

A method was previously developed to predict the fracture toughness (stress intensity factor at failure) of composites in terms of the elastic constants and the tensile failing strain of the fibers. The method was applied to boron/aluminum composites made with various proportions of 0 deg and +/- 45 deg plies. Predicted values of fracture toughness were in gross error because widespread yielding of the aluminum matrix made the compliance very nonlinear. An alternate method was develolped to predict the strain intensity factor at failure rather than the stress intensity factor because the singular strain field was not affected by yielding as much as the stress field. Far-field strains at failure were calculated from the strain intensity factor, and then strengths were calculated from the far-field strains using uniaxial stress-strain curves. The predicted strengths were in good agreement with experimental values, even for the very nonlinear laminates that contained only +/- 45 deg plies. This approach should be valid for other metal matrix composites that have continuous fibers.

Poe, Clarence C., Jr.↗

NASA NTRS1979

Bonded orthotropic strips with cracks

The elastostatic problem for a nonhomogeneous plane which consists of two sets of periodically arranged dissimilar orthotropic strips is considered. It is assumed that the plane contains a series of collinear cracks perpendicular to the interfaces and is loaded in tension away from and perpendicular to the cracks. The problem of cracks fully imbedded into the homogeneous strips is considered. The singular behavior of the stresses for two special crack geometries is studied. The first is the case of a broken laminate in which the crack tips touch the interfaces. The second is the case of cracks crossing the interfaces. An interesting result found from the analysis of the latter is that for certain orthotropic material combinations the stress state at the point of intersection of a crack and an interface may be bounded whereas in isotropic materials at this point stresses are always singular. A number of numerical examples are worked out to separate the primary material parameters influencing the stress intensity factors and the powers of stress singularity, and to determine the trends regarding the influence of the secondary parameters. Some numerical results are given for the stress intensity factors in certain basic crack geometries and for typical material combinations.

Delale, F.↗

NASA NTRS1978

Bonded orthotropic strips with cracks

The elastostatic problem for a nonhomogeneous plane which consists of two sets of periodically arranged dissimilar orthotropic strips is considered. First, the problem of cracks fully imbedded into the homogeneous strips is considered. Then, the singular behavior of the stresses for two special crack geometries is studied in some detail. The first is the case of a broken laminate in which the crack tips touch the interfaces. The second is the case of cracks crossing the interfaces. A number of numerical examples are worked out in order to separate the primary material parameters influencing the stress intensity factors and the powers of stress singularity, and to determine the trends regarding the influence of the secondary parameters. Finally, some numerical results are given for the stress intensity factors in certain basic crack geometries and for typical material combinations.

Delale, F.↗

NASA NTRS1975

Crack growth in bonded elastic half planes

Two solutions were developed for the two dimensional problem of bonded linearly elastic half-planes. For each solution, numerical results are presented for the stress intensity factors, strain energy release rate, stresses, and displacements. The behavior predicted by the studies was investigated experimentally using polymers for the material pairs. Close agreement was found for the critical stress intensity factor at fracture for the perpendicular crack near the interface. Fracture along the interface proved to be inconclusive due to difficulties in obtaining a brittle bond. Some interesting and predictable behavior regarding the potential for the crack to cross the interface was observed and is discussed.

Goree, J. G.↗

NASA NTRS1996

Nonlinear Response and Residual Strength of Damaged Stiffened Shells Subjected to Combined Loads

The results of an analytical study of the nonlinear response of stiffened fuselage shells with long cracks are presented. The shells are modeled with a hierarchical modeling strategy and analyzed with a nonlinear shell analysis code that maintains the shell in a nonlinear equilibrium state while the crack is grown. The analysis accurately accounts for global and local structural response phenomena. Fuselage skins, frames stringers and failsafe straps are included in the models. Results are presented for various combinations of internal pressure and mechanical bending, vertical shear and torsion loads, and the effects of crack orientation and location on the shell response are described. These results indicate that the nonlinear interaction between the in-plane stress resultants and the out-of-plane displacements near a crack can significantly affect the structural response of the shell, and the stress-intensity factors associated with a crack that are used to predict residual strength. The effects of representative combined loading conditions on the stress-intensity factors associated with a crack are presented. The effects of varying structural parameters on the stress-intensity factors associated with a crack, and on self-similar and non-self-similar crack-growth are also presented.

Starnes, James H., Jr.↗

NASA NTRS1986

The surface crack problem in an orthotropic plate under bending and tension

The elasticity problem for an infinite orthotropic flat plate containing a series of through and part-through cracks and subjected to bending and tension loads is considered. The problem is formulated by using Reissner's plate bending theory and considering three dimensional materials orthotropy. The Line-spring model developed by Rice and Levy is used to formulate the surface crack problem in which a total of nine material constants has been used. The main purpose of this study is to determine the effect of material orthotropy on the stress intensity factors, to investigate the interaction between two asymmetrically arranged collinear cracks, and to provide extensive numerical results regarding the stress intensity factors. The problem is reduced to a system of singular integral equations which is solved by using the Gauss-Chebyshev quadrature formulas. The calculated results show that the material orthotropy does have a significant effect on the stress intensity factor.

Wu, B. H.↗

NASA NTRS1987

The surface crack problem in an orthotropic plate under bending and tension

The elasticity problem for an infinite orthotropic flat plate containing a series of through and part through cracks and subjected to bending and tension loads is considered. The problem is formulated by using Reissner's plate bending theory and considering three-dimensional material orthotropy. The Line-spring model developed by Rice and Levy is used to formulate the surface crack problem in which a total of nine material constants were used. The effects of material orthotropy on the stress intensity factors was determined, the interaction between two asymmetrically arranged collinear cracks was investigated, and extensive numerical results regarding the stress intensity factors are provided. The problem is reduced to a system of singular integral equations which is solved by using the Gauss-Chebyshev quadrature formulas. The calculated results show that the material orthotropy does have a significant effect on the stress intensity factor.

Wu, Bing-Hua↗

NASA NTRS1978

A thick-walled cylinder with an axisymmetric internal or edge crack

The paper considers the elastostatic axisymmetric problem for a long thick-walled cylinder containing a ring-shaped internal or edge crack. Using the standard transform technique the problem is formulated in terms of an integral equation which has a simple Cauchy kernel for the internal crack and a generalized Cauchy kernel for the edge crack as the dominant part. As examples the uniform axial load and the steady-state thermal stress problems have been solved and the related stress-intensity factors have been calculated. Among other findings the results show that in the cylinder under uniform axial stress containing an internal crack the stress-intensity factor at the inner tip is always greater than that at the outer tip for equal net ligament thicknesses and in the cylinder with an edge crack which is under a state of thermal stress the stress-intensity factor is a decreasing function of the crack depth, tending to zero as the crack depth approaches the wall thickness.

Erdol, R.↗

NASA NTRS1994

Review of modelling small-crack behavior and fatigue-life predictions for aluminum alloys

The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic-zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic-zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.

CRACK CLOSURE MODELLING↗

NASA NTRS1988

Strain intensity factor approach for predicting the strength of continuously reinforced metal matrix composites

A method was previously developed to predict the fracture toughness (stress intensity factor at failure) of composites in terms of the elastic constants and the tensile failing strain of the fibers. The method was applied to boron/aluminum composites made with various proportions of 0 to + or - 45 deg plies. Predicted values of fracture toughness were in gross error because widespread yielding of the aluminum matrix made the compliance very nonlinear. An alternate method was developed to predict the strain intensity factor at failure rather than the stress intensity factor because the singular strain field was not affected by yielding as much as the stress field. Strengths of specimens containing crack-like slits were calculated from predicted failing strains using uniaxial stress-strain curves. Predicted strengths were in good agreement with experimental values, even for the very nonlinear laminates that contained only + or - 45 deg plies. This approach should be valid for other metal matrix composites that have continuous fibers.

Poe, C. C., Jr.↗

NASA NTRS1984

Three-dimensional finite-element analysis of chevron-notched fracture specimens

Stress-intensity factors and load-line displacements were calculated for chevron-notched bar and rod fracture specimens using a three-dimensional finite-element analysis. Both specimens were subjected to simulated wedge loading (either uniform applied displacement or uniform applied load). The chevron-notch sides and crack front were assumed to be straight. Crack-length-to-specimen width ratios (a/w) ranged from 0.4 to 0.7. The width-to-thickness ratio (w/B) was 1.45 or 2. The bar specimens had a height-to-width ratio of 0.435 or 0.5. Finite-element models were composed of singularity elements around the crack front and 8-noded isoparametric elements elsewhere. The models had about 11,000 degrees of freedom. Stress-intensity factors were calculated by using a nodal-force method for distribution along the crack front and by using a compliance method for average values. The stress intensity factors and load-line displacements are presented and compared with experimental solutions from the literature. The stress intensity factors and load-line displacements were about 2.5 and 5 percent lower than the reported experimental values, respectively.

Raju, I. S.↗

NASA NTRS1999

Analysis of an Interface Crack for a Functionally Graded Strip Sandwiched between Two Homogeneous Layers of Finite Thickness

The interface crack problem for a composite layer that consists of a homogeneous substrate, coating and a non-homogeneous interface was formulated for singular integral equations with Cauchy kernels and integrated using the Lobatto-Chebyshev collocation technique. Mixed-mode Stress Intensity Factors and Strain Energy Release Rates were calculated. The Stress Intensity Factors were compared for accuracy with relevant results previously published. The parametric studies were conducted for the various thickness of each layer and for various non-homogeneity ratios. Particular application to the Zirconia thermal barrier on steel substrate is demonstrated.

Shbeeh, N. I.↗

NASA NTRS2004

Anomolous Fatigue Crack Growth Phenomena in High-Strength Steel

The growth of a fatigue crack through a material is the result of a complex interaction between the applied loading, component geometry, three-dimensional constraint, load history, environment, material microstructure and several other factors. Previous studies have developed experimental and computational methods to relate the fatigue crack growth rate to many of the above conditions, with the intent of discovering some fundamental material response, i.e. crack growth rate as a function of something. Currently, the technical community uses the stress intensity factor solution as a simplistic means to relate fatigue crack growth rate to loading, geometry and all other variables. The stress intensity factor solution is a very simple linear-elastic representation of the continuum mechanics portion of crack growth. In this paper, the authors present fatigue crack growth rate data for two different high strength steel alloys generated using standard methods. The steels exhibit behaviour that appears unexplainable, compared to an aluminium alloy presented as a baseline for comparison, using the stress intensity factor solution.

Forth, Scott C.↗

NASA NTRS2018

Use of Simple Continuum Solutions in Finite Element Alternating Method for Fracture Problems

The performance of the finite element alternating (FEAM) method for two-dimensional crack problems is studied with respect to a polynomial pressure distribution fitted to the crack face stresses. The FEAM alternates between the analytical solution of crack in an infinite plate subjected to arbitrary polynomial distribution and a finite element solution of an uncracked body to satisfy the required boundary conditions in the crack problem. In this paper, the FEAM is applied to embedded crack and edge crack problems. For embedded crack problems, all of the constant, linear, and quadratic ( N=0,1, or 2, respectively) pressure distributions yield very accurate results with this algorithm with 4 to 5 iterations. The edge crack problems, on the other hand, require much higher order polynomials distributions (N=5 to 6) to yield accurate solutions. For slant edge crack problems, the mode-I stress-intensity factors have better accuracy than the mode-II stress-intensity factors for the same convergence tolerance.

Krishnamurthy, T.↗

NASA NTRS1973

Growth characteristics of a plane crack subjected to three-dimensional loading

The closed form expressions for the stress intensity factors due to concentrated forces applied to the surfaces of a half plane crack in an infinite body are used to generate solutions for distributed loads in this geometry. The stress intensity factors for uniformly distributed loads applied over a rectangular portion of the crack surface are given in closed form. An example of non-uniformly distributed loads which can be treated numerically is also included. In particular, combinations of normal and shear stresses on the crack which simulate the case of loading at an angle to the crack front are considered. The resulting stress intensity factors are combined with the strain energy density fracture criterion for the purpose of predicting the most likely direction of crack propagation. The critical value of the energy density factor can then be used for determining the allowable load on a specimen with a crack front not perpendicular to the tensile axis.

Hartranft, R. J.↗