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I. INTRODUCTION
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They are often located at the former austenite grain boundaries. Elongated M-A particles, located between the bainite
laths, were found using transmission electron microscopy to
be mostly austenitic. All M-A particles are rich in carbon
(1.0 to 1.4 wt pct). Only 10 pct of the retained austenite further
transforms into martensite upon cooling to 196 C.
B. Experimental Procedures
The effect of microstructure on fracture toughness properties was investigated using fatigue-precracked three-point
bend (TPB) 10 20 100 mm3 specimens (ligament size of
10 mm). The specimens were fatigue precracked using a maximum load level lower than 4500 N and a load ratio of 0.1.
The number of cycles used in the precracking procedure was
about 4.5 105. The specimens were cut in the midthickness
of the plate, along the transverse direction, with the crack propagating along the rolling direction. Calculation of the J integral
was carried out using the area under the load-load line displacement curve following ASTM standard E1820-01.[20] The JIc
values were converted into a stress intensity factor (KJ) by
assuming plane-strain conditions: KJ (E JIc)1/2 (1 2)1/2,
where is the Poisson ratio and E is the Youngs modulus of
the material. In this study, the upper-limit criterion for JIc (J
Table I. Heat Treatment and Metallurgical Features of the Simulated HAZ Microstructures
Mean Size (m)
Heat Treatment
Microstructure
Tp1 (C)
Tp2 (C)
t 8/5 (s)
Former
Grains
CGHAZ-25
ICCGHAZ-25
CGHAZ-120
1250
1250
1250
775
25
25
120
56
60
76
Bainite
Packets
(EBSD)
Area Fraction
of Second Phases
(Optical Microscopy,
in Pct)
Pct Retained
Austenite (X-Ray
Diffraction)
12
12
35
4
8
5
2
4
4
Table II. Impact Toughness and Room-Temperature Properties of the Investigated Microstructures
(Midthickness, Transverse Direction)*
Microstructure
HV10
YS (MPa)
TS (MPa)
Fracture
Elongation (Pct)
Reduction in
Area (Pct)
YS/TS
T70J (C)
Base metal
CGHAZ-25
ICCGHAZ-25
CGHAZ-120
168
225
203
184
433
580
475
476
534
690
680
625
22
23
26
25
77
79
73
79
0.19
0.08
0.12
0.14
0.81
0.84
0.70
0.76
89
31
11
15
*HV is the Vickers hardness, YS the yield strength, TS the tensile strength, n the strain hardening exponent, and T70J the temperature for which the
mean Charpy V-notch impact energy is 70 J.
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(a)
(b)
(c)
(d)
Fig. 1Light optical micrographs of the base metal (midthickness, nital etching) and simulated heat-affected zone (1 pct sodium bisulphite etching)
microstructures: (a) base metal, (b) CGHAZ-25, (c) ICCGHAZ-25, and (d) CGHAZ-120. Some M-A constituents are indicated by white arrows.
C. Numerical Procedures
A local approach to cleavage fracture consists of applying a
physically based fracture criterion at every location of a loaded
component, in order to derive a failure criterion for this component using a weakest-link assumption.[22,23] This requires the
knowledge of the local stress and strain fields at any point in the
component. The stress and strain fields were determined using a
finite-element (FE) method for all specimen-geometry and test
conditions with the finite deformation formalism, updated geometry, and a global convergence criterion. Quadratic elements
(eight nodes) with reduced integration (four Gauss points per
element) were used for all calculations, and the Youngs modulus
and Poisson ratio were taken to be 210 GPa and 0.3, respectively.
All materials were assumed to follow the Von Mises yield
criterion. Elastic-plastic constitutive equations were thoroughly
determined as a function of test temperature for all microstructures using the tensile properties determined with smooth
specimens (gage length as small as 10 mm for the simulated
HAZ microstructures). For the base metal, a power-law hardening equation was found to best represent the tensile properties.
For the simulated HAZ microstructure, a nonlinear isotropic
hardening rule was chosen with two hardening variables, as
given by the following equation in the uniaxial case:
s R0 Q1(1 exp (b1 # p)) Q2 (1 exp (b2 # p))
[1]
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(a)
(b)
Fig. 2Size distribution of (a) bainitic packets and (b) second-phase particles in the simulated HAZ microstructures.
In Eq. [1], the parameters R0, Q1, Q2, b1, and b2 depend on
both the material and test temperature, and p is the cumulative
plastic strain. The constitutive equations had to be slightly
modified (reduction of the R0 parameter by about 5 pct) to
accurately represent the load-load line displacement curves of
RN specimens. This is due to a pseudo-Lders plateau observed
in the tensile stress-strain curves. More details concerning the
fitting procedure can be found elsewhere.[19]
For RN specimens, the stress and strain fields were computed in axisymmetrical conditions using the constitutive
equations determined previously and a minimum mesh size
of 200 m. For each temperature, material, and specimengeometry condition, the load was applied by displacement
control remote from the gage area. The mean stress (mean,
i.e., the calculated macroscopic load divided by the updated
area of minimum diameter) and mean radial strain (mean
2 ln (0/), with being the calculated minimum diameter,
having an initial value 0) were then calculated and compared with experimental data. Excellent agreement was
obtained between experimental and simulated mean vs mean
curves.
For TPB specimens, the loadcrack mouth displacement
curves fall between those calculated assuming plane-stress
and plane-strain conditions, respectively. Thus, only a threedimensional (3-D) mesh could allow accurate prediction of
the loadcrack mouth displacement curve. This was confirmed by carrying out calculation in 3-D conditions for one
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(a)
(b)
(c)
(d)
Fig. 3Temperature dependence of yield strength (YS), tensile strength (TS), and reduction in area (RA) of (a) base metal, (b) CGHAZ-25, (c) ICCGHAZ-25,
and (d) CGHAZ-120 microstructures. Solid lines are for the (YS vs temperature) fit used in the constitutive equations.
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(a)
(c)
(b)
(d)
Fig. 5Brittle to ductile toughness transition curves obtained with TPB specimens: (a) base metal, (b) CGHAZ-25, (c) ICCGHAZ-25, and (d) CGHAZ-120
microstructures. Open symbols indicate that significant (
0.2 mm) ductile crack propagation occurred before cleavage fracture. Solid lines (respectively,
dotted lines) show fracture probabilities of 10 and 90 pct given by the Beremin model (respectively, by the Master curve approach). Dashed lines indicate
the upper limit for calculation of the KJ parameter (J
(W a) y /M), with (W a) the ligament size (10 mm).
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Fig. 6Cleavage crack initiation observed after interrupted test of a fracture mechanics specimen; T 20 C, ICCGHAZ-25 microstructure. The
cleavage crack initiated near a M-A constituent (arrow), as shown after
Villela etching of the fracture surface.
[2]
(b)
Fig. 7Fracture surfaces of RN2 specimens (ICCGHAZ-25 microstructure). (a) Ductile fracture at T 20 C (fracture strain 53 pct). (b) Brittle cleavage fracture at T 160 C (fracture strain 4 pct). Both smallest
ductile dimples and cleavage facets are found to initiate near M-A constituents, as indicated by arrows (Villela etching).
METALLURGICAL AND MATERIALS TRANSACTIONS A
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hinder the propagation of cracks initiated from M-A constituents. The micromechanical model proposed in the last
part of Section IV is an attempt to take into account this
double barrier (DB) phenomenon evidenced for cleavage
cracking in the simulated HAZ microstructures.
IV. MODELING
(a)
(b)
KIc S
(c)
Fig. 8Arrested cleavage microcracks obtained with interrupted tests on
RN0.1 specimens using acoustic emission analysis. (a) Fracture surface after
subsequent fatigue crack propagation (T 30 C) Some EBSD indexations
of crack arresting boundaries are given. (b) EBSD map of a polished cross
section (T 20 C). Thin lines and thick lines denote low-angle and highangle boundaries, respectively. (c) Scanning electron micrograph and disorientation analysis along the crack path, showing microcrack arrest at
high-angle boundaries (same area as b).
1n
# X1/2
# sf 2n # sy
0
1n
2n
[3]
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as long as it remains very small). Concerning fracture probability, the PZ is divided into N independent units having the
same volume (V0). The value of V0 must be high enough to
contain a cleavage crack initiator with a reasonable probability
and low enough to allow one to neglect the stress gradients
within V0. Here, V0 was taken to contain about eight prior
austenite grains, i.e., V0 (100 m)3. In every unit of volume
V0, the size distribution density of defects (where cleavage
microcracks initiate) is represented using a power law:
p(a) a # ab
[4]
where a is the defect size and and are V0-dependent material constants. Assuming a Griffith-like criterion, the probability
for a given elementary unit to fracture under maximum principal stress () is then given by
P(s)
p(a) da,
ac(s)
with ac(s)
p#E#g
(Griffith-like criterion) [5]
#
2 (1 n2) # s2
sw m
dV 1/m
[7]
b b with sw a sIm
b
su
V0
PZ
[8]
Here, y is the yield stress and Cm,n is an elliptic integral depending both on m (the Weibull shape factor), on n (the strainhardening exponent), and on the two-dimensional plastic zone
size. The parameter B is the thickness of the specimen, and
KI is the stress intensity factor. The size effect (here, thickness effect) is given by the fact that in plane-strain conditions,
the product K4Ic B is constant. In plane-strain conditions, the
effect of temperature is driven by the yield stress as follows:
KIC (sy)(m/4)1 constant
[9]
Table III. Parameters of the Beremin Model (Unit Volume V0 (100 m)3) and of the Master Curve Approach
for the Investigated Microstructures; T100 is the Temperature for which KIc 100 MPa 1m
Beremin Model
Microstructure
u (MPa)
Base metal
CGHAZ-25
ICCGHAZ-25
CGHAZ-120
2158
2670
2351
2085
27
20
20
20
Experimental Values
T28J (C)
T100 (C)
100
40
15
15
140
55
20
10
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B KI Kmin 4
a
b b
B0 K0 Kmin
[10]
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Fig. 10Schematic representation of the role of microstructural barriers on failure micromechanisms. For the sake of simplicity, the crack was assumed
to nucleate from an intragranular M-A constituent: (a) undamaged material, (b) microcrack initiation (step 0) and propagation (step 1) in the M-A particle,
(c) microcrack propagation across the particle/matrix interface of strength pm (step 2), and (d) microcrack propagation across a bainite high-angle packet
boundary of strength mm (step 3), leading to final failure. I is the local maximum principal stress, and M-A is the stress in the M-A particle, of critical
value scM-A.
METALLURGICAL AND MATERIALS TRANSACTIONS A
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mm), leading immediately to final failure. Thus, in temperature range II, failure is controlled by the strength of the
particle/matrix interfaces. Cracked particles may be observed
near the fracture surface, in agreement with experiment.
3. At higher temperatures (temperature range III), the
strength of the matrix/matrix interfaces is high and y
pm mm. Upon loading, I increases, so that microcracks initiate in particles (M-A
scM-A), propagate
through the particle/matrix interface (I
pm), and stop
at matrix/matrix interfaces. Upon further loading, the
value of I is still increasing, and, as soon as I
mm
(at least locally), an arrested microcrack can further propagate across the matrix/matrix interface and leads to final
failure. Thus, in temperature range III, failure is controlled by the strength of matrix/matrix interfaces, i.e.,
of high-angle bainite packet boundaries. This is consistent
with experimental detection of microcrack propagation
through bainite packets and of microcrack arrest at highangle boundaries at T 60 C.
4. At even higher temperatures (temperature range IV), mm
is very high, and ductile fracture (possibly initiated at
M-A particles) occurs before cleavage cracking could
develop into the bainitic matrix.
Temperature ranges II and III correspond to propagationcontrolled cleavage cracking (in our case, for T
170 C),
where cleavage microcracks were experimentally found to
initiate at M-A constituents, propagate through the M-A/
bainite interface, and occasionally stop at high-angle bainite
packet boundaries.
The input parameters of the model are as follows.
1. The parameter p(c) is the fracture probability of a M-A
constituent of size c (crack initiation criterion). For the
sake of simplicity, it was chosen here to be a threshold
function. As soon as M-A
scM-A (with M-A given locally
by Eq. [2]), particle cracking occurs.
2. The parameters fc(c) and fg(D) are the size distribution functions of M-A constituents and bainitic packets, respectively.
Lognormal equations were fitted to the experimental distributions as shown in Figure 2.
1050VOLUME 35A, MARCH 2004
Fc(c*s c D*s)
p(c) # f (c) # dc
c
[13]
c*s
Fg(c*s c D*s)
a1 exp aNVc #
pD3 #
b
6
D*s
N
g
V
PZ
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[16]
The stress in the particle was calculated using Eq. [2]. The
initial value of scM-A, which is a material parameter, was estimated using the micromechanical approach discussed before
to be 2200 MPa.
With the simplifying assumptions presented here, four paramc
eters had to be determined: sM-A
(the critical fracture stress of
pm
M-A particles), KIa (assumed to be the same for all micromm
structures), and KIa
for both the CGHAZ-25 and ICCGHAZ-25
microstructures. The values of Kmm
Ia differ between these
microstructures, because the numerous, martensitic M-A particles located at high-angle boundaries of ICCGHAZ-25
microstructure were found to enhance cleavage crack propagation across these boundaries, thus decreasing the value of
Kmm
Ia . All four parameters were fitted using the experimental
results of tests on RN specimens (Figure 11 and Table IV). The
value of scM-A is close to the initial value assessed with the
micromechanical approach. The value of Kmm
Ia is up to 3 times
higher than the values given in literature,[15,42,46] but only refers
to the high-angle packet boundaries, i.e., to those having the
highest fracture toughness in the microstructure.
The agreement between fracture probability given by the
model and experimental data for RN specimens is good for
the ICCGHAZ-25 microstructure. However, agreement is
less good for the CGHAZ-25 microstructure. Nevertheless,
c was supposed to be the same for both microstructures,
although the size distributions of second-phase particles significantly differ in CGHAZ-25 and ICCGHAZ-25 (Figure 2).
The fitting procedure then leads to an overestimation of Kmm
Ia
in the CGHAZ-25 microstructure, whereas quantitative agreement is obtained with the ICCGHAZ microstructure.
The model was then applied to fracture toughness specimens. The evolution of fracture toughness with temperature
is well represented in both the CGHAZ-25 and ICCGHAZ-25
microstructures. Quantitative agreement is obtained with the
ICCGHAZ microstructure concerning fracture probability
(compare the solid lines with solid symbols in Figure 12).
The model well accounts for experimental scatter, which is
very satisfactory, as the prediction of scatter derives directly
from the experimental size distribution of second phases and
bainitic packets.
(a)
(b)
Fig. 11Fracture probability vs strainexperimental data and results of
fitting the double barrier model parameters: (a) CGHAZ-25 microstructure
and (b) ICCGHAZ-25 microstructure.
Table IV. Parameters of the Double Barrier Model Identified on RN Specimens, Compared with Literature Data
Parameter
Present Study
Value
scM-A (MPa)
Klapm (MPa 1m )
2112
7.8
Klamm (MPa1m )
CGHAZ-25:
28 (160 C)
ICCGHAZ-25:
18 (135 C)
Literature Data
Value
Microstructural Unit
Reference
2.5 to 5.0
2.5
1.8
5.0 to 7.0
7.0 (196 C)
7.5
4.8 (196 C)
15.2 (50 C)
carbides
globular carbides
TiN particles
bainite packets
bainite packets
ferrite grains
bainite packets
bainite packets
42
47
46
15
42
47
46
46
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APPENDIX
AE Detection of Microcracking Events
As explained in more detail in Reference 21, acoustic
emission was continuously recorded during the tests by
(a)
(b)
Fig. A1Typical curves obtained with AE monitoring of microcrack propagation. (a) Evolution of the average signal level (ASL) and load for a RN0.1
specimen of CGHAZ-120 microstructure tested at 20 C. (b) Evolution of
cumulative energy with time for TPB specimens of ICCGHAZ-25 microstructure. Specimen fracture is indicated by open symbols. Energy peaks corresponding to microcrack propagation and arrest events are indicated by arrows.
METALLURGICAL AND MATERIALS TRANSACTIONS A
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