STUDIES ON CRACK GROWTH RATE UNDER HIGH

TEMPERATURE CREEP, FATIGUE AND

CREEP-FATIGUE INTERACTION-I

ON THE EXPERIMENTAL STUDIES ON CRACK GROWTH RATE

AS AFFECTED BY ,,/&sg,~, AND TE~PE~TURE

T. YOKOBORI
Research Institute for Strength and Fracture of Materials, Tohoku University. Sendai, Japan

and

H. SAKATA
Department of Mechanical Engineering II, Tohoku University, Sendai, Japan

Abstract-Many experimental studies have been reported on the measurements ofcrack growth rate
and the observation of crack growth behaviour under high temperature creep, fatigue and creep-
fatigue interaction in literatures. However, many of them have been done in air atmosphere.
Furthe~ore, in many of them the measurements of the crack growth rate have been carried out by
interrupting inte~ittently the running of the testing machine. In such experiments the complex effects
due to the atmosphere, the interruption period and the corresponding unloading operation for the
crack length measurement might have been involved.
In the present paper in order to eliminate such effects, series of experimental studies on the crack
growth behaviour under creep, fatigue and creep-fatigue interaction conditions on 304 stainless steel
have been carried out by using high temperature microscope and observing the crack length
continuously during running the test without interruption in vacuum of low5 mm Hg.
Among the results, it was found that crack growth rates on a time basis, da/dt, under high
temperature creep and creep-fatigue interaction conditions can not be described in terms of solely
elastic stress intensity factor K, or only net section stress one,, both independent of gross section stress
09. The relation between crack growth rate and stress intensity factor under high temperature fatigue
condition changes with some trend according to gross section stress at lower K, level and it can be
approximately described in terms of stress intensity factor II, only, at higher K, level. The threshold
stress intensity factor and the threshold net section stress under high temperature creep, fatigue and
creep-fatigue interaction conditions appears to be almost independent of temperature.

NOTATION
a equivalent crack length = a, + a*
the length of initial notch
,*: actual crack length
da
crack growth rate on a cycle basis
dN
da
crack growth rate on a time basis
dt

bg gross section stress

*“,I net section stress
1. IN~ODUC~ON
MANY EXPERIMENTAL studieshave been reported on the measurements of crack growth rate
and the observation of crack growth behaviour under high temperature creep, fatigue and
creep-fatigue interaction in literatures [l-l 1 J. However, many of them have been done in air
atmosphere [l-IO]. Furthermore, in many of them the measurements of the crack growth
rate have been carried out by interrupting intermittently the running of the testing machine
[S-11]. In such experiments the complex effects due to the atmosphere, the interruption
period and the corresponding unloading operation for the crack length measurement might
have been involved.
In the present paper in order to eliminate such effects, series ofexperimental studies on the
crack growth behaviour under creep, fatigue and creepfatigue interaction conditions at high
temperature on 304 stainless steel have been carried out by using high tem~rature
microscope [ 121 and observing the crack length continuously during running the test
without interruption in vacuum of 10e5 mm Hg.
509
EFMVol. 13, No. I-F
510 T. YOKOBORI and H. SAKATA

Among the results, it was found that crack growth rates on a time basis, daldt, under high
temperature creep and creep-fatigue interaction conditions can not be described in terms of
solely elastic stress intensity factor K, or only net section stress cne,, both independent of
gross section stress og. The relation between crack growth rate and stress intensity factor
under high temperature fatigue condition changes with some trend according to gross
section stress at lower K, level and it can be approximately described in terms of stress
intensity factor K, only, at higher K, level. The threshold stress intensity factor and the
threshold net section stress under high temperature creep, fatigue and creep-fatigue
interaction conditions appears to be almost independent of temperature.

2. MATERIALS, EXPERIMENTAL APPARATUS AND PROCEDURE

High temperature creep-fatigue testing machine was designed for this study (Figs. la and
b). Tests were carried out in a vacuum of IO- 5 mm Hg. Crack lengths were measured
continuously during running the tests without stopping the tests by using the high
temperature microscope through a peeping window with 100 times magnification. Specimen
temperatures were continuously monitored with thermo-couple spot-welded in the vicinity
of the notch of the specimen surface. The load waves were controlled as shown in Figs.
2(a)-(c) for the fatigue, creep and creep-fatigue interaction tests respectively. Since the load
wave (a) is a sine wave, the stress gradient with respect to time equals to zero at the instant
when maximum tensile stress omaxis reached and, thus, the shock effect can be avoided. Thus,
by changing the holding time t,, the load wave (c) which is the combination of the fatigue load
wave (a) and the creep load wave (b) can be obtained. The frequency of the load wave (a) is
40 cpm. The minimum stress (T,,,~” was zero for all the tests and the gross section stresses erg
corresponding to the maximum value of tensile stress (T,,, were 18.1, 19.5 and 20.9 kg/mm’.
Tests were performed at the temperatures of 600,650 and 700°C and the temperatures were
held constant to within k 1°C.
The material used is 304 stainless steel. It was solution heat treated at 1050°C. The
chemical composition and the mechanical properties at room temperature are given in
Tables 1 and 2, respectively.
Double edge notched specimen was used as shown in Fig. 3.

3. EXPERIMENTAL RESULTS
Crack growth rates were determined from the plots of crack length vs. time using a slope
measuring device.

3.1 Relation between crack growth rate and stress intensity jhctor K,
In this section, tentatively experimental values of crack growth rate were plotted vs the
conventional stress intensity factor K, [2-4,131 which is obtained from

K, = cl&o,, (1)
where (TVis gross section stress, a is the equivalent crack length including the notch length,
and CIis the correction factor expressed as [14]:
c( = (1.98 + 0.36(a/W) - 2.12(a/W)’ + 3.42(a/W?), (2)
where W is half width of the specimen

Fig. l(b). Details of the testing machine. (1) Test specimen; (2) Heater; (3) Thermocouple; (4)
Loading direction; (5) Rotating window; (6) Peeping window; (7) Objective lens; (8) Cooling water.
 Studies on crack growth rate under high temperature creep 511

Fig. I (a) Appearance of the high temperature creep-fatigue testing machine with high temperature
microscope in vacuum. (1) Furnace body; (2) Microscope; (3) Equipment to apply the load; (4) Dial
gauge.
 Studies on crack growth rate under high temperature creep 513

lime

Fig. 2. Loading wave; (a) fatigue test, (b) creep test, and (c) creepfatigue interaction test.

t=1
notch
part
z
-rGI d

P = 0.05
i

Fig. 3. Specimen shape and dimension (in mm).

Table 1. Chemical com~sition (wt %)

C Si Mn P s Cr Ni

0.094 0.56 1.28 0.027 0.013 18.0 8.81

Table 2. Mechanical properties (room temperature)

Ultimate
tensile
Yield stress strength Elongation
&g/mm*) fWmm2) (%)

33.4 66.3 47
 20 25 30 35 40
KI ( kg fmm”2 )

t I I 1 1 I

O_

I_

2_

65OT , FATIGUE
0 fig= 20 9 kgimd
3_
l 6g.19 5 kg/mm*

A &=lS 1 kgtmm2

15 20 25 30 35 40

Kl ( kg fmm”2 1

Fig. 4, Relation between crack growth rate da/dt and stress intensity factor (effect of gross section
stress).
 Studies on crack growth rate under high temperature creep 515

(a) Efict of gross section stress. Experimental values of crack growth rate, da/dt, were
plotted in Figs. 3(a)-(d) vs the stress intensity factor K, with gross section stresses as
parameter at specified temperature under creep, fatigue and creep-fatigue interaction
conditions, respectively. Typical examples of experimental relation between logarithm of
crack growth rate and logarithm of stress intensity factor are as shown in Fig. 4, and may be
divided into three regions. That is, Region I: the initial growth region nearly parallel to the
log,, (da/dt ) axis, Region II: the subcritical growth region which shows straight line, and
Region III: the rapid growth region in which the crack grows rapidly and final fracture
occurs. Figures4(a)-(d) show that in Region I crack growth rate depends on both K, and gross
section stress dg and the threshold stress intensity factor (KJlh for crack growth increases with
increase of gross section stress og under high temperature creep, fatigue and creep-fatigue
interaction conditions. Also, in Region II, it is found that crack growth rate da/dt under high
temperature fatigue condition is almost independent of the gross section stress (TVand these
data fall nearly on the same straight line as shown in Fig. 4(d), while crack growth rate da/dt
under high temperature creep and creep-fatigue interaction conditions depends on gross
section stress og and increases with increase of gross section stress (TVas shown in Figs.
4(a)-(c).
Experimental values of crack growth rate per cycle, da/dN, were plotted against the stress
intensity factor K, with gross section stresses as parameter at the same temperature under
creep, fatigue and creep-fatigue interaction conditions, respectively, and they show the
similar tendency to those in Fig. 4 with respect to the effect of gross section stress op.
(b) EJ&ectof holding time. Experimental values ofcrack growth rate, da/dt, were plotted in
Figs, 5(a)-(e) against the stress intensity factor K, with holding times as parameter at the
same temperature and gross section stress. Crack growth rate seems to converge into the
same curve at lower K, level as shown in Fig. 5 and thus crack growth rate da/dt in Region II
appears to be almost independent of holding time t,. Also, in Region II, it can be seen that
crack growth rate da/dt depends on the holding time t, and take the maximum value at the
specific value of t,.
Experimental values of crack growth rate per cycle, da/dN, plotted vs. the stress intensity
factor K, decrease with decrease of holding time t,, that is, with increase of frequency f which
is defined by [15]:

f = ll(th + ‘sin)> (3)

where tsin is the period of the sine wave shape in Fig. 2(c).
(c) Eflect of temperature. Experimental values of crack growth rate, da/dt, were plotted in
Figs. 6(a)-(d) vs. the stress intensity factor K, with temperatures as parameter at the same
gross section stress under creep, fatigue and creep-fatigue interaction conditions,
respectively. It can be seen from these figures that crack growth rate da/dt increases with
increase of temperature as shown in Fig. 6. The temperature dependence of the crack growth
rate under high temperature fatigue appears to be small compared with those under high
temperature creep and creep-fatigue interaction conditions within Region II. Moreover,
Figs. 6(a)-(d) show that the threshold stress intensity factor (K,),,, for crack growth under
high temperature creep, fatigue and creep-fatigue interaction conditions is almost
independent of the temperature.
Experimental values of crack growth rate per cycle, da/dN, plotted vs. the stress intensity
factor K, show the similar tendency to those shown in Fig. 6 with respect to the effect of
temperature.

3.2 Relation between crack growth rate and net section stress unet
In this section, experimental values of crack growth rate were plotted vs. the net section
stress on__,obtained from

u ,6,= a,/(1 - a/W. (4)

2

+ + th=l#mln Q CREEP

3
17

* th=mmk”
f h I,,=! “7lt-t

A FATIGUE
f

Fig. 5. Relation between crack growth rate da/dr and stress intensity facmr (effect of hAding time).
 517

-I _

l 650-C
A 700-C

-‘ IL
$5 20 25 30 35
KI (kg~mm~'2)

to 0

.I _

.2

-3

10
IfI 20
20 25 30 35 Kl
KI ( kgimm"')

Fig. 6. Relation between crack growth rate du/dt and stress intensity factor (effect of temperature),
 650-C. CREEP
0 tip=20 9 kg/mm* I
650°C. ,,,=I mt”
. bg= 19 5 kqlmm’ 0 bp=20 9 kglmd
A dg=18 1kqhd . Ug=l9 5 kghd
,3 bp=lB I kglmd
35
i
uret ( kg/mm’) 20 25 30 31
C&t (kg/md)

1081 -

10 o_

- 10-I _

z
-I _

-I_
650 'C FATIGUE

0 dq=ZO 3 kg/mm2
650-C. b,=lOmn
0 Ug=20.9 kglmd O&=195 kg/mm2
. 6g.19.5 kq/md A d9=18 I kqlmm2
A 6g=l8.1 kg/mm2

I I I
‘
20 25 30 35

0net ( kg /mm’)

Fig. 7. Relation between crack growth rate du/dt and net section stress (effect ofgross section stress).
 Studies on crack growth rate under high temperature creep 519

(a) Effect of’ gross section stress. Experimental values of crack growth rate, da/dt, were
plotted in Figs. 7(a)-d) vs the net section stress G,,,~with gross section stresses as parameter
at the same temperature under creep, fatigue and creep-fatigue interaction conditions,
respectively. Experimental values of crack growth rate may be also divided into three regions,
that is, Region I (the initial growth region), Region II (the subcritical growth region), and
Region III (the rapid growth region) similarly as shown in Fig. 4. It can be seen that Fig. 7
shows the similar tendency to Fig. 4 with respect to the effect of gross section stress (T, and
thus crack growth rate da/dt depends on gross section stress crBalso. It is, therefore,
concluded that net section stress crne,is not only mechanical parameter which controls crack
growth rates under high temperature creep, fatigue and creep-fatigue interaction conditions.
Furthermore, the effect of gross section stress og on the crack growth rate within Region II in
Fig. 7 appears to be small compared with that in Fig. 4.
Experimental values of crack growth rate per cycle, da/dN, plotted against net section
stress b,,, show the similar tendency to those in Fig. 7 with respect to the effect ofgross section
stress cg.
(b) Efict ofholding time. Experimental values of crack growth rate, da/dt, were plotted in
Figs. 8(a)-(e) vs net section stress cnet with holding times as parameter at the same
temperature and gross section stress. Figs. 8(a)-(e) show the similar tendency to Figs.
5(a)-(e) with respect to the effect of holding time and thus the effect of stress intensity factor
on crack growth rates appears to be similar to that of the net section stress on them.
Experimental values of crack growth rate per cycle, da/dN, plotted vs. net section stress
B,,~ show the similar tendency to the cases plotted vs the stress intensity factor K,, and da/dN
decreases with increase of frequency f:
(c) Efect oftemperature. Experimental values of crack growth rate, da/d& were plotted in
Figs. 9(a)-(d) vs net section stress one, with tempratures as parameter at the same gross
section stress under creep, fatigue and creep-fatigue interaction conditions, respectively.
Figure 9(a)-(d) show the similar tendency to Figs. 6(a)-(d) with respect to the effect of tem-
perature. For example, onet value of the vertical portion in Region I, that is, the threshold net
section stress (crneJthfor crack growth under high temperature creep, fatigue and creep-fatigue
interaction conditions appears to be almost independent of the temperature within the
present test conditions.
Experimental values of crack growth rate per cycle, du/dN, plottedvs net section stress one,
show the similar tendency to those in Fig. 9 with respect to the effect of temperature.

4. CONCLUSIONS
From series of studies on crack growth rate behaviour under high temperature creep,
fatigue and creep-fatigue interaction conditions on 304 stainless steel by using high
temperature microscope and observing the crack length continuously during running the test
without interruption in vacuum of low5 mm Hg, the following conclusions are obtained:
(1) Crack growth rate on a time basis, da/d& under high temperature creep and creep-
fatigue interaction conditions can not be described in terms of elastic stress intensity factor K,
only or net section stress B,,, alone independently of gross section stress og.
(2) The relation between crack growth rate and stress intensity factor K, under high
temperature fatigue condition changes with some trend by gross section stress gg at lower K,
level and it can be approximately described in terms of stress intensity factor K, only, at
higher K, level.
(3) The threshold stress intensity factor (K,),, and the threshold net section stress (cnet)Ih
under high temperature creep, fatigue and creep-fatigue interaction conditions appear to be
almost independent of temperature.

Acknowledgements-The research has been carried out as a project of INTERNATIONAL COOPERATIVE

FRACTURE INSTITUTE. Also, the author should like to appreciate that a part of the work has been financially
sponsored by The Mitsubishi Foundation.
 0 CREEP
a,=16 1 kQ/mn~
* lh=iomln 0 CREEP
A tw , ml* * lh=tOm$n

. FATIGUE a lh’I nun

. FATIGUE
f

-e
&et ( kghd )
35

6t)O’C
Ug=r4 5kgtmd
0 CREEP
. Ih:lomm
A lh’, mm
. FATIGUE

&et f kgfmm” 1

Fig. 8. Relation between crack growth rate du/dt and net section stress (effect of holding time).
 th’t ml,”

Up=19
5 kglmmz

0 6OO’C
. sso*c
i tB ?OOY

I
I I
25 30 35 &O

cr,, kg,2)
25( &et ( kgh-n’ )

-T----l--l--

1
10’

FATiGLlE
Ut~=19.5 kg/m&

0 6OO’C

0 650 “C

A 7OO’C

Fig. 9. Relation between crack growth rate du/dt and net section stress (effect of temperature).
522 T. YOKOBORI and H. SAKATA

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(Received 31 July 1979: recekedfbr publication IO September 1979)