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ABSTRACT
Magnetic emission (ME) and potential drop (PD) techniques were used for
instrumented Charpy impact testing in order to determine critical crack initiation properties of
standard pre-cracked three-point bending specimens at room temperature. Results for high
strength low-alloyed steel specimens, with ductile properties, were compared for determina-
tion of critical fracture mechanics parameters upon the onset of ductile crack growth.
In the case of ductile, or mixed ductile/cleavage fracture at temperatures well above
nil-ductile, or at lower impact energies, it is sometimes difficult to distinguish crack initiation
from ME signal, while the integrated magnetic emission signal (MF) sometimes has a slower
changing rate. Results were also obtained by applying the potential drop technique with single
specimen HSLA steels and by evaluating the R-curve. Initiation of stable crack growth may
also be depicted from local minimum (or maximum) of potential drop value and it may not
give clear local extreme values when conditions of fracture change from brittle to ductile.
Alternatively, if the change of slope in the PD-t diagram can be used to evaluate critical crack
behaviour, compared to similar changes of slope in the MF-t diagram, it may provide a better
understanding of both.
Keywords: fracture mechanics, impact testing, ductile crack growth, magnetic emission,
potential drop, dynamic resistance curve.
72 Z RADAKOVI(g, ET AL.
INTRODUCTION
Micro-alloyed steels have a wide range of use in metal structures in general. The
tested ferrite-pearlite steel is micro-alloyed with Nb and Ti and is obtained by controlled
rolling and accelerated cooling. The yield stress is 411 MPa, and the material is very ductile at
lower temperatures, with a wide brittle-to-ductile transition range. The as-received chemical
composition (in wt. %) is shown in Table 1.
Upper shelf values for ductile fracture at room temperature are evident from load-time
or load-displacement data. All tests are performed at room temperature. The standard V-
notched Charpy specimens were cut from a 12 mm plate perpendicular to rolling direction,
and pre-cracked by high frequency fatigue in programmed sequence in order to avoid large-
scale plastic deformation. Owing to experience, specimens were then prepared in the manner
for applying the potential drop technique [4]. In Fig. l, the required instrumentation is shown
connected to the specimen, positioned on the anvil of the Charpy machine. Thin steel-wire,
Ni-wire, or Ni-Cr-wire connections for PD signal output were either resistance-spot-welded,
or soldered to the specimen at positions in the vicinity of notch opening (locations A, Fig. 1).
Massive input Cu-wires from the DC power source were connected to the specimens by bolts
(position III on Fig. 1). The power source input DC electric current of 30 A was selected as
Determination of Ductile Crack Initiation 73
nominal for producing output PD values that could be distinguished, ranging from several to
at least 10 mV. In order to produce stronger output signals, some specimens required input
signals as high as 40 A, even 50 A, being the limit, since higher values produce electrically
induced heat. Locally induced, this heat might affect pronounced ductility behaviour by
additional softening of the material, predominantly within the fracture-processing zone ahead
of the crack, since electric currents must close the circuit, passing through the ligament. Other
limiting effects contribute from massive wire connections, e.g. inertial characteristics of
specimens are influenced, and this problem is yet to be solved. As a consequence, 'interrupted'
fracture occurs at higher strain rates. During impact, this is caused by mutual contact and/or
collision of wire-connections with inclined anvil wall surfaces, appearing much later after
stable crack initiation, even after the maximal force (Fro), and so these unwanted effects are
not taken into consideration. These effects are evident from the load-time, and MF--time or
PD-time diagrams, Fig. 2, and in the shown example appear at approximately 3.5 ms.
PC desktop
computer
Spreadsheet
D.C.
analysts
Constant
power supl:~y
Pendulum ' Load
measurement
Specimen
1 !
,/ ,'" i~ probe
vDOCmeter I' I\ !\Strain gauge
S and Ii F :\
Magnetic aml ~ifier J ~ ~Pendulum
probe Oscdloscope i" .... :
7- [00004 7 1 tO004
i
6 00003 6~ 0003
i
St 00002 5 o oo2
4 0O0O1 4 OOOl
z z
>
tu 3 o E ua 3
o ~2
0
u. 2 . -0 (xx)1 2 .oool
I .0 0 0 0 2 I .o002
0 -0 0003 0
I
!
i
-1 ,---~ . . . . . . . . . . . . ,i .O(XX)4 -1 J, . . . . . . . . . . . . . .
0 2 4 6 8 ~0 ~2 0 2 4 6 8 lo 12
T1ME t. m s TIME t. ms
Changes in the external magnetic field are recorded in the vicinity of the propagating
crack, through the magnetic emission probe, Fig. 1. The TEKTRONIX TDS 420A data
acquisition equipment is connected to a DC amplifier and voltage supply. The HP transient
recorder with an interior circuit amplifier is tied to the remaining channel on the oscilloscope.
Both magnetic and electric potential drop signals are monitored and recorded in real sampling
time intervals of 2, 4, 10 and 40 Its. All data is handled by spreadsheet procedures, including
the evaluation of absorbed energy (U) and the fracture resistance critical dynamic J-integral.
6 [ - - o 0024 6 ; - 0O02
I
5 . . . . ~ 0002 5 t . . . . . . 0001
4 ~ . . . . . . 'i 00016 4! 0
I
Z.x Z
.x J I
u.." 3 00012 u." 3 - -0001
n"
O 2) 00008 E ~ 2"
.. 9 ,. . j
i~ 0ooo4 i 9 ; " ~.~'x~. --~.o03
! ._.. i
o :,,r o o ,,.--
i
-1 . . . . . . . . . . . . . . . . . . . . . . . -0 0004 -1 -- , ................... ~. . . . . . . . . . . 4) 005
-2 0 2 4 6 e 10 12 14 16 -2 0 2 4 6 8 10 12 14 16
DISPLACEMENT f, mm DISPLACEMENT f, m m
5L
i ; o0oo4
5, !~~, ;~..e..~'*~r ooo,
'4...4w, ;
i 4, 9 !- ..
uS 3 >
, \ , oool 6
L&. Ii
t -0002
! 7 , ~ '
-00002 [ -0 003
0 0 '
; ,
Fig. 4. F(t) diagrams with MF and PD signals for specimen A6, shown time-to-fracture (tF),
(measured and calculated data: pre-crack length ao=5.38 mm; crack extension Aa=3.99 mm;
impact load rate vo=2.56 ms ~', maximum impact load F,~x=5.14 kN', stable crack initiation
times (time-to-fracture), and released energies, determined from ME and PD tests, in respect:
b(M~.)=460 Its, t;(p[))=458 las, U(M~.)=4.39 J, U(pD)=4.36 J; dynamic J-integral values calculated
from ME and PD tests: J,:md= 190.'1 kJm 2, Jcpdd= 189.1 kJm 2)
Determination of Ductile Crack Initiation 75
Fracture resistance is determined from the J-integral at the initiation of stable crack
growth under dynamic conditions (j]d), and is determined from the most appropriate formula,
for single or multiple specimen testing:
jd = qU
Bn(W_ao), (1)
where 1"1=2 for single edge notch bend specimens, and B,=B is the non-sidegrooved specimen
thickness. The released energy U, in the upper formula, is the area under the load-displace-
ment curve F(t)-f(t) and is integrated according to:
U, = riF(f)df (2)
0
300 r
I 300 r
i I
250. I
250 '
o
test ,~ .~. 0
E Q
9 ME ' ~
... ~ ~ 9 9
-) 200 i ~ o .-'-" _-~--~ O PDtest E :' o...._ ~}--.;._$ o
'o u I
-- - - Power (ME test) -'~ 200 I- - ~ ~ ~ _ _ ~"~,;... i~
150~ o
150 - o
100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 i _. . . . . . . . .
V, m s "I ao, am
Merkbl~itter procedure 002 (1987), and by assuming plane strain conditions, the characteristic
equation for the critical J-integral can be described in the form"
3500-
A A
3000-'
J = 600 + 5256.,7 A~
I
R 2 = 0.901 j~' A
2500-, ~"
I
lh,
9 A
E
-b 2000 9 /A
AI ~ 0
9 O
9 1500,
L~ J
1000 t 0 Jcorr
-- - - P o w e r (Jcorr)
:
Jco- = 695 + 3 9 4 ~ o 5r -- - - Linear (J)
~)0 ""
R 2 = 0.629
0 ".' . . . . . . . . . . . . . . . . . T - " 9 . . . . . . . . . .
DISCUSSION
Analysis of the fractured surface shows portions of 'slant' and 'square' type surfaces,
indicating a fracture profile typical of the both plane stress and plane strain modes. This is
regularly noticed when using non-side grooved specimens for this type of steel.
It is noticed that by fitting the dynamic R-curve (Fig. 7) by the equation of the general
form: J = A + C'Aa D, where A, C and D are constants, results in a linear behaviour.
It is interesting to notice that if the fracture resistance determined from J-integral
calculation allowing for crack growth is corrected according to certain test procedures [8,9]
given for quasi-static conditions, using the formula:
Determination of Ductile Crack Initiation 77
(0.75rl - 1)An }
J:Jo 1- (W_ao) ' (4)
where errors in the J-values should be negligible only for crack growth less than 0.1(W-ao),
the corrected J-integral values become sufficiently lower, from 14.9% to 43.7% lower than if
calculated from Eq.(1). All the crack growth values are within the range Aa=2.28+4.13 mm,
and relative differences between J and Jo, below 40%, are in 12 of the total 19 specimens. In
these cases the initial impact energies were below 60 J, and it is only for these cases that the
fractured surface did not extend over the entire net surface area. However, in the performed
dynamic tests, all fractured surfaces were generally ductile, where the ratio of elastic/plastic
energy was very small (Jel < 0.03"Jpl).
The dynamic fracture toughness of the material is affected by strain rate, and for
ductile materials, the fracture mechanism is controlled by the strain field. This may increase
or decrease, depending on the loading rate [4,5]. The presence of the corresponding ductile
fracture model here is particularly sensitive to the absolute size and spacing of the various
populations of microstructural panicles. For this type of ductile steel, it is possible that the
volume-fraction of carbide panicles is much less than that of oxides, and a larger degree of
crack-tip deformation is required to increase crack-tip radii and enclose a sufficient number of
the oxide panicles, within the logarithmic spiral field of large plastic-strain and high mean-
normal stress, to form the fracture surface [7]. Preliminary SEM fractographic analyses show
that stretch zone widths have values that range from as low as 20 pm to as high as 130 pm.
CONCLUSIONS
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the support of the OTKA T 030057 project.
78 Z. RADAKOVI(I', ET AL.
REFERENCES