c


Determination of Plane Strain Fracture Toughness of

a)Y 6uenched and tempered 4340 steel

b)Y Structural Aluminium, Al alloy





a)Y Determine fracture toughness, KIC of both materials

b)Y Determine whether the sample was in plane stress or plane strain
c)Y Determine plastic zone size

x





Ships, aircraft and rockets are extremely complex engineering systems with many
thousands of components. In the construction of such systems it is impossible to complete avoid
the presence of flaws such as cracks. Understanding the strength of materials in the presence of
cracks is thus key to developing reliable aerospace and ocean engineering hardware. This
experiment is designed to illustrate how strength in the presence of cracks - termed Fracture
Toughness - is characterized and measured. [3]

Stress intensity factor,K can be considered as a stress-based estimate of fracture

toughness. It is derived from a function which depends on the applied force at fracture. K
depends on geometry (the flaw depth, together with a geometric function, which is given in test
standards for each test specimens geometry). [4]

CTOD or (crack-tip opening displacement) can be considered as a strain-based estimate

of fracture toughness. However, it can be separated into elastic and plastic components. The
elastic part of CTOD is derived from the stress intensity factor, K. In some standards, the plastic
component of CTOD is obtained by assuming that the specimen rotates about a plastic hinge.
The plastic component is derived from the crack mouth opening displacement (measured using a
clip gauge). The position of the plastic hinge (defined by rp ) is given in test standards for each
specimen type. Alternative methods exist for estimating CTOD, which make no assumption
regarding the position of the plastic hinge. These require the determination of J from which
CTOD is derived. CTOD values determined from formulations assuming a plastic hinge may
differ from those determined from J. [4]


 
 


1.Y Testing Machine:

a)Y Instron machine 250 kN Dynamic
b)Y Instron tensile/compress 100kN
c)Y ESH machine 50kN
d)Y Instron machine ± upgrade to test resources (200kN-state and 100kN dynamic)

2.Y Crack Opening Displayment Gauge

3.Y Compact Tension (CT) specimen test machine
4.Y Single Notch Edge Bend (SNEB) specimen machine
5.Y Materials:
a)Y 6uenched and tempered 4340 steel
b)Y Structural Aluminium alloy








Figure 1: Specimen for Single Notch Edge Bend (SNEB) specimen and compact tension (CT)
specimen

For the first test, which is for quenched and tempered 4340 steel, we are used Compact Tension
Specimen test. The second test, which is for structural Aluminium alloy, we are used Single
Notch Edge Bend specimen test.

(A)YDetermining the sample dimensions

1.Y Measure the half height h and width (to hole centers), W of each samples using the
caliper provided.
2.Y Measure the thickness, t of each sample using the micrometer.
3.Y The length of the initial crack ai, measured from the hole centers will also be needed.
However, it is unlikely that this will be clearly visible until you can examine the fracture
surfaces after the sample is broken.
4.Y Make the pre-cracking on the specimen before start the test.
(B)YPreparing the sample for test

1.Y Before testing the specimen it is necessary to attach the clip of displayment gauge.
2.Y The jaws of the clip of displayment gauge.rest in notches cut into the side of the sample.

(C)Y Mounting the specimen in the testing machine

1.Y Load is applied to the specimen.

2.Y Mount one to the base of the testing machine and one to the crosshead using the dowel
pins provided. If necessary get the operator to move the crosshead up to give you enough
space.
3.Y Make sure that the flat side of both grips face to the left. Place the specimen in the slot in
the lower grip with the displayment gauge on the left and secure it with a dowel pin.
(Note that the dowel pin should be a snug fit, but you should be able to push it in by
hand. Don't be tempted to hammer the pin in or you may never get it out).
4.Y Lower the crosshead slowly until the holes in the sample and upper grip line up
accurately enough to push a dowel pin through them.
5.Y Estimate the primary uncertainty in the load by looking at the load with no force being
applied. Estimate the primary uncertainty in displacement by looking at the fluctuations
in indicated displacement as the sample sits there (the displacement will be zeroed before
the test, and so only the perturbations from that zero will be visible).
 (D)YRunning the test

1.Y Remove the pin holding the extensometer jaws.

2.Y Set the computer program ready to take data.
3.Y Set the Testing Machine controller to raise the crosshead at a speed of 0.05 inches per
minute. As the test begins watch the drawing of the load/displacement diagram.


ü


A)Y 6uenched and tempered 4340 steel

Load (Ib) C.O.D (in)

500 0.04
1000 0.07
1500 0.11
2000 0.14
2500 0.18
3000 0.21
3500 0.25
4000 0.30
4500 fail 0.35
Table 1: 6uenched and tempered 4340 steel

Yield strength of 4340 steel = 57 ksi

Specimen dimension: B = 1.00 inch, W = 2 inch

After completion of the test the crack length at the centre and quarter points measured were 1.10,
1.06, 1.07 inch respectively.

    

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 B)Y Structural Aluminium, Al alloy

Load (Ib) C.O.D (in)

8.5 0.013
9.5 0.0145
10.38 0.016
11.35 0.0175
12.00 0.019
13.0 0.0213
13.75 0.0233
14.08 0.0255
14.18 0.0275
14.2 0.0290
Table 2: Structural Aluminium alloy

The specimen exhibited linear elastic behavior up to load 8.5 kips (kilo pounds) and opening
displacement (COD) 0f 0.013 inch.

Yield strength of structural steel= 49.8 ksi

Specimen dimension: S = 8 inch, B = 1.00 inch, W = 2 inch

After completion of the test the crack length at the centre and quarter plane were measured:

ÐY a (centre plane) = 1.050 inch

ÐY a (quarter plane) = 1.030 inch
ÐY a (quarter plane) = 1.026 inch
ÐY a (surface) = 0.989 inch
ÐY a (surface) = 0.990 inch

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 Experiment 1: Determination of Plane Strain Fracture Toughness
Aluminium
4340 steel
Specimen Material Alloy
Yield Strength 57 ksi 49.8 ksi
Specimen Thickness, B 1 inch 1.001 inch
Specimen Width, W 2 inch 1.998 inch
Crack length measured after fracture 1.077 inch 1.017 inch
Determining load at fracture

Initial slope of elastic deformation, m 48 52.5

m5 = 95% m 45.5 50
Load P5 4175 Ib 13.7 Ib
Maximum Load, Pmax 4250 Ib 14.2 Ib
P6 4175 Ib 13.7 Ib
Determination the stress intensity factor at fracture

Non-dimensional crack length, Y = f(a/w) 10.98 2.73

Stress intensity factor at fracture K6 (see table 32415

26.45 Ib¥inch
from notes) Ib¥inch

Determining whether the sample was under plane strain or stress

2.5 (K6 / YS)

2 0.8085 7 ɯ 10-7

Is 2.5 (K6 / ıYS)2 less than B, a, W-a? Yes Yes

Pmax / P6 1.018 1.036

Is Pmax / P6 less than 1.1? Yes Yes
Plane
Plane Strain
Plane stress or plane strain? Strain
Determining plastic zone size and final results

For plane strain

Plastic zone size ro =
For plane stress - -
Plastic zone size ro = - -
Is LEFM valid?
? 


From the experiment, the result obtained show that materials, 4340 steel and Aluminium
alloy are under plain strain. This is because both satisfied the first and second condition for
determining the type of the plane for each material.

The fracture toughness of both materials can be obtained from the intensity factor for
each material. This is because materials, 4340 steel and Aluminium alloy react under plain strain.





Based on the both experiments, both materials are under plane strain. The intensity factor
for 4340 steel is 32415 Ib¥inch, while for Aluminium alloy is 26.45 Ib¥inch. Therefore, the
fracture toughness, KIC equal to K6. Mean that the fracture toughness for 4340 steel is 32415
Ib¥inch, while the fracture toughness for Aluminium alloy is 26.45 Ib¥inch.

Stress intensity and fracture toughness are critically important fracture mechanics
parameters used by materials engineers and designers. We saw that there are a lot of factors that
determine fracture of a material. KIc is an unique material property, that is used by engineers to
design and manufacture products for durability and safe operation.


ü  

1.Y Chapter 19 Fracture Testing, 19.1 Why Fracture Testing?

2.Y W J Devenport, è
 
 èèèBased on ESM
Laboratory Course Notes by Prof. N. Dowling, December 22nd, 2006.
3.Y http://www.sv.vt.edu/classes/MSE2094_NoteBook/97ClassProj/frames.html

4.Y TWI Knowledge Summary, Fracture toughness testing by Henryk Pisarski