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NASA TECHNICAL
MEMORANDUM
COCOI
X
NASA TM X-3316
c
AN INVESTIGATION OF FRACTURE TOUGHNESS,
FATIGUE-CRACK GROWTH, SUSTAINED-LOAD
FLAW GROWTH, AND IMPACT PROPERTIES
OF THREE PRESSURE VESSEL STEELS
C. Michael Hudson, J, C. Newman, Jr.,
and Peter E. Lewis
Langley Research Center
Hampton, Va. 23665
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION • WASHINGTON, D. C. • DECEMBER 1975
https://ntrs.nasa.gov/search.jsp?R=19760007154 2018-05-18T06:20:15+00:00Z
1. Report No.
NASA TMX-33162. Government Accession No.
4. Title and Subtitle
AN INVESTIGATION OF FRACTURE TOUGHNESS, FATIGUE-CRACK GROWTH, SUSTAINED-LOAD FLAW GROWTH, ANDIMPACT PROPERTIES OF THREE PRESSURE VESSEL STEELS
7. Author(s)
C. Michael Hudson, J. C. Newman, Jr., and Peter E. Lewis
9. Performing Organization Name and Address
NASA Langley Research CenterHampton, Va. 23665
12. Sponsoring Agency Name and Address
National Aeronautics and Space AdministrationWashington, D.C. 20546
3. Recipient's Catalog No.
5. Report DateDecember 1975
6. Performing Organization Code
8. Performing Organization Report No.
L- 1044710. Work Unit No.
505-02-31-0111. Contract or Grant No.
13. Type of Report and Period Covered
Technical Memorandum14. Sponsoring Agency Code
15. Supplementary Notes
16. Abstract
Tests to determine fracture toughness, fatigue-crack growth, sustained-load flaw growth,and impact properties were conducted on three pressure vessel steels: A. O. Smith VMS 5002and VMS 1146A, and ASTM A- 225 Gr.B. The data obtained will help relieve the general pau-city of such data on these pressure vessel steels.
The elastic fracture toughness of the three steels does not decrease significantly withdecreasing temperature from room temperature to about 244 K (-20° F). The elastic fracturetoughness of the three steels increases with increasing specimen width and thickness.
The fatigue- crack-growth data for all three steels fall into relatively narrow scatterbands on plots of rate against stress-intensity range. Barsom's equation (Transactions ASME,Journal of Engineering for Industry, Nov. 1971) predicts the upper bounds of the scatter bandsreasonably well.
Charpy impact energies decrease with decreasing temperature in the nominal tempera-ture range from room temperature to 244 K (-20° F).
The nil- ductility temperatures of VMS 5002 and A- 225 Gr.B are 250 K (-10° F) and 241 K(-25° F), respectively. A lack of test material precluded obtaining the nil-ductility temperatureof VMS 1146A.
17. Key Words (Suggested by Author(s))VMS 5002VMS 1146AA- 225 Gr.BFracture toughnessFatigue-crack growth
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AN INVESTIGATION OF FRACTURE TOUGHNESS, FATIGUE-CRACK GROWTH,
SUSTAINED-LOAD FLAW GROWTH, AND IMPACT PROPERTIES
OF THREE PRESSURE VESSEL STEELS
C. Michael Hudson, J. C. Newman, Jr.,and Peter E. Lewis
Langley Research Center
SUMMARY
Tests to determine fracture toughness, fatigue-crack growth, sustained-load flawgrowth, and impact properties were conducted on three pressure vessel steels:A. O. Smith VMS 5002 and VMS 1146A, and ASTM A-225 Gr.B. The data obtained willhelp relieve the general paucity of such data on these pressure vessel steels.
The elastic fracture toughness of the three steels does not decrease significantlywith decreasing temperature from room temperature to about 244 K (-20° F). Theelastic fracture toughness of the three steels increases with increasing specimen widthand thickness.
The fatigue-crack-growth data for all three steels fall into relatively narrow scatterbands on plots of rate against stress-intensity range. Barsom's equation (TransactionsASME, Journal of Engineering for Industry, Nov. 1971) predicts the upper bounds of thescatter bands reasonably well.
Charpy impact energies decrease with decreasing temperature in the nominal tem-perature range from room temperature to 244 K (-20° F).
The nil-ductility temperatures of VMS 5002 and A-225 Gr.B are 250 K (-10° F) and241 K (-25° F), respectively. A lack of test material precluded obtaining the nil-ductilitytemperature of VMS 1146A.
INTRODUCTION
The development of fracture mechanics analysis into a practical tool for predictingthe behavior of cracked structures has precipitated a need for fracture toughness andfatigue-crack-growth data on many materials. Relatively large quantities of such datahave been generated for materials used for aerospace applications (ref. 1). However,there are relatively few such data on materials used for pressure vessel applications.Consequently, when a fracture mechanics analysis was recently performed on a series of
pressure vessels at the Langley Research Center, the needed data had to be generated.A series of fracture-toughness and fatigue-crack-growth tests were conducted onthree pressure vessel steels: A. O. Smith VMS 5002, A. O. Smith VMS 1146A, andASTM A-225 Gr.B. The test temperatures ranged from room temperature to 227 K(-50° F) in the fracture-toughness tests. The test temperature was room temperature inthe fatigue-crack-growth tests.
Sustained-load flaw-growth, Charpy impact fracture, and drop-weight impact frac-ture experiments were conducted on the three steels. Properties determined by theseexperiments were also needed in evaluating the integrity of the vessels.
This report presents the results of all experiments conducted. The results can beused to predict crack growth and failure in these three pressure vessel steels. TheCharpy results are suitable for determining the minimum allowable operating temperaturefor the steels, according to the current ASME Boiler and Pressure Vessel Code (ref. 2).
Chicago Bridge & Iron Company and Lenape Forge Division of Gulf & WesternIndustrial Products Company supplied the steels tested. Under contract to LangleyResearch Center (LaRC), the following companies performed the tests indicated:Spectrochemical Laboratories Inc., the chemical analysis; Martin Marietta Aerospace(jointly with LaRC), the fracture-toughness, fatigue-crack-growth, and sustained-loadflaw-growth tests; Martin Marietta Aerospace, the Charpy impact tests; and PittsburghTesting Laboratory, the drop-weight tests.
SYMBOLS AND ABBREVIATIONS
Except for the figures, this paper presents physical quantities in both the Interna-tional System of Units (SI) and the U.S. Customary Units. For clarity, the figures showonly SI units. All measurements and calculations were made in U.S. Customary Units.Reference 3 presents factors relating the two systems, and appendix A presents thosefactors used in the present investigation.
a crack length, mm (in.)
a^ crack length at start of fracture-toughness test, mm (in.)
asi crack length at start of sustained-load flaw-growth test, mm (in.)
CyN energy absorbed in impact test on Charpy V-notch specimen, N-m (ft-lbf)
da/dN rate of fatigue-crack growth, nm/cycle (in/cycle)
e elongation in 51-mm (2-in.) gage length, percent
K rate of change of stress intensity factor with time, (MN/m3/2J/s
AK stress-intensity-factor range, MN/m / \ksi-in / J
Kp. material fracture-toughness parameter, MN/m / Vksi-in ' }
Kje elastic fracture toughness, MN/m / Vksi-in1/2)
KT, elastic stress-intensity factor at start of sustained-load flaw-growth test,MN/m3/2 (ksi-in1/2)
maximum stress-intensity factor, MN/m / Vksi-in / j
minimum stress-intensity factor, MN/m3/ ^si-"1 /
Ze lateral expansion obtained from Charpy impact test, mm (in.)
m material fracture-toughness parameter
Po maximum load applied to specimen during fracture-toughness test, N (Ibf)
Pm maximum applied load, N (Ibf)
]?min minimum applied load, N (Ibf)
R ratio of minimum stress to maximum stress »
Sn elastic nominal failure stress, Pa (ksi)
Su elastic nominal stress required to produce fully plastic hinge on net section,Pa (ksi)
T test temperature, K (°F)
t specimen thickness, mm (in.)
w specimen width, mm (in.)
CTU ultimate tensile strength, Pa (ksi)
Oy yield strength (0.2-percent offset), Pa (ksi)
Abbreviations:
COD crack opening displacement
CS compact specimen configuration
LVDT linear variable differential transformer
NDT nil-ductility temperature, K (°F)
NFG no flaw growth in sustained-load flaw-growth test
WOL wedge-opening-load specimen configuration
SPECIMENS, TESTS, AND PROCEDURES .
Specimens
Test specimens were made of VMS 5002, VMS 1146A, and A-225 Gr.B ferriticsteels. The VMS 5002 and VMS 1146A are proprietary steels developed by A. O. SmithCorporation for fabricating laminated pressure vessels. The A-225 Gr.B is an ASTMpressure vessel steel (ref. 4). Table I presents the results of the tensile and chemicaltests conducted on the three steels tested in this investigation. The specimens used toobtain the tensile properties met ASTM standards (ref. 5).
As mentioned in the Introduction, several laboratories generated the data presentedherein. Each laboratory used specimen configurations adaptable to the testing equipmenton hand. Consequently, two, and sometimes three, specimen configurations were testedto determine fracture toughness, fatigue-crack growth, and sustained-load flaw growth.The results of these tests were analyzed by using the appropriate stress-intensity factorfor each configuration.
Fracture-toughness specimens.- Figures 1, 2, and 3 show the configurations of thecompact specimens (CS) tested. The following table gives the configurations, thicknesses,and widths of the various specimens for each material:
Material
VMS 5002
VMS 1146 A
A-225 Gr.B
Configuration
Type
CSCSCS
CSCS
CSCS
CS
Figure
Ka)Kb)Kc)
l(a)2
l(a)Kb)3
Specimenthickness
mm
25.445.7
109.2
25.425.4
25.445.783.8
in.
1.01.84.3
1.01.0
1.01.8
3.3
Specimenwidth
mm
50.891.471.1
50.891.4
50.891.471.1
in.
2.03.62.8
2.03.6
2.0
3.62.8
A chevron notch was machined into each specimen to initiate fatigue cracks. The25.4- and 45.7-mm (1.0- and 1.8-in.) thick specimens met at the ASTM standards (ref. 6)for specimen configuration. The 83.8- and 109.2-mm (3.3- and 4.3-in.) thick specimensdid not meet the ASTM standards; however, a boundary collocation analysis (ref. 7) gavestress-intensity factors for these nonstandard specimens. These factors were used tocalculate the fracture toughness of the specimens at failure.
Fatigue-crack-growth specimens.- Figures l(a) and 4 show the configurations of thecompact specimens (CS) tested. The following table gives the thicknesses and widths ofthe specimens:
Material
All three steelsAll three steels
.Configuration
Type
CSCS
Figure
Ka)4
Specimenthickness
mm
25.45.1
in.
1.00.2
Specimenwidth
mm
50.863.5
in.
2.02.5
Chevron and straight^through notches were machined into the 25.4-mm (1.0-in.)thick and the 5.1-mm (0.2-in.) thick specimens,.respectively, to initiate fatigue cracks.Fine lines scribed on the surfaces of the 25.4-mm (1.0-in.) thick specimens marked inter-vals along the crack path. The spacing between lines was 1.3 mm (0.050 in.). Thesescribe lines provided a means of monitoring crack growth but1, being parallel to the loadingdirection, introduced no stress concentration in the specimens. The 5.1-mm (0.2-in.)thick specimens required no scribe lines, because a crack-opening-displacement (COD)gage monitored crack growth. , , ...
Sustained-load flaw-growth specimen.- Figures l(a) and 5 show the configurationsof the compact (CS) and wedge-opening-load (WOL) specimens tested. The following tablegives the thicknesses and widths of the specimens:
Material
All three steelsVMS 5002 and
A-225 Gr.BVMS 1146A
Configuration
Type
CSWOL
WOL
Figure
Ka)5(a)
5(b)
Specimenthickness
mm
25.435.6
25.4
in.
1.01.4
1.0
Specimenwidth
mm
50.891.4
91.4
in.
2.03.6
3.6
Chevron and straight-through notches were machined into the CS and WOL speci-mens, respectively, to initiate fatigue cracks.
Charpy impact specimens.- Figure 6 shows the configuration of the Charpy impactspecimens tested. These specimens were 55.9 mm (2.2 in.) long and 10.2 mm (0.4 in.)thick. A 2.0-mm (0.08-in.) deep V-notch was cut into the center of each specimen toinitiate failure. This configuration met the ASTM standards (ref. 8) for Charpy impactspecimens. Specimens were machined from all three steels.
Drop-weight test specimens.- Figure 7 shows the configuration of the drop-weightspecimens tested. These specimens were 127.0 mm (5.0 in.) long, 50.8 mm (2.0 in.)wide, and 15.7 mm (0.62 in.) thick. A brittle weld bead was laid in the center of eachspecimen, and a notch cut across the crown of the weld to initiate failure. This config-uration met the ASTM standards (ref. 9) for drop-weight specimens. Specimens weremachined from VMS 5002 and A-225 Gr.B steels.only. A lack of material precludeddrop-weight testing the VMS 1146A.
Testing Machines
Fracture-toughness testing machines.- The following table lists the capabilities ofthe three testing machines used for the fracture-toughness tests:
Machine type
HydraulicHydraulicHydraulic
Maximum loadcapacity
kN
89445
4448
Ibf
20 000100 000
1 000 000
Machine descriptionsource
Ref. 10Appendix B
. Appendix B
Fatigue-crack-growth testing machines.- The following table lists the capabilitiesof the two testing machines used for the fatigue-crack-growth tests:
Machine type
Inertia forcecompensation
Hydraulic
Maximum loadcapacity
kN
89
445
Ibf
20 000
100 000
Operatingfrequency used
Hz
20
5 to 10
cpm
1200
300 to 600
Machine descriptionsource
Ref. 11
Appendix B
Sustained-load flaw-growth testing machine.- Static loads were applied to the CSspecimens by a tester having a 44-kN (10 000-lbf) static load capacity (ref. 12). Staticloads were applied to the WOL specimens by tightening the bolt which is threaded throughthe upper half of the specimen and butts against the lower half. (See fig. 5.)
Charpy impact and drop-weight testers.- Standard Charpy impact and drop-weighttesters were used for the impact and drop-weight tests. References 8 and 9 describe thetest apparatus in detail.
Test Procedures
Fracture-toughness tests.- Test specimens were fatigue cracked to predeterminedlengths (final a/w values varied from 0.375 to 0.625) by applying constant-amplitudefatigue loadings with R ~ 0 and AK g 0.30KIe. This cracking was done at room tem-perature. The specimens were then cooled (if called for in the test program) and monoto-nically loaded to failure at stress-intensity rates K between 0.92 and 2.75 \MN/m ' j/s(,50 and 150 ksi-in ' /miiy. Throughout each fracture-toughness test a calibrated CODgage was mounted in the machined notch of each specimen. The output from this gage andthe output from the testing-machine load cell were continuously recorded for each speci-men. These records indicated the maximum load at failure.
The 71.1-mm (2.8-in.) wide VMS 5002 and A-225 Gr.B specimens were cooled to thetest temperature by flowing cold nitrogen gas into a plastic shroud taped around the testsection. Once the test temperature was reached, the flow of cool gas was manuallycontrolled to keep the specimen at the test temperature. The specimens were held at thetest temperature for 3.6 ks (1 hr), and then were pulled to failure. A thermocouple spot-welded to the specimen was used to record specimen temperature.
The 91.4-mm (3.6-in.) wide VMS 5002, VMS 1146A, and A-225 Gr.B specimens werecooled to the test temperature by pouring a mixture of alcohol and dry ice into a containersurrounding the test section. Dry ice was added to the mixture until the specimen temper-ature approached the test temperature. Once the test temperature was reached, small
quantities of dry ice were added to the mixture in order to keep the solution at the testtemperature. The specimens were held at the test temperature for approximately 1.8 ks(1/2 hr), and then were pulled to failure. A thermocouple spotwelded to the specimenindicated specimen temperature.
The 50.8-mm (2.0-in.) wide VMS 5002, VMS 1146A, and A-225 Gr.B specimenswere all tested at room temperature.
Fatigue-crack-growth tests.- Constant-amplitude loadings were applied in mosttests. However, in several tests, specimens were tested at two stress amplitudes.The stress-intensity ranges AK applied in the crack-growth tests varied from 20 to73 MN/m^/2 (l8 to 66 ksi-in1/2). The stress ratio used was approximately zero(R = 0.05), and the test temperature was room temperature.
Fatigue-crack growth in the 50.8-mm (2.0-in.) wide specimens was visually moni-tored. The number of cycles required to propagate the cracks to each scribe line wasrecorded. The crack growth rates were calculated from the slope of the plots of cracklength against number of cycles.
A calibrated COD gage mounted in the machined notch was used to monitor fatigue-crack growth in the 63.5-mm (2.5-in.) wide specimens. The load-displacement data wererecorded against the number of cycles. Analysis of these records gave crack growthrates in these specimens.
Sustained-load flaw-growth tests.- Constant-amplitude fatigue loadings with R ~ 0and AK 0-5Kje were applied to the test specimens until fatigue cracks of predeter-mined length were developed. (Final a/w values varied from 0.48 to 0.55.) Sustained-load flaw-growth tests at room temperature were then conducted in air, in distilled water,and in distilled water containing a rust inhibitor. The Kj values applied in these tests _ranged from 107 to 67 MN/m^' (97 to 61 ksi-in__- ),- and the maximum testing time wasgreater than-3600^ks~(1000lir)7
Different test procedures were used to load and wet the different width specimens.For the 50.8-mm (2.0-in.) wide specimens, load was applied by manually tightening themean-load spring on the testing machine (ref. 12) until the desired load was reached. (Acalibrated, load-readout system on the testing machine indicated the load.) However, thecompliance of the specimens tended to increase with crack growth and caused a relaxationin the load. Consequently, the load was periodically adjusted in order to keep the loadapproximately constant. During tests in aqueous environments, the 50.8-mm (2.0-in.)wide specimens were immersed by flowing the desired liquid into a plastic shroud tapedaround the test section.
For the 91.4-mm (3.6-in.) wide specimens, load was applied by manually tighteningthe loading bolts (fig. 5) until the desired load was reached. (A calibrated COD gage
8
mounted in the machined notch was used as a load indicator.) No crack growth occurredin these tests; consequently, there was no need to adjust loadings during the tests. Duringtests in aqueous environments, the entire 91.4-mm (3.6-in.) wide specimen was sub-merged in a bath filled with the desired liquid.
Charpy impact and drop-weight tests.- The Charpy impact and drop-weight speci-mens were tested in accordance with the procedures specified in references 8 and 9,respectively.
RESULTS AND DISCUSSION
Fracture-Toughness Experiments
Table II presents the results of the fracture-toughness experiments on all threesteels. This table gives the specimen thickness t, the specimen width w, the testtemperature T, the crack length at the start of the fracture-toughness test a^, the maxi-mum load-applied to the specimen during the fracture-toughness test Pj, and the elasticfracture toughness Kjg. Equations (Cl) to (C4) in appendix C were used to calculate theKje values. Figures 8, 9, and 10 show the variation of Kje with temperature for theVMS 5002, VMS 1146A, and A-225 Gr.B specimens, respectively.- These figures indicatethat, for all three steels, Kje does not decrease significantly with decreasing tempera-ture from room temperature to about 244 K (-20° F). However, the larger specimenthicknesses and specimen widths tended to produce larger Kje values for the threesteels.
Newman's elastic-plastic failure analysis (refs. 13 and 14) was also used to analyzethe fracture-toughness data. Equation (C5), appendix C, is the pertinent relationship forthis analysis. The material fracture-toughness parameters Kp and m in equation (C5)were determined with a best-fit procedure described in reference 13. Figures 11, 12,and 13 show the variation of Kje with specimen width for the 25.4- and 45.7-mm (1.0-and 1.8-in.) thick specimens. These figures show that Kje is larger for~larger speci-men-widths^as'predicted by Newman's analysis (solid curve). Figures 11 to 13 do notinclude the data for the 83.8- and 109.2-mm (3.3- and 4.3-in.) thick specimens. Thesedata are excluded because, as appendix C explains, Kp and m vary with thickness.Consequently, the values of KF and m shown in these figures do not apply for thethicker specimens. The thickness difference between the 25.4- and 45.7-mm (1.0- and1.8-in.) thick specimens is considered insignificant as far as Kp and m are concerned.
Figure 14 shows the variation of Kje with a/w for the 25.4-mm (1.0-in.) thickVMS 5002 specimens. The larger values of a/w produce smaller Kje values.Newman's analysis accounted for this trend.
Fatigue-Crack-Growth Experiments
Table in presents the results of the fatigue-crack-growth experiments on all threesteels. This table gives the stress-intensity-factor range AK and the correspondingfatigue-crack-growth rate da/dN. The stress-intensity-factor range was calculatedfrom equations (C7) to (C9) in appendix C.
Figures 15, 16, and 17 show the variations of da/dN with AK for the steelsVMS 5002, VMS 1146A, and A-225 Gr.B, respectively. The data from the different labora-tories fell into relatively narrow scatter bands. These figures also show a plot ofBarsom's equation (ref. 15). This equation has the form
^| = (6.92 x 10-3)(AK)3 (1)
where the coefficient 6.92 x 10~3 is for SI Units. (The coefficient for U.S. CustomaryUnits is 3.6 x 10" .j Barsom showed that this equation fit the upper boundary of theda/dN data generated in tests on a large number of ferrite-pearlite steels. This equationfits the upper boundary of the VMS 5002 and A-225 Gr.B data very well (figs. 15 and 17).The equation fell somewhat below the upper boundary of the VMS 1146A data (fig. 16).However, this underestimation was not large. Thus, the present data further verifyBarsom's equation as a useful tool for predicting an upper boundary on crack growth ratesin ferrite-pear lite steels.
Sustained-Load Flaw-Growth Experiments
Table IV presents the results of the sustained-load flaw-growth experiments on thethree steels. This table gives the test fluid, specimen width w, crack length at the startof the sustained-load flaw-growth test ag^, the maximum load applied to the specimenPmax, the stress-intensity factor applied at the start of the tests K^, the test duration,and whether failure occurred or not. The stress-intensity factors were calculated fromequations (C8) and (CIO) in appendix C.
Figures 18, 19, and 20 show a plot of KJJ against test duration. Arrows on thesymbols indicate test specimens which did not fail. No failures occurred in eitherVMS 5002 or VMS 1146A. The highest K^ value applied for these two materials was107 MN/m3/2 (97 ksi-in1/2) for VMS 5002 and 79 MN/m3/2 (?2 ksi-in1/2) for VMS 1146A.Failures did occur in A-225 Gr.B, but only at Kji values greater than 78 MN/m3/2
(71 ksi-in1/2]. Figures 18, 19, and 20 also indicate that distilled water had no adverseeffect on sustained-load flaw growth.
10
Charpy Impact Experiments
Table V presents the results of the Charpy impact experiments on all three steels.This table gives the test temperature t, the energy absorbed during each test CyN, andthe lateral expansion on the.compression side of each specimen le.
Figures 21, 22, and 23 show the variation of Cyj^ with temperature. For all threesteels, Cyjr values were smaller at lower temperatures in the nominal temperaturerange from room temperature to 244 K (-20° F).
The difference in the temperature effect for the fracture-toughness experiments(Kje = Constant) and the Charpy impact experiments (CyN proportional to temperature!over the same temperature range is probably due to the difference in loading rates for thetwo types of experiments. If the loading rates are sufficiently low, significant plasticdeformation can occur at a crack or notch root before a specimen fails. In the fracture-toughness experiments with relatively low loading rates, this plastic deformationapparently enabled the steels to maintain their room temperature toughness at lowertemperatures. In the Charpy impact experiments with very high loading rates, there wasapparently insufficient time for significant plastic deformation, and, consequently, notchsensitivity increased with decreasing temperature.
Drop-Weight Experiments
Table VI presents the results of the drop-weight tests on VMS 5002 and A-225 Gr.Bsteels. This table gives the test temperature T, whether the test specimens broke or not,and the nil-ductility temperatures for the two steels. The nil-ductility temperature is themaximum temperature at which a standard drop-weight specimen breaks when testedaccording to prescribed methods (ref. 9). Table VI indicates that the nil-ductility temper-atures of VMS 5002 and A-225 Gr.B are 250 K (-10° F) and 241 K (-25° F), respectively.A lack of material precluded drop-weight testing the VMS 1146A.
SUMMARY OF RESULTS
Tests to determine fracture toughness,, fatigue-crack growth, sustained-load flawgrowth, and impact properties were conducted on three pressure vessel steels: A. O.Smith VMS 5002 and VMS 1146A, and ASTM A-225 Gr.B. The results of these tests aresummarized as follows:
1. The elastic fracture toughness of the three steels does not decrease significantlywith decreasing temperature.from room temperature to about 244 K (-20° F).
11
2. The elastic fracture toughness of the three steels increases with increasingspecimen width. Newman's elastic-plastic failure analysis (Engineering FractureMechanics, Sept. 1973) accurately predicts this increase.
3. For all three steels, the data for fatigue-crack-growth rate fall into relativelynarrow scatter bands on plots of rate against stress-intensity-factor range.
4. Barsom's equation (Transactions ASME, Journal of Engineering for Industry,Nov. 1971) predicts the upper boundary of the VMS 5002 and A-225 Gr.B fatigue-crackgrowth-rate data very well. However, the equation slightly underestimated the upperboundary of the VMS 1146A data.
5. The VMS 5002 and VMS 1146A specimens did not fail at stress-intensity factorsof 107 and 79 MN/m3/2 (97 and 72 ksi-in1/2), respectively, in sustained-load flaw-growthtests. Some A-225 Gr.B specimens did fail at a stress-intensity factor of 79 MN/m3/2
(72 ksi-inx/2).
6. For all-three steels, Charpy impact energies are smaller at lower temperatures,in the nominal temperature range from room temperature to 244 K (-20° F).
. 7. In standard drop-weight tests, VMS 5002 and A-225 Gr.B exhibit nil-ductilitytemperatures of 250 K (-10° F) and 241 K (-25° F), respectively.
Langley Research CenterNational Aeronautics and Space AdministrationHampton, Va. 23665November 17, 1975
12
APPENDIX A
CONVERSION OF SI UNITS TO U.S. CUSTOMARY UNITS
The International System of Units (SI) was adopted by the Eleventh GeneralConference on Weights and Measures held in Paris in 1960 (ref. 3). Conversion factorsrequired for units used herein are given in the following table:
Physical quantity
ForceLength
StressStress intensityFrequency iTemperature
SI Unit
(a)
newtons (N)meters (m)
pascals (Pa)newtons per meter3/2 (N/m3/2)hertz (Hz)kelvins (K)
Conversionfactor
(b)
0.22480.3937 x IO2
0.145 x 10'6
0.9099 x IO-6
60|K - 459.7
U.S. CustomaryUnit
Ibf
in.ksi = IO3 lbf/in2
ksi-in1/2
cpm. OF
aPrefixes and symbols to indicate multiples of units are as follows:
Multiple
10-9io-6
10~3
IO3
IO6
IO9
Prefix
nano
micromillikilo
megagiga
Symbol
n
MmkMG
"Multiply value given in SI Unit by conversion factor to obtain equivalent in U.S.Customary Unit, or apply the conversion formula.
13
APPENDIX B
DESCRIPTION OF THE 445- AND 4448-kN (100 000- AND 1 000 000-lbf)
TESTING MACHINES
The 445- and 4448-kN (100 000- and 1 000 000-lbf) testing machines are analogclosed-loop servocontrolled hydraulic testing systems. (Fig. 24 shows a schematic dia-gram of these testing systems.) These systems may be used for either fracture-toughnessor fatigue testing.
To use these systems for fracture-toughness testing, the operator sets the functiongenerator to the ramp position and to the desired loading rate. The operator then initiatesloading by pushing the load button on the function generator. The loading increases mono-tonically until the specimen fractures.
To use the systems for fatigue testing, the operator first applies the desired meanload by adjusting the mean-load potentiometer. He then (a) sets the function generator tothe desired waveform (e.g., sine, square, or sawtooth) and to the desired loading fre-quency, and (b) sets the alternating-load potentiometer to the desired alternating loadlevel. The operator initiates loading by pushing the run button on the function generator.The loading cycles about the mean load symmetrically until either the specimen fails orthe loading is stopped.
In operation, the conditioned-command signal is fed into the servoloop summingpoint. The voltage from either the load cell transducer or the LVDT transducer is alsofed into this summing point. The command and transducer voltages are summed, andsuitably amplified, to form a,signal which drives the servovalve. This servovalve directsoil to the appropriate side of the hydraulic cylinder to obtain the commanded load.
During fracture-toughness tests, loads are monitored and recorded on a calibratedoscillograph in order to determine the load at failure.
During fatigue tests, loads are monitored by comparing, on an oscilloscope, theoutput voltage from the load cell (or LVDT) with an adjustable bias voltage which corre-sponds to the desired load level for the test. When the sum of these voltages is zero, thedesired load is on the test specimen. This comparison is made at both the maximum andthe minimum loads in the cycle.
14
APPENDIX C
METHODS OF ANALYSES
Fracture Toughness
The fracture-toughness data were analyzed using both linear-elastic fracturemechanics (ref. 16) and an elastic-plastic failure analysis (refs. 13 and 14). The followingrelationships were used for the linear-elastic fracture mechanics analysis. For the50.8- and 91.4-mm (2.0- and 3.6-in.) wide specimens, the elastic fracture toughness(elastic stress-intensity factor at failure) is given by
P.
where from reference 7 (in the present notation)
2|) . 4.55 - 40.32® + 414.7(|) - 1698(|)
+ 3781(|)4 - 4287(|)5 + 2017(i)6 <C2>
for a/w values from 0.2 to 0.8. .
For the 71.1-mm (2.8-in.) wide specimens, the elastic fracture toughness isgiven by
P,KT = TzWl) ' ' <C3>fc"VA
Boundary-collocation analysis (ref. 7) indicates that for the a/w ratio of 0.55 used inthis investigation,
f2(|) = 12.59 . (C4)
Subsequent finite-element stress analysis confirmed the boundary-collocation results.
In equations (Cl) to (C4), Pf is the maximum load applied to a specimen during a
fracture-toughness test, t is the specimen thickness, a is the crack length, and w isthe specimen width.
15
APPENDIX C
The following relationship was used for the elastic-plastic failure analysis (ref. 13):
Kle (Sn < Su) (C5)
where Kp and m are two material fracture-toughness parameters, Kje is the elasticfracture toughness (elastic stress-intensity factor at failure), and Sn is the elastic nomi-nal failure stress. The stress Su is computed from the load required to produce a fullyplastic region, or hinge, on the net section (based on the ultimate tensile strength cruj.For the compact specimen, Su is a function of load eccentricity (ref. 14) and is 1.62au
for a/w = 0.5.
The parameters KF and m are assumed to be constant in the same sense as theultimate tensile strength; that is, the parameters may vary with material thickness, stateof stress, temperature, and rate of loading. To obtain fracture constants that are repre-sentative for a given material and test temperature, the fracture data should be from asingle batch of material of the same thickness and from tests that encompass a wide rangeof specimen widths or crack lengths.
Fatigue-Crack Growth
The fatigue-crack-growth data were analyzed using procedures based on the stress-intensity factor. Numerous investigators (e.g., refs. 15 and 17) have demonstrated thatthe rate of fatigue-crack growth is a function of the stress-intensity range; that is,
where
AK = Kmax - Kmin (C7)
for the specimen configurations used,
f~Pmax\,. /a
"^ " W1/2'
and
where equation (C2) gives fj(—\.
16
APPENDIX C
Sustained- Load Flaw Growth
Stress-intensity analysis procedures were also used to analyze sustained-load flaw-growth data. For the 50.8-mm (2. 0-in.) wide specimens, KJi is given by equation (C8).For the 91.4-mm (3.6-in.) wide specimens, KIi is given by
(r-in\(C10)
where figure 7 in reference 18 gives (in the present notation) f^f—J.
17
REFERENCES
1. Damage Tolerant Design Handbook. HB-01, MCIC, Battelle Columbus Lab., Sept. 1973.
2. Ferrous. Part A of Section n-Material Specifications, ASME Boiler and PressureVessel Code, July 1, 1974.
3. Metric Practice Guide. E 380-72, American Soc. Testing Mater., June 1972.
4. Standard Specification for Pressure Vessel Plates, Alloy Steel, Manganese-Vanadium.ASTM Designation: A 225-72. Part 4 of 1974 Annual Book of ASTM Standards,1974, pp. 140-141. . .r ,
5. Standard Methods of Tension Testing of Metallic Materials. ASTM Designation: E 8-69.Part 10 of 1974 Annual Book of ASTM Standards, 1974, pp. 90-110.
6. Standard Method of Test for Plane-Strain Fracture Toughness of Metallic Materials.ASTM Designation: E 399-74. Part 10 of 1974 Annual Book of ASTM Standards,1974, pp. 432-451.
7. Newman, J. C., Jr.: Stress Analysis of the Compact Specimen Including the Effects ofPin Loading. Fracture Analysis, Spec. Tech. Publ. 560, American Soc. TestingMater., 1974, pp. 105-121.
8. Standard Methods for Notched Bar Impact Testing of Metallic Materials. ASTMDesignation: E 23-72. Part 10 of 1974 Annual Book of ASTM Standards, 1974,pp. 167-183.
9. Standard Method for Conducting Drop-Weight Test To Determine Nil-Ductility Transi-tion Temperature of Ferritic Steels. ASTM Designation: E 208-69. Part 10 of1974 Annual Book of ASTM Standards, 1974, pp. 302-321.
10. Imig, L. A.: Effect of Initial Loads and of Moderately Elevated Temperature on theRoom-Temperature Fatigue Life of Ti-8Al-lMo-lV Titanium-Alloy Sheet. NASATND-4061, 1967.
11. Hudson, C. Michael: The Fatigue-Crack Growth and Fracture Characteristics of aPrecipitation-Hardened Semiaustenitic Stainless Steel. M. S. Thesis, VirginiaPolytech. Inst. & State Univ., Apr. 1965.
12. Grover, H. J.; Hyler, W. S.; Kuhn, Paul; Landers, Charles B.; and Howell, F. M.:Axial-Load Fatigue Properties of 24S-T and 75S-T Aluminum Alloy as Determinedin Several Laboratories. NACA Rep. 1190, 1954. (Supersedes NACA TN 2928.)
13. Newman, J. C., Jr.: Fracture Analysis of Surface- and Through-Cracked Sheets andPlates. Eng. Fract. Mech., vol. 5, no. 3, Sept. 1973, pp. 667-689.
18
14. Newman, J. C., Jr.: Plane-Stress Fracture of Compact and Notch-Bend Specimens.NASA TM X-71926, 1974.
15. Barsom, J. M.: Fatigue-Crack Propagation in Steels of Various Yield Strengths.Trans. ASME, Ser. B: J. Eng. Ind., vol. 93, no. 4, Nov. 1971, pp. 1190-1196.
16. Fracture Toughness Testing and Its Applications. Spec. Tech. Publ. No. 381,American Soc. Testing Mater., Apr. 1965.
17. Paris, Paul C.: The Fracture Mechanics Approach to Fatigue. Fatigue - An Inter-disciplinary Approach, John J. Burke, Norman L. Reed, and Volker Weiss, eds.,Syracuse Univ. Press, 1964, pp. 107-132.
18. Wessel, E. T.: State of the Art of the WOL Specimen KIc Fracture Toughness Testing.Eng. Fract. Mech., vol. 1, no. 1, June 1968, pp. 77-103.
19
TABLE I.- TENSILE AND CHEMICAL PROPERTIES OF THE THREE STEELS TESTED
(a) Tensile
Steel
VMS 5002VMS 1146 AA-225 Gr.B
CTu
MPa
675698566
ksi
97.9101.382.1
ayMPa
507517403
ksi
73.575.058.4
e,percent
2831
34
(b) Chemical'
Steel
VMS 5002VMS 1146 AA-225 Gr.B
C
0.23.21.15
Mn
1.451.311.27
P
0.015.014.013
S
0.023.024.026
Si
0.30.28.27
V
0.15.15.12 .
Ni
0.59.55
—
Fe
Bal.Bal.Bal.
aValues are in percent.
20
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'toi
CM
C»3
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to
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CM
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c n m y f i n o c M C M m c o c - i n c n c ot - H O i O C D C M ^ f ^ ^ ^ C M C O t - C D ^
T - H - ^ - ^ ^ C M C O C O O i ' - l i - l ' C M C D C OC O O . - l O C o m < M l « T t < m c n c O C O
u i o c o o ^ r - e o . o o c s r j ' i n i n o• * ^ m o j i n i M ( M C O C O O C D C T i ^ 'CM *-t •-! ^ J H m ' T T U O ^ m C D O ^ C O
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O C M C O O ' - f ^ C D m t - C O a i c O C OO « O « D M « . O C O C O C O i - l o a N ' a ' C -i - l C M C M i - H C M e M C M ^ ^ C O
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21
TABLE III.- FATIGUE-CRAGK-GROWTH DATA
AK
MN/m3/2 - ksi-in1/2
da/dN
run/cycle in/cycle
VMS 5002
20.021.121.421.922.622.923.724.2-24.524.724.8
. 25.526.026.326.527.027.628.028.128.829.529.829.930.130.230.931.231.432.032.232.332.5"33:233.434.2
^34"; 3."'; ,.'34.6
: 34.6 ":'35.7 : -.
18.219.219.519.920.620.821.622.022.322.522.623.223.723.924.124.625.125.5
'25.626.226.827.127.227.427.528.128.428.629.129.329.429.6' -
' 30.2' '. 30.4
31.1. 3:1.2; •::
31.53i.5~
•: 32.5- •-.
45.730.538.130.563.5
. 35.625.473.786.450.843.2
111.840.658.473.799.166.0
142.268.6
127.091.4
147.3111.861.0
221.061.0
157.5119.4185.4205.7127.0
' 190.5304.8101.6 .144.8304.8 !381.0 ;
'254.0 ••• .78.7 -
1.8 x 10-6
1.2 x 10"6
1.5 x ID'6
1.2 x lO'6
2.5 x 10-6
1.4 x 10-6
1.0 x 10'6
2.9 xlO'6
3.4 x 10'6
2.0 x lO'6
1.7 x 10~6
4.4 x 10'6
1.6 x 10~6
2.3 x ID"6
2.9 x lO'6
3.9 x 10'6
2.6 xlO-6
5.6 x 10-6
2.7 x 10"6
5.0 xlO'6
3.6 xlO'6
5.8 x lO"6
4.4 x lO'6
2.4 x 10'6
8.7 x 10"6
2.4 x l6~6
6.2 x 10'6
4.7 x 10-6
7.3 x 10-6
8.1 xlO'6
5.0 x 10~6
7.5 x 10~6
1.2 xlO-5
4.0 x 10'6
5.7 x 10'6
' O x 1Q-5
l .SxlO'5
1.0 x 10"5
3.1. xlO-6
4K
MN/m3/2 ksi-in1/2
da/dN
nm/cycle in/cycle
VMS 5002
35.936.336.436.536.537.037.438.639.639.840.141.842.943.043;744.346.347.747.848.950.051.852.255.456.156.457.158.2
'..59.160.262.663.464.6 "66.568.5•68:7 _:
70.1" 72.8
32.733.033.133.233.233.734.035.136.036.1.36.538.039.039.139.840.342.143.443.544.545.547.147.550.451.051.3
. 52.053.053.854.857.0
;. 57.7 .-.-58.860.562.3
. 62.563.866.2
165.1279.4685.8152.4
78.7111.8381.068.6
228.6180.3142.2406.4431.8609.6228.6233.7584.2203.2
• 609.6787.4711.2939.8889.0965. 2584.2609.6889.0
1219.21320.8838.2
1270.01371.6
711.21117.6990.6
1981.22082.82794.0
6.5 x 10~6
1.1 x 10-5
2.7 x 10'5
6.0 x 10~6
3.1 x 10~6
4.4 x 10-6
1.5 x 10-5
2.7 x 10-6
9.0 x 10-6
7.1 x 10-6
5.6 x 10-6
1.6 x 10~5
1.7 x 10-5
2.4 x 10~5
9.0 x 10~6
9.2 x 10~6
2.3 x 10-5
8.0 x 10-6
2.4 x lO-5
3.1 x 10"5
2.8 x lO'5
3.7 x 10-.5
3.5 x lO-5
3.8 x 10~5
2.3 x 10-5
2.4 x lO-5
3.5 x 10'5
4.8 x 10~5
5.2 x 10~5
3.3 x 10-5
5.0 x l(T5
5.4 x 10~5
2.8 x lO'5
4.4 x 10'5
3.9 x 10~5
7.8 x 10"5
8.2 x 10"5
1.1 x 10-4
22
TABLE III.- Continued
4K
MN/m3/2 ksi-in1/2
da/dN
nm/cycle in/cycle
VMS 1146A
30.232.332.334.134.636.336.838.439.039.040.441.441.841.842.644.544.544.7
47.847.848.051.951.952.557.664.5
27.529.429.431.031.533.033.534.9
35.535.536.837.7
38.038.038.840.540.540.7
43. b43.543.747.247.247.852.458.7
254.0304.8330.2381.0406.4508.0482.6147.3
482.6609.6457.2210.8457.2558.8144.8482.6914.4279.4
1016.01219.2381.0965.2
1117.6457.2482.6787.4
1.0 x lO'5
.1.2 x 10'5
1.3 x ID"5
1.5 x 10'5
1.6 x 10"5
2.0 x 10'5
1.9 x 10~5
5.8 x 10'6
1.9 x 10~5
2.4 x 10-5
1.8 x 10"5
8.3 x lO'6
1.8 x 10"5
2.2 x 10'5
5 .7x lO- 6
1.9 x 10"5
3.6 x 10'5
l . lx lO ' 5 .4.0 x 1Q-5
4.8 x 10'5 ,1.5x 1Q-5
3.8 x 10~5
4.4 x lO'5
1.8 x 10'5
1.9 x 10'5
3.1 x 10'5
23
TABLE III.- Concluded
AK
MN/m3/2 ksi-in1/^
da/dN
nm/cycle in/cycle
A-225 Gr.B
24.225.627.730.230.230.231.931.931.932.934.134.134.136.336.336.336.636.737.337.938.8
— ^38.838.838.939.740.340.7
22.023.325.227.527.527.529.029.029.029.931.031.031.033.033.033.033.333.433.934.5
- 35.335.335.335.436.136.737.0
30.550.8
109.2119.4121.9132.1111.8121.9172.791.4
180.3213.4279.4152.4165.1228.6119.4152.4233.7198.1254.0381.0431.8248.9254.0241.3165.1
1.2 x 10"6
2.0 x 10~6
4.3 x 10'6
4.7 x 10'6
4.8 x 10~6
5.2 x 10-6 v
4.4 x 1(T6
4.8 x 10'6
6.8 x 10'6
3.6 x 10~6
7.1 x 10~6
8.4 x 10~6
1.1 x 10-5
6.0 xlO' 6
6.5 xlO'6
9.0 x 10"6
4.7 x 10'6
6.0 x 10'6
9.2 x 10~6
7.8 x 10'6
-l,.0-x-10=£-1.5 x 10-5
1.7x 10'5
9.8 x lO'6
1.0 x 10'5
9.5 x 10'6
6.5 x 10'6
AK
MN/m3/2 ksi-in1/2
da/dN
nm/cycle in/cycle
A-225 Gr.B
41.541.541.542.042.943.944.044.544.544.546.047.847.847.847.949.852.252.252.252.65475 ~59.665.065.366.767.471.9
37.837.837.838.239.039.940.040.540.540.541.943.543.543.543.645.347.547.547.547.949.654.259.159.460.761.365.4
279.4482.6812.8279.4304.8132.1
-. 175.3213.4304.8381.0355.6218.4508.0635.0330.2355.6381.0406.4482.6
__155.S609.6660.4939.8
1701.8965.2609.6
1346.2
1.1 x 10'5
1.9 x 10~5
3.2 x 10"5
1.1 x lO"5
1.2 x lO"5
5.2 xlO-6
6.9 x 10'6
8.4 x 10'6
1.2 x 10~5
1.5 x lO'5
1.4 x 1Q-5
8.6 x 10-6
2.0 xlO'5
2.5 xlO'5
1.3 x 10'5
1.4 xlO'5
1.5 x 10"5
1.6 x 10"5
1.9 x 10"5
1,.4-x 10 ~5
2.4 x 10~5
2.6 xlO'5
3.7 x 1C'5
6.7 xlO'5
3.8 xlO-5
2.4 xlO'5
5.3 x 10~5
24
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25
TABLE V.- CHARPY IMPACT DATA
T
K . °F
CVN
N-m ft-lbf
'e
mm in.
-VMS 5002
311297283283266255244239227227
100755050200
-20-30-50-50
7288
6134462234142420
53654525341625101815
0.711.12.79..41.56.28.41.08.28.23
0.028.044.031.016.022.011.016.003.011.009
VMS 1146 A
339311297266255244239233227197
15010075200
-20-30-40-50-105
13212210768475618244214
9790795035
4113183110
1.171.14.97 ..86;.53.69.20.33.56.18
0.046.045.038.034.021.027.008.013.022.007
A-225 Gr.B
366311297266255244239233227
20010075200
-20-30-40-50
47525637342727
3.127
353841272520202320
0.79.94.84.64.69.38.43.46.43
0.031.037.033.025.027.015.017.018.017 '
26
TABLE VI.- DROP-WEIGHT DATA
T
K 0FTest results-
NDT
K OF
VMS 5002
255255255250250244241227
000
-10
-10-20-25-50
Specimen survivedSpecimen survivedSpecimen survivedSpecimen survivedSpecimen failedSpecimen failedSpecimen failedSpecimen failed
250
A-225 Gr.B
255247247241
236227
0-15-15-25
-35-50
Specimen survived
Specimen survivedSpecimen survivedSpecimen failedSpecimen failedSpecimen failed
241
-10
-25
27
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Temperature, K
Figure 8.- Variation of KIe with temperature for VMS 5002 steel.
38
200.-
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100
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OO
OO
t = 25 .4mm,w = 50.8mm
O t = 25 .4mm, w = 9 l .4mm
220 260 300
Temperature, K
Figure 9.- Variation of KIe with temperature for VMS 1146A steel.
39
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0220
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= 83.8mm
260 300
Temperature, K
Figure 10.- Variation of KIe with temperature for A-225 Gr.B steel.
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Figure 15.- Variation of da/dN with AK for VMS 5002. R * 0.
45
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Figure 16.-Variation of da/dN with AK for VMS 1146A. R « 0.
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Figure 21.- Variation of CyN with temperature for VMS 5002.
51
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200 300 400
Temperature, K
Figure 22.- Variation of Cy^ with temperature for VMS 1146A.
52
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Figure 23.- Variation of CyN with temperature for A-225 Gr.B.
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54 NASA-Langley, 1975 L-10447
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION
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