Crack Initiation and Propagation

BRITTLE FRACTURE MECHANISM DOE-HDBK-1017/2-93 Brittle Fracture When a small flaw is present, the tensile strength follows the dashed Curve C. At elevated temperatures, Curves A and C are identical. At lower temperatures, approximately 50°F above the NDT temperature for material with no flaws, the tensile strength curve drops to the yield curve and then follows the yield curve to lower temperatures. At the point where Curves C and B meet, there is a new NDT temperature. Therefore, if a flaw exists, any failure at a temperature equal or below the NDT temperature for flawed material will be brittle. Crack Initiation and Propagation As discussed earlier in this chapter, brittle failure generally occurs because a flaw or crack propagates throughout the material. The start of a fracture at low stresses is determined by the cracking tendencies at the tip of the crack. If a plastic flaw exists at the tip, the structure is not endangered because the metal mass surrounding the crack will support the stress. When brittle fracture occurs (under the conditions for brittle fracture stated above), the crack will initiate and propagate through the material at great speeds (speed of sound). It should be noted that smaller grain size, higher temperature, and lower stress tend to mitigate crack initiation. Larger grain size, lower temperatures, and higher stress tend to favor crack propagation. There is a stress level below which a crack will not propagate at any temperature. This is called the lower fracture propagation stress. As the temperature increases, a higher stress is required for a crack to propagate. The relationship between the temperature and the stress required for a crack to propagate is called the crack arrest curve, which is shown on Figure 2 as Curve D. At temperatures above that indicated on this curve, crack propagation will not occur. Fracture Toughness Fracture toughness is an indication of the amount of stress required to propagate a preexisting flaw. The fracture toughness of a metal depends on the following factors. a. Metal composition b. Metal temperature c. Extent of deformations to the crystal structure d. Metal grain size e. Metal crystalline form The intersection of the crack arrest curve with the yield curve (Curve B) is called the fracture transition elastic (FTE) point. The temperature corresponding to this point is normally about 60°F above the NDT temperature. This temperature is also known as the Reference Temperature - Nil-ductility Transition (RT_NDT) and is determined in accordance with ASME Section III (1974 edition), NB 2300. The FTE is the temperature above which plastic deformation accompanies all fractures or the highest temperature at which fracture propagation can occur under purely elastic loads. The intersection of the crack arrest curve (Curve D) and the tensile strength or ultimate strength, curve (Curve A) is called the fracture transition plastic (FTP) point. The temperature corresponding with this point is normally about 120°F above the NDT temperature. Above this temperature, only ductile fractures occur. MS-04 Page 4 Rev. 0