Chapter 7: Plane-Strain Fracture Toughness

7.1 Introduction

7.2 Specimen size requirements

7.3 Plain strain fracture specimens

7.4 Specimen preparation

7.5 Fracture test
7.1 Introduction
In chapter 4, we have shown that the plain-strain condition leads to
the largest constraint and the smallest plastic zone. Based on the
Griffith-Irwin fracture theory, we can argue that the smallest plastic zone
results in the lowest fracture toughness. The plain-strain fracture
toughness is designated by KIC or GIC for mode I loading. The plain-
strain toughness is used to design nuclear structures, oil pipe lines, or
where the structure is subjected to low temperatures. The test methods
are documented in American Society for Testing and Materials
Handbooks (E-399).
Small
Plane Strain Test Procedure
1. Selection of specimen geometry/configuration.

2. Starter notch.

3. Introduction of Sharp Crack
Fatigue cracking & validity of the fatigue cracked specimen.
0.95 aav ai aav
|(as aav)|/aav 0.1
amin > 0.05-in

4. Fracture test.
Load versus deflection plot
Fracture load
Calculate SIF
a
s
= Crack length at the surface
a
av
= Average Crack length
a
min
= Minimum crack length
7.2 Specimen size requirements
Parameters those influence the validity of the plain-strain fracture
toughness are the crack length, specimen thickness, and uncracked
ligament (W-a). These parameters have to be large compare to the
plain-strain plastic zone size (Irwins equation).
rp
B
a W-a
W
P
P
Crack length, a
KIC
Thickness, B
KIC
Thickness B >> rp
Crack length, a >> rp
Uncracked ligament, W-a >> rp
2
2
3
ys
IC
p
K
r
to
=
p
ys
IC
p
ys
IC
p
ys
IC
r
K
a W
r
K
a
r
K
B
25 5 . 2
25 5 . 2
25 5 . 2
2
2
2
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7.3 Plain Strain Fracture Toughness Test Specimens
Plain strain conditions:
- Highest triaxsial constraint.
- Smallest plastic zone
(about 1/3 of plain stress)
- Therefore, expect smallest
fracture toughness.
American Standard for Testing and Materials (ASTM)
- Established test procedure (E339)
Developed by Ed Srawley and Frank Brown.
P
P
W
0.25 W
1.25 W
B
a = 0.45 - 0.55 W
1
.
2

W

0
.
5
5

W

Compact (B = 0.25 W to 0.5 W)
B
P
P/2 P/2
5W
S=4W
W
a = 0.45 - 0.55 W
Bend (B = 0.25 W to 1.0 W)
2
3
4 3 2
2
1
1
6 . 5 72 . 14 32 . 13 64 . 4 866 . 0 2
|
.
|

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|

(
(

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+ |
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+ |
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+
=
W
a
W
a
W
a
W
a
W
a
W
a
BW
P
K
2
3
2
2
1
2
3
1 2 1 2
7 . 2 93 . 3 15 . 2 1 99 . 1 3
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.
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+
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=
W
a
W
a
W
a
W
a
W
a
W
a
W
a
BW
PS
K
7.4 Specimen Preparation
inches
K
ys
FATIGUE
,
2
max
|
|
.
|

\
|
o
in 05 . 0 *
1 . 0 *
05 . 1 95 . 0 *
min
>
s
s s
a
a a a
a a a
av av S
av i av
B B
Chevron Notch
Fatigue
Cracks
Normal Edge Notch
B
a1
as
a3 a2
W
Notch
1. Starter Notch
2. Fatigue cracking
0.00 0.02 0.04 0.06 0.08 1.0 1.2
40
30
20
10
Maximum SIF during fatigue cracking = 0.6 KIC
KIC
7075-T651 Al-alloy
042 . 0
79
27
2
max
=
(
(

=
=
ys
FATIGUE
ys
IC
K
ksi
in ksi K
o
o
7.5 Fracture Test
Displacement, v
L
o
a
d
,

P

Load- Displacement Response
Select Critical Load, PQ based on the above figure.
Check the Validity of the test

Compute K
Q
from PQ
Check : initial crack length
If yes, then KQ =KIC, Fracture toughness of the material
95%
95%
95%
Pmax
Pmax PQ
PQ=P5
PQ
P5
P5
1 . 1
max
s
Q
P
P
Check : thickness
2
5 . 2
|
|
.
|

\
|
>
ys
Q
K
a
o
2
5 . 2
|
|
.
|

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>
ys
Q
K
B
o
Conduct fracture test, record load (P) and load-point displacement (v)
Repeat for 3 to 5 specimens