Title: Virtual Testing of Fatigue/Creep/Environmental Cracking using a Meso-scale Fracture Mechanics Model

Authors: Kamran Nikbin

DOI: 10.33599/nasampe/s.24.0094

Abstract: This paper presents an overview of research and development of virtual meso-scale models for crack initiation/growth under creep/fatigue/environment, or a combination thereof, which can be used in the design and life assessment of high temperature plant components. As these three mechanisms are fundamentally the main reasons for damage and failure in metallic components it is essential to be able to simulate their long-term effects based on short term experimental data. The meso-scale based modelling presented uses virtual test methods to optimise accelerated testing and determine the remaining life of components. The procedure is applicable for analysing defects in components where uniaxial and multiaxial properties are available, and which are used with the respective constitutive creep/fatigue/environmental properties. To model the cracking behaviour with the different failure mechanisms idealised microstructure meshing containing grains, grain boundaries, voids and inclusions is constructed, and virtual tests carried out to predict the effects on crack growth. Examples of the results are shown using appropriate user-subroutines in conjunction with FEM. An integrated model is thus presented which can be used to predict time dependant intergranular creep, cycle dependant trans-granular fatigue and time-dependant surface corrosion or oxidation damage or cracking in components.

References: 1.K.M. Nikbin, D.J. Smith, and G.A. Webster: Prediction of Creep Crack-Growth from Uniaxial Creep Data. Proceedings of the Royal Society of London Series a-Mathematical Physical and Engineering Sciences. 396, 183-197 (1984). 2.K. Nikbin, D. Smith, and G. Webster: An engineering approach to the prediction of creep crack growth. Journal of Engineering Materials and Technology. 108, 186-191 (1986). 3.A. Mehmanparast, C. Davies, G. Webster, and K. Nikbin: Creep crack growth rate predictions in 316H steel using stress dependent creep ductility. Materials at High Temperatures. 31, 84-94 (2014). 4.Y. Takahashi: Study on creep-fatigue evaluation procedures for high-chromium steels—Part I: Test results and life prediction based on measured stress relaxation. International Journal of Pressure Vessels and Piping. 85, 406-422 (2008). 5.E. Hosseini, S. Holdsworth, and E. Mazza: Advanced constitutive modelling for creep-fatigue assessment of high temperature components. Materials at High Temperatures. 35, 504-512 (2018). 6.X. Zhang, S.-T. Tu, and F. Xuan: Creep–fatigue endurance of 304 stainless steels. Theoretical and Applied Fracture Mechanics. 71, 51-66 (2014). 7.S. Holmström and P. Auerkari: A robust model for creep-fatigue life assessment. Materials Science and Engineering: A. 559, 333-335 (2013). 8.J.-L. Bouvard, J.L. Chaboche, F. Feyel, and F. Gallerneau: A cohesive zone model for fatigue and creep–fatigue crack growth in single crystal superalloys. International Journal of Fatigue. 31, 868-879 (2009). 9.V. Shlyannikov: Creep–fatigue crack growth rate prediction based on fracture damage zone models. Engineering Fracture Mechanics. (2019). 10.L. Zhao and K. Nikbin: Characterizing high temperature crack growth behaviour under mixed environmental, creep and fatigue conditions. Materials Science and Engineering: A. 728, 102-114 (2018). 11.J. JianPing, M. Guang, S. Yi, and X. SongBo: An effective continuum damage mechanics model for creep–fatigue life assessment of a steam turbine rotor. International Journal of Pressure Vessels and Piping. 80, 389-396 (2003). 12.S.P. Zhu, H.Z. Huang, L.P. He, Y. Liu, and Z.L. Wang: A generalized energy-based fatigue-creep damage parameter for life prediction of turbine disk alloys. Engineering Fracture Mechanics. 90, 89-100 (2012). 13.Z. Fan, X. Chen, L. Chen, and J. Jiang: A CDM-based study of fatigue–creep interaction behavior. International Journal of Pressure Vessels and Piping. 86, 628-632 (2009). 14.F.R. Biglari and K.M. Nikbin: A diffusion driven carburisation combined with a multiaxial continuum creep model to predict random multiple cracking in engineering alloys. Engineering Fracture Mechanics. 146, 89-108 (2015). 15.A.C.F. Cocks and M.F. Ashby: Intergranular fracture during power-law creep under multiaxial stresses. Metal Science. 14, 395-402 (1980). 16.J.R. Rice and D.M. Tracey: On the ductile enlargement of voids in triaxial stress fields∗. Journal of the Mechanics and Physics of Solids. 17, 201-217 (1969). 17.M. Spindler: The multiaxial creep ductility of austenitic stainless steels. Fatigue & fracture of engineering materials & structures. 27, 273-281 (2004). 18.J.-F. Wen and S.-T. Tu: A multiaxial creep-damage model for creep crack growth considering cavity growth and microcrack interaction. Engineering Fracture Mechanics. 123, 197-210 (2014). 19.L. Zhao, L. Xu, and K. Nikbin: Predicting failure modes in creep and creep-fatigue crack growth using a random grain/grain boundary idealised microstructure meshing system. Materials Science and Engineering: A. 704, 274-286 (2017). 20.L. Zhao, N. Alang, and K. Nikbin: Investigating creep rupture and damage behaviour in notched P92 steel specimen using a microscale modelling approach. Fatigue & Fracture of Engineering Materials & Structures. 41, 456-472 (2018). 21.M. Yatomi and M. Tabuchi: Issues relating to numerical modelling of creep crack growth. Engineering Fracture Mechanics. 77, 3043-3052 (2010). 22.K. Nikbin and S. Liu: Multiscale-constraint based model to predict uniaxial/multiaxial creep damage and crack growth in 316-H steels. International Journal of Mechanical Sciences. 156, 74-85 (2019). 23.J. Lemaitre and A. Plumtree: Application of Damage Concepts to Predict Creep-Fatigue Failures. Journal of Engineering Materials and Technology. 101, 284-292 (1979). 24.W. Ostergren: A Damage Function and Associated Failure Equations for Predicting Hold Time and Frequency Effects in Elevated Temperature, Low Cycle Fatigue. Journal of Testing and Evaluation. 4, 327-399 (1976). 25.ABAQUS 2023-FEM package- (2023) 26.Y. Hu, Y. Wang, J Xi, K Nikbin, ‘Effects of Grain and Grain Boundary Elongation on Creep Crack Growth Using Virtual Test Model of Compact Tension Specimens’, DOI: 10.1520/STP164320210101.; In book: ‘Advances in Accelerated Testing and Predictive Methods in Creep, Fatigue, and Environmental ‘, May (2023) 27.ASTM, ASTM E2760-10e2: Standard Test Method for Creep-Fatigue Crack Growth Testing, United States: American Society for Testing Materials.(2019) 28.A. E1457-19: Standard Test Method for Measurement of Creep Crack Growth Times and Rates in Metals., (2019) 29.P.C. Paris: A rational analytic theory of fatigue. The trend in engineering. 13, 9 (1961). 30.BS7910, 'guide to methods for assessing the acceptability of flaws in metallic structures, BSI, (2020) 31.Z. Tang, H. Jing, L. Xu, L. Zhao, Y. Han, B. Xiao, Y. Zhang, and H. Li: Investigating crack propagation behavior and damage evolution in G115 steel under combined steady and cyclic loads. Theoretical and Applied Fracture Mechanics. 100, 93-104 (2019).

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000094

Pages: 26

Price: $52.00