AN EVALUATION OF THE CRACK GROWTH AND

FRACTURE PROPERTIES OF AISI 403 MODIFIED

12 CR STAINLESS STEEL

W. A. LOGSDON
Westinghouse Research Laboratories. Pittsburgh, Pennsylvania 15235, U.S.A.

Abstract-The plane strain fracture toughness, &, and fatigue crack growth rate material properties were developed for
three heats of AISI 403 modified 12 Cr stainless steel. Valid (per ASTM requirements) fracture toughness tests were
conducted in the temperaa range -2oooF to 17YF. In addition, both the room temperature air environment plus52tPF,
12OOpsi distilled water envhonment fatigue crack growth rate material properties are presented. Finally, a hypothetical
example problem is included which demonstrates the application of fracture mechanics technology to an AISi 403 modified
12 Cr stainkss steel turbine rotor.

THE~A~-EL~C fracture mechanics approach to design against faifureof structuralmaterials is

basically a stress intensity consi~ration in which criteria are established for fracture insanity
in the presence of a crack [l-4], The essence of the ~proa~h is to relate the stress field developed
in the crack vicinity to the applied nominal stress on the statue, the material properties, and to
the geometryand size of defect necessary to initiate faihrre.
Therefore, successful use of fracture mechanics techndogy as a tool for design against faikue
requires basic notation in three areas of concern: materialproperties, stress analysis and
defect character&&on. In addition, an appropriate expression @enera@referred to as the stress
intensity expression or K-cakibration)which de&is the relationship between these factors for
the structural ccmtlgtuationof interestmust be avaiIabk[S].Providing our fracture mechanics
material properties in&de data for both the rapid propagation (fracture toughness) and s4ow
growth (crack growth rate) phases of fracture, we can evaluate the fracture potential of
components in various situations. Specifically,it is possible to:
select materials to provide the desired reliability against fracture;
develop a quantitative evaluation of the brittle fracture potential of components in specific
situations;
predict the useful life expectancy of components under sustained and/or cyclic loading
conditions;
establish realistic acceptance and nondes~ctive inspection specificationsthat will assure
the desired degree of immunity from brittle failure for the required lie of the structure.
The purpose of this investi~tion was to develop the required material properties necessary to
apply fracture mechanics technology to AISI 403 rn~i~ed 12Cr stainIess steel turbine rotors, As
a resuft, fracture toughness and crack growth rate material properties were developed for three
heats of ;4ISI 403 modified 12 Cr stainkss steel. Valid (per ASTM ~u~ments[6)) fracture
toughness tests were conducted in the temperature range -200F to 1WF. In addition to room
temperature air environment crack growth rate properties, the crack growth rate properties of a
single heat of AXSI403 modified 12Cr stainless steel were developed in a SWF, 1200psi distilled
water envrionment. Although the actual turbine rotor service environment is saturated steam
at a temperature between 500Fand 55OF,the test system availablefor generating fatigue crack
23
24 W. A. LOGSDON

growth rate data in a high temperature and pressure environment required water as opposed to
steam to operate; thus, the reason for conducting the fatigue crack growth rate tests in a 52WF,
1200psi distilled water environment. Also, recent test results on a type 403 stainless steel showed
a 212F steam environment only slightly more severe in terms of crack growth rate than a 2OtYF
distilled water environment[fl. Therefore, we feel confident in utilizing the high pressure and
temperature distilled water environment to estimate the effects of the actual dry, saturated steam
service environment.
Finally, an example problem which illustrates the application of linear elastic fracture
mechanics technology to an AISI 403 modified 12 Cr stainless steel turbine rotor is presented.
Two aspects of rotor operation were investigated: (a) determination of the critical flaw size for
failure during a single cycle at 20 per cent overspeed, and (b) determination of the cyclic life at
normal operating conditions.

MATEIuAL
The fracture toughness and fatigue crack growth rate material properties of three heats of
AISI 403 modified 12 Cr stainless steel were examined in this investigation. This material is
primarily utilized in rotor forgings subjected to high rotative stresses such as turbine rotors and
rotor parts. All the material was supplied by National Forge Company. The three heats of 12 Cr
stainless steel investigated will be referred to as heats 637, 933 and 484.
The chemical compositions and heat treatments of the three heats of stainless steel are
presented in Table 1. Essentially, heats 637 and 933 are from an older vintage composition while
heat 484 is an updated compsition distinguished primarily by its high Nickel content.
The room temperature tensile properties of all three heats of 12 Cr stainless steel are
presented in Tabk 2. Note the heat to heat tensile properties are relatively consistent.
The various fracture appearance transition temperatures applicable to these three heats of 12
Cr stainless steel are summarized in Table 3. The fracture appearance transition tunperature
(FATI) as employed here is defined as the temperature at which the fracture is 50% brittIe
(granular) and 50% ductile (fibrous), or the temperature at which the metal fmcture changes
from brittle to ductile fracture. Also presented are the room temperature and upper shelf energy

Tabk I. Chemicalcompositionsand heat treatmentsof AISI 403 modifkd 12Cr S~&~CSS

steel

Chemicalcompositions(wt%)
C Mn P S Si Ni Cr MO Cu

Heat 637 0.13 046 0.013 0.009 0.20 0.32 12.18 0.43 0.12
Heat 933 0.15 0.54 0.010 0.008 0.32 0.38 12.37 0.08 0.10
Heat 484 0.13 0.57 0.009 0*006 0.33 I.60 12.32 o-55 -

Heat trcotments
Heat 637. Hold over WF furnace.Chargedand held at SOOF for 2 hr. Raked 125OF per hr
to l75OT. Held at 1750Ffor 20 hr. oil quenched to 25ooF.Held 3 hr at room temperature.
Recharged into a 400F operating furnace. Held at 4OlYFfor 2 hr. Raised 125F per hr to
I WF. Held at I l4OF for 32 hr. Removed from furnace and air cooled.
Heat 933. Hold over H)IpF furnace.Chargedand held at SOOF for 2 hr. Raised 125F per hr
to 1750F.Held at l7WF for I6 hr. Oil quenched to 200/3OOF (agitated). Recharged in 4500F
weheated furnace. Held at 450F for 2 hr. Raised 1259: per hr to I MT. Held at I MPF for
i7hr. Air cooled.
Heat 484. Hold over 5OtTFfurnace. Charged and held at 5OOFfor 3 hr. Raised l25T wr hr
to l7WF. Held at l7HpF for I6 hr. Oil quenihed to 2tM/3ooOF. Recharged in u)(pF preheated
furnace. Held at 500F for 2 hr. Raised l2YF per hr to I MOT. Held at 1looOFfor 27hr.
Furnace coded to IoooOF.then air cooled.
 Crack growthand fracture properties of AISI 403modiied 12Cr stainless steel 25

Table 2. Tensile properties

of AISI 403 modii 12Cr stainless steel

0.2% Yield Ultimate Reduction

strength strength in area Elongation
(ksi) (ksi) (%6) (%I

Heat 637 93.4 112.1 56.5 IS.5

Heat 933 89.1 109*0 53-l 20.1
Heat 484 98.9 119.1 48.5 16.8

Tabk 3. Charpy V-notch impact properties of AN403 modified 12Cr stainless steel

Fracture
appearance Room Temperature of
transition temperature upper shelf Upper shelf
temperature energy level energy level energy level
(W (ft-lbs) (OF) (ft-lbs)

Heat 637 90 36 235 70

Heat 933 154 21 335 88
Heat 484 68 42 325 73

absorption values pertinent to these three heats of 12 Cr stainless steel and the temperatures
where the upper shelf energy values occur.

TEST mocEDuREs
Fracture toughness tests
Two tbrough eigbt inch thick compact tension (CT) type specimens were used to generate tbe
plane strain fracture toughness, KI,, data for our AISI 403 modified 12 Cr stainless steel in
accordance with the ASTM standard test method E3!B-72161.Figure 1provides tbe geom&y and
relative proportions of the compact tension specimens. Test specimen orientation within the
various rotor forgings placed the specimen notch directions as near radial as possible.
Prior to conducting tests for fracture toughness, the compact tension specimen starter
notches were extended to fatigue crack severity. In order to avoid introducing any hias Cotbe K,=
test results, tbe amount of crack-tip plasticity created during fatigue precracking was limited to
amounts less than those anticipated in the subsequent fracture toughness tests. Consequently, the
resulting K,= values represent lower limits ,of fracture toughness. For all compact tension
specimens involved in this program, a fatigue stress intensity (&) of 25ksi inlR accomplished
precrack initiation while fatigue stress intensities of 20 ksi inIn and 15ksi inIRgenerated the initial
and final crack extensions, respectively.
After precracking, the compact tension specimens were fracture toughness tested. Fracture
toughness tests (also referred to as rising load tests) involve tension loadii the compact tension
specimens until failure. Two X-Y recorders registered autographicallythe load vs displacement
occurring across the notch at the specimen edge and the load vs time to failure for each specimen.
All precracking and test procedures adhered to the previously cited ASTM requirements[6].

Crock growth rate tests

Fatigue crack growth rate tests were conducted on the two inch thick wedge open loadii
(WOL) specimens illustrated in Fig. 1. Test specimen orientation within the various rotor
forgings placed the specimen notch directions as near radial as possibk. All WOL specimens
26 W.A.LOGSDON

Side 9fooycs -O*OS 3 drap, 45. included angle,

0.01 in root radior
7 Type WOL specimen

I-----+ /
Compact if,, specimen

Plg.l.Compctbacnw~sspecimeas.Relotive~~s:Ttype WOL:W=2~55B;a=i.OBI,
H-1*24e,, D-0*7OB',W,-3.2OB', T=042SB'.C#nppctK,; W12-08, a=bOB, If-1.2B,
DPO.~~.W,~~.SB,H,~O.~~B.

were precracked (O-150in,) in air at a maximum alternating load of 10,000lb (AK * I5 ksi in)
prior to generating crack growth rate data.
Fatigue crack growth rate testing was conducted on a constant load universal hydraulic
fatigue machine under sinusoidaltension Ioadii (0 to maximrrmload). The maximuma&ernating
load (AP) was maintained constant trout each individti test. Test frequency equaled
10Hz. Wedge open loading specimens were tested at eternal loads of Il,ooOIb
{1~12,~ lb) and 14,0@lb (1~~5,~ lb), where the co~es~n~ stress ratios, R, (where
= K&K,&) equaled O-083and O-067,respectively.
R = OnzinjUjnn,
The extent of fatigue crack growth encountered during room temperature air environment
cyclic loadingwas measured and recorded with an ultrasonic nondestructive testing crack growth
monitor developed specificallyfor use with the WOL specimen[g].The test procedure exhibits a
crack length measurement sensitivity of -CO-010 in. and provides a continuous record of crack
length (a) vs number of elapsed cycles (IV).This raw test data was subsequently translated into
the crack growth rate (da/dN) vs stress intensity factor range (AK) data required to conduct a
fracture mechanics failure prevention analysis.
V. J. McLaughlin designed the high pressure chamber employed for the 52&T, IZOOpsi
distilled water env~onment tests [S].This test chamber is pictured in Fig. 2 along with a 2TWOL
specimen loaded in position. Circulating water can be supplied to the pressure vessel at any
desired pressure. The crack length monitor is a linear variable differential transformer (LVDT)
 Crack growth and fracture properties of AISI 403 modified 12Cr stainless steel 21

Rod
Air cooled seal ,

_.--Pressure vessel head

_,~Flexitalic goskct

Ftg. attached to tube

fig. attached to rod----

COOlinQwater jacket--y PIWM and Teflon seals

a
~

Fii. 2. Test sotup.

which is locat6d outside the chamt)er and which measur6s the sprxiolen crack opening
diwnt (COD), hence, crack length. The LVDT is connected to a high sensitivity
diffarmtlsi tmnsformer input moduk. This moduk has a sp6cialoutput amplifierwhich is used to
drive a galvanomet6r. The galvanometsr deflection is calibrated to the LVDT deflection on a
precision drum micrometer before testing is started.
In ord6r to dy~~y calibrate the LVDT against crack kngth, test ~~u6n~y was varied
from 10to 1 Hz for 20-30 min. intervals three times per each test. LVDT readings were taken just
before and during each frequency change. By this method bench marks, and hence crack lengths,
were found for various LVDT displacements. This permitted construction of a LVDT
displacement vs crack length plot for each particular specimen. From this plot, the crack length
(a) vs elapsed cycles (N) curve relative to each particular~specimenwas d6V6lOped. This raw test
data was subsequ6~y translated into the fatigue crack growth rate (dowdy) vs stress intensity
factor rang6 (AK) data necessary to conduct a fracture mechanics failure prevention analysis.

TEST RESULTS AND DISCUSSION

Fracture toughness tests
The l~d~efl~tion records obtained from compact tension specimen fracture toughness ttsts
were interpreted according to the ASTM standard requirements for obtaining valid plane-strain
fracture toughness datat61. This procedure for evaluaGon of load-deflection records permits
direct determination of the conditional stress intensity factors, Ke The reh&6n&ip between
stress intensity factor, applied load and crack length which determined the conditional stress
28 W. A. LOGSDON

intensity factors for the compact tension specimens involved in this investigationis given by the
expression:

where PQ is the applied load determined from the load-deflection curve, W is the specimen
width, B is the specimen thickness, LI is the crack length measured from the centerline of
loading and Y is a compliance constant dependent upon crack length[4]. IL is the plane-strain
critical stress intensity factor repre~n~tive of the inherent material tou~ss. X, becomes a
vahd measure of KI, when
2

where tq8 is the materialsyield strength at the particularfracture toughness test temperature.
The plane strain fracture toughness, L, test resuts for AISI 403 modtied 12 Cr stainless
steel are presented graphicallyin Figs. 3 through 5. Fire 6 provides a summary and comparison
of all the fracture toughness data generated for our three heats of AISI 403 modified 12 Cr
stainless steel. Note the fracture toughness of heat 484 (high Nickel composition) exceeds the
fracture .tou~~ss of heats 637 and 933bust the entire test ~~~~ range. Also; the
maximum temperature at which valid fracture toughness data could be generated utilizing 4-b.
thick compact tension specimens for 12Cr stainless steel, heats 484and 933,was 50Fand MPF,
respectively.

Crack growth raterests

The room ~rn~~~, air env~nment fatigue crack growth rate properties of our three
heats of AISI 403 modiied 12Cr s&Mess steel are presented in Fiis. 7 through 9 in terms of the
change in stress intensity factor (AK) vs crack growth rate (da/dN). In addition, Fii. 10preseuts
the fatigue crack growth rate properties of 12 Cr stainless St&, heat 933, in a TZPF, 12OOpsi
distilled water environment also in terms of the change in stress intmsity factor vs crack growth
Y , 120
-s I20
I I
I
I I I k 1

zi
; loo
hi-

~ i;;:fj

.c
$ zo- -20

I I 1 I I I 1 1 I #
i
n o-2OO -175 --I20 -I25 -100 -75 -50 -25 0 O

Tempercrbe. OF

Yt 3. Tompwaturedepeadeaee of yield strengthand plane strain fractureto@ans, I&, of AISI 403

modiW 12Cr%ainksssteel, heat637.
 Crackgrowthand fracturepropertiesof AISI403modified12Cr stainlesssteel 29

2x30
r.Im
:
C 180 - - 160
I
iii
xi SO- - 160

i-3
y- MO- - I40 z

.
0 Ix,- -I20 *
i% I
c P
s loo- -loo Y
:! 5

zz 80 -80 ;

g 5:
60- --6o
rL

5 -40
c do-

i 20: -20

o-2oo
i 1 -150I -IQ0I -93 I 0I I
50 I
1ocl Ix)I I
200 I
250 m 0

Temperdun. lF
Fig. 4.Temper&w dependence of yidld strength and plane sbain fracture tott$mess, K,c, of AISI 403
modified12Cr stainiesssteel,heat933.Key;0 = 2TCT:D = 4TcT: V = 6TCX.

.f lea- -I60
.E

2 HO-
Y

Temperature, *F
Fig. 5. Tcmperatur~&pa&ace of yield strength and plane strain frachw tou@tness,lu,, of AISI 403
modified12 Cr stainless steel, heat 484. Key; 0 = 2TCR 0 = 3TCTz!J = 4TCE V = 6TCT.

rate. These crack growth rates were established by means of a computerized curve-fitting
analysis of the crack length vs number of elapsed cycles data obtained directly from the fatigue
crack growth rate experiments [ lo], The AK value associated with a specific crack growth rate
was determined from the following expression:
I2
AK=&_-K,_Y!++ -
yPha'R
BW
 W. A. LOGSDON

I60 ( I I
I I I I I I I

NO- Upper band --J 2aT9b3a3nd-

heat 484 ;

0 I I I I I I I I J
-200 -Ix) -100 -50 0 SO 100 IS0 200 250
Temperature. l F

Fb. 6. Mnmav and comparison of the pbe strain fracture toughness, K,, of AISI 403 mod&d 12Cr
stainless SteeI.

Specimen ALoad
idew 0

631-CCG2 lOJoo
637-CCG-s Ii,Ow
637-CCc3-6 Il,fmo
;: 63%CCG-7 14,000
0 637-CCG-a 14,OtNl
A 637.CCG-9 14,000

Yield stress (75F)- 93,4 ksi

2TwoL specimens
IO Frequency = 10Hz
8 Room temperature
Air environment.
:
4

Stress mtcns~ty factor rongc, AK, krl- in*

Fig. 7. Fatigue crack &rate properties of AISI 403modified 12Cr stainless steel. heat 637.
 31

Specimen A had
Slqpc, n=2.4 - loo
identity (fb)
-80
i?!
933_cCG-1 Iu@o
z Q 93~CCG-2
: tr,Ooo
-40 2 933_CCG-3 t1,000
- 30 x ; 93~&~ 14,OMJ
0 933-CCG-5 14,000
20 & A 9335CG-6 14,000

YieM stnss (?YF) = 89-I ksi

- IO 2TWOL specimens
-6 Frequency = 10Hz
Room tempature
-E Air enviroament
-4

-3

Stress inArMy factor mnpc, AK, kri - in

where P,, and I-@,,are the maximum and minimum values of the alternatingload, respectively.
The nearly linear relationship between log (da /dN) and log AK shown in Figs. 7 through 10is
typical of most fatigue crack growth rate data. Since this linear relationship exists; the crack
growth rate data can be expressed in terms of the generalized fatigue crack growth rate law
developed by Parisfll]. This crack growth rate law is expressed as:

where (do/dN) is the rate of c~ck_~o~h, C, is an intercept constant determined from the log
[dafdN) vs log AK plot, n is the slope of the log-log plot and AK is the stress intensity factor
range. Since the upper scatterband data rePresent a conservative estimate of the materialscrack
growth rate properties, the generalized crack growth rate expression describing this fine is
normally reported as the materials crack growth rate properties.
Figure 11 summarizes the fatigue crack growth rate data generated for AISI 403 modified 12
Cr stainless steel. Note the slope (II) in all four crack growth rate expressions is within the range
23-2-4. Observing the three room temperature air e~~~onrne~tcrack growth rate expressions,
the crack growth rate expression for heat 933is the least conservative and will yield the greatest
rate of crack growth. Therefore, the crack growth rate expression

$ = 2.95x IQ4AK2
32 W. A. LOGSDON

+ 600
-500
400
xx)

200

sfxcimeP LiLaad
identity Obl
484aG-1 14,oorJ
: 484-CCG-2 14,ooo
4a4-ccG-4 ll.iWJ
:: 4WCCG-5 I4,oao
A 484-CCG-6 11&m

Yield strma(7ST)= 98.9 ksi

2mOL spscimens
- IO
Frequency * 10Hz
-6
Rodm tempmavE
-6 Air t!twiromt
-5
-4
-3

-2

lo-a,( 20 3040%6080too 200300

I

Stress intensityfactor ranpc, AK, kri- invz

F&9. Fa~cnek~ratepmpatiesofAfS1403mociifkd12Crs~ss~,hen1~.

should be employed when making fatigue life predictions or calculating initial allowable liaw
sizes applicable to AISI 403 mod&d 12 Cr stainless steel structures subjected to a room
temperature air environment. Also, note the crack growth rate expression for heat 484yields the
slowest rate of crack growth. Therefore, the fracture toughness and fatigue crack growth rate
material properties of heat 484 (high Nickel chemical com~si~n) are signScantly superior to
those of heats 637 and 933 (original chemical composition).
Again noting Fig. 11, we can observe the moderately detrimental effect of the 520F,1200psi
distilled water environment on the crack growth rate properties of 12Cr stainless steel, heat 933.
It should be pointed out, however, that the 52tYF, 12OOpsidistilled water environment crack
growth rate tests were conducted at a frequency of 10 Hz and a lower cyclic frequency may result
in an increased detrimental effect on the crack growth rate properties of 12 Cr stainless steel.
Since the corresponding crack growth rate expression

yields a greater rate of crack growth than any of the room temperature air env~o~ent crack
growth rate expressions, this expression should be employed when making fatigue life
predictions or calculating initial allowable flaw sires applicable to AISI 403 modified 12 Cr
stainless steel structures subjected to a high temperature and pressure water or steam
environment.
 Crnckgrowthandfracturcpropcrtiesof
AISI403modiiicci
l2Crstainlessstccl 33

200

- loo
Spccimcn ALoad
-60 2
identity (lb)
-60 ::
-60
-40 2 933axb7 14,OMl
5 i!i 933-CCG-9 14.000
-30
0 933ax-10 14,oMJ
-20 06
Yieid stress(75.F)= 89.1ksi
2TwOL spednens
- IO Freqwncy= 10Hz
-6 Tempcratwc= S2OT
Pressure= 12OOpsi
-6
-5 Distilledwaterenvironment
-4
-3

-2

Stress intenriiy fot3or rongc, AK, hi-in

EXAMPLEPROBLEM
An example problem which illustrates the application of linear elastic fracture mechanics
technology to an AISI 403 mod&d 12Cr stainless steel turbine rotor is presented in this section.
Two aspects of rotor operation will be investigated: (1) determination of the critical flaw size for
failme in a single loading cycle at 20 per cent overspeed, and (2)determination of the cyclic life at
normal operating conditions.
Recall, successful use of fracture mechanics technology as a tool for design against-faibue
requires basic information in th& areas of concern: material properties, defect chatacterization
and stress analysis. Regard@ material properties, tbe pertinent material pmperties (fmcture
toughness and fatigue crack growth rate data) required for our calculations were presented
previously in this paper. To keep our faihrre analysis as conservative as possihk, tbe fracture
toughness and fatigue crack growth rate material properties measured for 12 Cr stainless steel,
heat 933, will be utilixed in this analysis.
An adequate fracture mechanics failure prevention analysis requires information concerning
the size, shape, location and orientation of tbe most critical defects which exist or are likely to be
developed in tbe structure of concern. Tbis example assumes that the most critical defect for the
application is a long-shallowsurface crack intersecting the axial bore of the 12 Cr stainless steel
rotor with the major plane of tbe crack normal to the tangential bore stresses. For this example,
surface flaws with length to deptb ratios of 4 : I and 10: 1 were considered. These surface defect
 W. A. LOGSDON

---I!
adN -

-200
300

- loo
-80 $

-60 5 Heat Enviranment

-50 &
-40 r -.- 637 Room temp.Air
933 Room temp. Air
30 :ti ____ 933 QOT, 12OOpsi
- 20 Di8tiuedwater
-484 Room temp. Air

- IO Frequency= 10Hz
-6 2TWOLspecimens

-:
-4

-3

-2

II 20 30405000080100 2003m
Stress inhmrty factor ranqe, AK, kri -in*

Fiill. SummarydthcfatiguecrPck~~ratedatD~fotAISI403~12Crstriaksaatal.

geometries span the range of typical surface defects which might be encountered in a turbine
rotor.
Problem L-Determine the critical size of a crack intersecting the bore wall? which would
cause faihtre in one loading cycie of an AISI 403 modified 12 Cr stair&as steel turbine rotor
during a 20 per cent overspeed test.
Turbine rotors are normally overspeed tested at temperature in their operating environment,
i.e., temperatures ranging from SOOTto SWFand a saturated steam environment. Although the
outside of the turbine rotor is subjected to this environment, the bore temperature is closer to
150F.
The tangential stresses normal to the bore defect at 20 per cent overspeed never exceed 80 per
cent of the materialsminimum specifiedO-2per cent yield strength[ 121.Therefore, based on the
0.2 per cent yield strength of 12 Cr stainless steel, heat 933, at 1WF (85.5ksi), the maximum
applied nominal tension stress equals 68.4ksi. The fracture toughness of 12Cr stainless steel at
1WF equals 105ksi inIn (from Fig. 6,.heat 933, lower scatterband).
The pertinent stress intensity expression for this conliguration(a surface crack oriented with
the major plane of the crack perpendicular to a uniform tension stress field) is

l*21a~u2
K, =
Q
IThis defect location is selected because it representsthe regionof highest stress in the rotor.The methodof solution
would be equally applicableto other types of defects located in other regions of the rotor.
 35

where
i(i =nominal stress intensity factor, ksi inn
a = surface crack depth, in.
o= applied nomin~ stress, ksi
Q= flaw &ape parameter (from Fig. 12)

The flaw shape parameter (Q) permits us to evaluate the severity of defects with d&rent shapes
by ~c~nti~ for surface or internal defects with various length to depth ratios. The flaw shape
parameter Q is obtained from Fig. 12, which also illustrates prototype surface and internal
defects and the necessary dimensions required for ob~i~ng length to depth ratios. As mentions
previously, we will consider surface defects with two length to depth (2cta) ratios; 4 to f and IO
to I. The corresponding flaw shape parameters for (alayS) = 0.8 are I a33and O+%,respectively.

We now have all the i~o~at~n required to calculate the critical flaw sixes necessary to
cause failure of the AISI 403mod&d 12Cr stainless steel turbine rotor in one cycle of loading. If
we rearrauge the terms in the previous equation and set RXequal to & and 0 equal to the
critical flaw size, &,, we obtain the following critical flaw size expression

~u~ti~ti~ the appropriate vales of D ffS4 ksi), & ftO5ksi in*>and Q (I.33 or 0-W)into
the above expression yields the critical flaw sizes presented in the following table.

T&It 4.

critical saw size

Surface flawkngth
to depth ratio Q ~~m. f .

4 to I 1.33 042 3.32

10 to 1 o-96 0-M) 6-o
36 W. A. LOCBDON

These are the flaw sizes required to cause failure as the result of a single cycle of loading during a
20 per cent overspeed test. These flaw sizes are well within present inspection capabilities.
Problem 2-Determine the cyclic life characteristics of the same 12Cr stainless steel turbine
rotor under normal operating conditions for a range of initial defect sizes at three applied stress
levels.
The pertinent nominal stress information required for a fracture mechanics analysis of a
structure subjected to cyclic loading includes knowledge of the maximum nominal applied
stresses developed in the structure as well as the alternatingstresses. For this problem, the applied
nominal stresses and alternating (cyclic)stresses were assigned parametric values equivalent to a
specificpercentage of the materialsyield strength. ,The applied nominal and alternating stress to
yield stress ratios (ala,) considered in this analysis equaled 0~30,040 and 0.50.In addition, the
same two surface defect geometries were investigated as in the previous problem.
Assume that the normal operating conditions involve a minimum service temperature of 75F.
The first step in the cyclic life calculationsis to determine the criticalflaw size necessary to cause
failure as a result of a single load application.The same procedure is followed as that described
above for the overspeed situation. The O-2per cent yield strength and plane strain fracture
toughness, &, of AISI 403 modified 12Cr stainless steel at 75Fequals 89.1 ksi and 69 ksi in,
respectively (KIc from Fig. 6, heat 933, lower scatterband). Utilizing equation (2) leads to the
followingcriticalflawsizes for our three applied stress levels and two surface defect geometries.

Table 5.

Critical flaw
Applied stress size (in.)
Surface flaw kngth
to depth ratio Q uluw level
(ksi) Depth Length

4 to 1 1.43 0.30 26.7 2.510 10.04

4 to I 1.42 040 35.6 I 405 5.62
4 IO I 140 0.50 44.6 0.880 3.52
loto 1 I.07 o-30 26.7 I.880 18.80
loto 1 I.06 040 35.6 I a045 IO-45
lot0 I I.04 040 44.6 0.655 6.55

Once the critical flaw sizes are known, the cyclic life considerations involve computing the
number of loading cycles required for an existing !law of some subcritical size to grow to the
critical size. Since this 12Cr stainless steel turbine rotor is subjected to a high temperature and
pressure saturated steam environment, the fatigue crack growth rate properties to be used in this
example problem are those developed for 12 Cr stainless steel, heat 933, in a 520F, 12OOpsi
distilled water environment (Fig. 10). These crack growth rate properties are represented
analytically by the generalized crack growth rate law expressed as

$ =34j9 x lO+AK*

where (da/dN) is the rate of crack growth, AK is the stress intensity factor range, 3.69x 10m9
represents the empirical intercept constant (CT,)and 2.4 denotes the slope (n ) of the log (da /dN)
vs log AK curve.
By combining these crack growth rate properties with our critical defect sizes, it is now
possible to compute the number of elapsed cycles required for an existing subcriticalflawto grow
 Crackgrrmth andfrafture PropertiEs
of AlsI $03 modified 12Cr stainiersSW 37

to failure. Wilsonhas developed a generalizedcyclic Me expression which readily determines the

number of cycles required for an existing defect to grow to the critical flaw size[13]. This
expression is presented below:

2 1 1
for nP2
N=(n-2)CFfido t --aI:2)R 1
1
for n=P2
N=C&fAaik t

N = number of cycles to failure

n = slope of the log (da/dN) vs AK curve
C, = intercept constant from log (dda/dN) vs log AK curve
ffi= initial flaw size
Qer- critical Qaw size
Au = alternating stress range
M = flaw shape and geometry parameter [for surface defects, M = (f*Zln/Q)l

The above expression is applicable to those loading situations where the rektionship between
applied load, gaw size and stress intensity factor has the form of & = o(&i~)~.In addition, it is
assumed that the cyclic stress range (AC) remains constant at the component life and
that the mean stress does not infhtence the results.
Soking this expression for N at the various cyclic stress ranges of interestandfor a values
ranging from the minimum detectable flaw size to the appropriate critical flaw size develops
cychc life curves which relate the maximum initial alkwabk flaw size to the number of cycIes
required to cause faihue at Merent stress kvek.
The resuhmg cyclic life curves for this problem are presented in Figs. 13aud 14,These cyclic
lie curves represent the most convenknt form of presentiug fatigue life information for a

24

2.2

2.0

I.8

1.6

I.4

I.2

t.0

0.6

0.6

0.4

0.2

0
i0
38 w. A. LOGSDON

I I I
2.6 -

i 2.4-

.- 22-

I 2-o-

Cycles to failure

Pig. 14. cyclic life curves for AM 403 mod@& 12 Cr stainkss steel turbine mtols. U~(75T.J- 89.1 hi;
(&/dN)=369x 10-AKz;wiptic*lsurtacedef~ IO-Wlk+~ratio.

specifk appkzation because the total life can readily be determined from a knowkdge of the
defect size known or assumed to be present at the start of life. From these results it is possible to
establish quantitative material acceptance and inspection requirements as well as realktic safety
factors for various practical situations where a given life and safety factor are desired.
As an exampk, if we assume a desired life of 14,600cycles (1 cycle per day for 40 yr), we
obtain the following initial ahowabk flaw sixes.

Tabk 6.

Initial aliowabk
llaw size (in.)
Surface tlaw kagth Applied stress
to depth ratio uiu,. level(hi)

4 to I O-30 267 1.50 6.00

4to I 0.40 35.6 0.58 2.32
4 to 1 0.50 44.6 0.22 0.88
loto 1 0.30 26.7
loto 1 0.40 35.6 ::; 9.40
3.30
IOIO 1 0.50 44.6 O*ll 1.10

These are the initial allowable flaw sizes which will grow to the critical sizes of concern in
14,600cycles when the 12 Cr stainless steel turbine rotors are subjected to either of the three
corresponding applied stress levels. Obviously, the inspection techniques employed must
accordingly be capable of locating and defining some smaller defect, the exact size of which
depends on the safety factors desired. Therefore, it is up to the designer to input whatever safety
factors (margins of error) he desires for a specific appli~ion.

CONCLUSIONS
(1) The plane strain fracture toughness, &, and fatigue crack growth rate materialproperties
were developed for three heats of AISI 403 modified 12Cr stainless steel. Essentially, two heats
 Crackgrowthand fracturepropertiesof AISI403modilied12Cr stainlesssteel 39

were manufactured to an older vintage chemical composition while the third heat was
manufactured to an updated chemical composition distinguished primarily by its high Nickel
content.
(2) Both the plane strain fracture toughness, KIc, and fatigue crack growth rate material
properties relative to the high Nickel composition 12Cr stainless steel were significantlysuperior
to those relative to the vintage composition 12 Cr stainless steel.
(3) Valid (per ASTM requirements) fracture toughness data were generated to 175F.
(4) The fatigue crack growth rate properties of AISI 403 modified 12 Cr stainless steel
conform to the generalized fracture mechanics crack growth law where:

(5) The room temperature air environment fatigue crack growth rate properties of AISI 403
modifled 12 Cr stainless steel can be summarized by the crack growth rate expression:

$ = 2.95X 10~AKzJ(in/cycle,ksi in)

(6) The fatigue crack growth rate properties of AISI 403 modified 12 Cr stainless steel in a
52OT, 12OOpsidistilled water environment can be summarized by the crack growth rate
expression:

$ = 3.69X 104AK2(in/cycle,ksi in)

(7) The 52OT, 1200psi distilled water environment produced only a moderately adverse
effect on the fatigue crack growth rate properties of AH1 403 mod&d 12 Cr stainless steel.

Acknowle&ma~ts-The author expresseshis apprceiationto Messrs.W. J. Erichsen and J. F. Van Epps, Westinghouse
Maine Divkion, for their interest end support of tbis work and to the National Forge Company for supplyhu the
mute& The author is alao h&&ted to his many associatesat the WestinghouseResearchLaboratorieswho contributedto
variousphasesof this hwesti&on. Particularrecqnitkm is due to Messrs.V.J. McLou#in,R. B. Stouffer,J. A. Bindas,and
J. R. Mdky of the MaterialsTest* and EvahmtionDepwtmentand Messrs.W. Ii. Pryk, R. R. HOVM,F. X. Gradichand A.
R. Pebush of the MechanicsDepartment.

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[3] C. F. TftIenyend J. N. Masters,AppliedFracture Mechanics.Fracrun Tau&~us Testingund Its Applications, AS7M
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[4] W. F. Brown,Jr. end J. E. Stawley,Plane Strain CrackToughnessTestiN of HighStrengthMetallicMaterials.ASTM
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40 W. A. LGGSDGN

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(Rm?kd 23fpffuory 1974)