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Metals
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Fracture, Fatigue and Structural Integrity of Metallic Materials
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Fracture, Fatigue and Structural Integrity of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 April 2019) | Viewed by 50289

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Prof. Dr. Sergio Cicero

E-Mail Website1 Website2
Guest Editor
Laboratory of Materials Science and Engineering (LADICIM), University of Cantabria, 39005 Santander, Spain
Interests: fracture; fatigue; structural integrity; notch mechanics; failure analysis
Special Issues, Collections and Topics in MDPI journals
Prof. José Alberto Álvarez Laso

E-Mail Website
Guest Editor
Materials Science and Engineering Department, Universidad de Cantabria, Santander, Spain
Interests: fracture; fatigue; structural integrity; small punch testing; stress corrosion cracking
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Fracture, fatigue and other subcritical processes, such as creep crack growth or stress corrosion cracking, present numerous open issues from both scientific and industrial points of view. These phenomena are of special interest in industrial and civil metallic structures, such as pipes, vessels, machinery, aircrafts, ship hulls and bridges, given that their failure may imply catastrophic consequences for human life, the natural environment and/or the economy. Moreover, an adequate management of their operational life, defining suitable inspection periods, repairs or replacements, requires their safety or unsafety conditions to be defined.

The analysis of these technological challenges requires accurate comprehensive assessments tools based on solid theoretical foundations, as well as structural integrity assessment standards or procedures incorporating such tools into industrial practice.

This Special Issue is focused on new advances in fracture, fatigue, creep and corrosion analysis of metallic structural components containing defects (e.g., cracks, notches, metal loss, etc.), and also on those developments that are being or could be incorporated to structural integrity assessment procedures such as BS7910, R6 or API 579-1/ASME FFS-1.

We invite you to submit original research and review articles, as well as short communications, related to these topics.

Prof. Sergio Cicero
Prof. José Alberto Álvarez
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Fracture
  • fatigue
  • structural integrity
  • creep
  • stress corrosion cracking
  • cracks
  • notches

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Related Special Issue

Published Papers (13 papers)

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Editorial

Jump to: Research

3 pages, 179 KiB  
Editorial
Fracture, Fatigue, and Structural Integrity of Metallic Materials
by Sergio Cicero and José Alberto Álvarez
Metals 2019, 9(8), 913; https://doi.org/10.3390/met9080913 - 20 Aug 2019
Cited by 2 | Viewed by 2629
Abstract
Fracture, fatigue, and other subcritical processes, such as creep crack growth or stress corrosion cracking, present numerous open issues from both scientific and industrial points of view [...] Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)

Research

Jump to: Editorial

19 pages, 12600 KiB  
Article
A Proposal for the Application of Failure Assessment Diagrams to Subcritical Hydrogen Induced Cracking Propagation Processes
by Borja Arroyo Martínez, José Alberto Álvarez Laso, Federico Gutiérrez-Solana, Alberto Cayón Martínez, Yahoska Julieth Jirón Martínez and Ana Ruht Seco Aparicio
Metals 2019, 9(6), 670; https://doi.org/10.3390/met9060670 - 10 Jun 2019
Cited by 6 | Viewed by 3189
Abstract
In this work, an optimization proposal for a model based on the definition of regions for crack propagation by means of the micromechanical comparison by SEM images and its application to failure assessment diagrams (FADs) is presented. It consists in three approaches. (1) [...] Read more.
In this work, an optimization proposal for a model based on the definition of regions for crack propagation by means of the micromechanical comparison by SEM images and its application to failure assessment diagrams (FADs) is presented. It consists in three approaches. (1) The definition of the crack propagation initiation in the elastic-plastic range. (2) A slight modification of the zones in which the FAD is divided for hydrogen induced cracking (HIC) conditions. (3) The introduction of a simple correction for the definition of the Kr coordinate of the FAD to take into account the fracture toughness reduction caused by an aggressive environment, instead of using a fracture parameter obtained from a test in air. For the experimental work, four medium and high strength steels exposed to a cathodic charge and cathodic protection environments were employed, studying two different loading rates in each case, and testing C(T) samples under slow rates in the environment. The study was completed with a subsequent fractographic analysis by SEM. A good degree of fulfilment was appreciated in both materials and environmental conditions, showing the validity of the predictions supplied by the FAD optimization model proposal, which constitutes an advance in the accuracy of the FAD predictive model. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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14 pages, 7865 KiB  
Article
Baking Effect on Desorption of Diffusible Hydrogen and Hydrogen Embrittlement on Hot-Stamped Boron Martensitic Steel
by Hye-Jin Kim, Hyeong-Kwon Park, Chang-Wook Lee, Byung-Gil Yoo and Hyun-Yeong Jung
Metals 2019, 9(6), 636; https://doi.org/10.3390/met9060636 - 1 Jun 2019
Cited by 12 | Viewed by 5144
Abstract
Recently, hot stamping technology has been increasingly used in automotive structural parts with ultrahigh strength to meet the standards of both high fuel efficiency and crashworthiness. However, one issue of concern regarding these martensitic steels, which are fabricated using a hot stamping procedure, [...] Read more.
Recently, hot stamping technology has been increasingly used in automotive structural parts with ultrahigh strength to meet the standards of both high fuel efficiency and crashworthiness. However, one issue of concern regarding these martensitic steels, which are fabricated using a hot stamping procedure, is that the steel is highly vulnerable to hydrogen delayed cracking caused by the diffusible hydrogen flow through the surface reaction of the coating in a furnace atmosphere. One way to make progress in understanding hydrogen delayed fractures is to elucidate an interaction for desorption with diffusible hydrogen behavior. The role of diffusible hydrogen on delayed fractures was studied for different baking times and temperatures in a range of automotive processes for hot-stamped martensitic steel with aluminum- and silicon-coated surfaces. It was clear that the release of diffusible hydrogen is effective at higher temperatures and longer times, making the steel less susceptible to hydrogen delayed fractures. Using thermal desorption spectroscopy, the phenomenon of the hydrogen delayed fracture was attributed to reversible hydrogen in microstructure sites with low trapping energy. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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10 pages, 1670 KiB  
Article
Finite Fracture Mechanics Assessment in Moderate and Large Scale Yielding Regimes
by Ali Reza Torabi, Filippo Berto and Alberto Sapora
Metals 2019, 9(5), 602; https://doi.org/10.3390/met9050602 - 24 May 2019
Cited by 12 | Viewed by 3335
Abstract
The coupled Finite Fracture Mechanics (FFM) criteria are applied to investigate the ductile failure initiation at blunt U-notched and V-notched plates under mode I loading conditions. The FFM approaches are based on the simultaneous fulfillment of the energy balance and a stress requirement, [...] Read more.
The coupled Finite Fracture Mechanics (FFM) criteria are applied to investigate the ductile failure initiation at blunt U-notched and V-notched plates under mode I loading conditions. The FFM approaches are based on the simultaneous fulfillment of the energy balance and a stress requirement, and they involve two material properties, namely the fracture toughness and the tensile strength. Whereas the former property is obtained directly from experiments, the latter is estimated through the Equivalent Material Concept (EMC). FFM results are presented in terms of the apparent generalized fracture toughness and compared with experimental data already published in the literature related to two different aluminium alloys, Al 7075-T6 and Al 6061-T6, respectively. It is shown that FFM predictions can be accurate even under moderate or large scale yielding regimes. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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11 pages, 4881 KiB  
Article
Fabrication and Fatigue Behavior of Aluminum Foam Sandwich Panel via Liquid Diffusion Welding Method
by Cheng Yao, Zhengfei Hu, Fan Mo and Yu Wang
Metals 2019, 9(5), 582; https://doi.org/10.3390/met9050582 - 20 May 2019
Cited by 16 | Viewed by 5071
Abstract
Aluminum Foam Sandwich panels were fabricated via liquid diffusion welding and glue adhesive methods. The Microstructure of the Aluminum Foam Sandwich joints were analyzed by Optical Microscopy, Scanning Electron Microscopy, and Energy Dispersive Spectroscopy. The metallurgical joints of Aluminum Foam Sandwich panels are [...] Read more.
Aluminum Foam Sandwich panels were fabricated via liquid diffusion welding and glue adhesive methods. The Microstructure of the Aluminum Foam Sandwich joints were analyzed by Optical Microscopy, Scanning Electron Microscopy, and Energy Dispersive Spectroscopy. The metallurgical joints of Aluminum Foam Sandwich panels are compact, uniform and the chemical compositions in the diffusion transitional zone are continuous, so well metallurgy bonding between Aluminum face sheet and foam core was obtained. The joining strength of an Aluminum Foam Sandwich was evaluated by standard peel strength test and the metallurgical joint Aluminum Foam Sandwich panels had a higher peel strength. Moreover, a three-point bending fatigue test was conducted to study the flexural fatigue behavior of Aluminum Foam Sandwich panels. The metallurgical joint panels have a higher fatigue limit than the adhesive joining sandwich. Their fatigue fracture mode are completely different, the failure mode of the metallurgical joint is faced fatigue; the failure mode for the adhesive joint is debonding. Therefore, the higher joining strength leads to a longer fatigue life. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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15 pages, 4476 KiB  
Article
Environmentally Assisted Cracking Behavior of S420 and X80 Steels Containing U-notches at Two Different Cathodic Polarization Levels: An Approach from the Theory of Critical Distances
by Pablo González, Sergio Cicero, Borja Arroyo and José Alberto Álvarez
Metals 2019, 9(5), 570; https://doi.org/10.3390/met9050570 - 16 May 2019
Cited by 4 | Viewed by 2648
Abstract
This paper analyzes, using the theory of critical distances, the environmentally assisted cracking behavior of two steels (S420 and API X80) subjected to two different aggressive environments. The propagation threshold for environmentally assisted cracking (i.e., the stress intensity factor above which crack propagation [...] Read more.
This paper analyzes, using the theory of critical distances, the environmentally assisted cracking behavior of two steels (S420 and API X80) subjected to two different aggressive environments. The propagation threshold for environmentally assisted cracking (i.e., the stress intensity factor above which crack propagation initiates) in cracked and notched specimens (KIEAC and KNIEAC) has been experimentally obtained under different environmental conditions. Cathodic polarization has been employed to generate the aggressive environments, at 1 and 5 mA/cm2, causing hydrogen embrittlement on the steels. The point method and the line method, both belonging to the theory of critical distances, have been applied to verify their capacity to predict the initiation of crack propagation. The results demonstrate the capacity of the theory of critical distances to predict the crack propagation onset under the different combinations of material and aggressive environments. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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9 pages, 8084 KiB  
Communication
Feasibility Study on Application of Synchrotron Radiation μCT Imaging to Alloy Steel for Non-Destructive Inspection of Inclusions
by Yoshinobu Shimamura, Shinya Matsushita, Tomoyuki Fujii, Keiichiro Tohgo, Koichi Akita, Takahisa Shobu and Ayumi Shiro
Metals 2019, 9(5), 527; https://doi.org/10.3390/met9050527 - 8 May 2019
Cited by 6 | Viewed by 2871
Abstract
In order to examine the feasibility of applying synchrotron radiation μCT imaging to alloy steels for non-destructive inspection of inclusions for potential origins of internal fatigue damage in the very high cycle region, synchrotron radiation μCT imaging was utilized for repeated non-destructive observation [...] Read more.
In order to examine the feasibility of applying synchrotron radiation μCT imaging to alloy steels for non-destructive inspection of inclusions for potential origins of internal fatigue damage in the very high cycle region, synchrotron radiation μCT imaging was utilized for repeated non-destructive observation of Cr-Mo steel. An ultrasonic fatigue testing machine was used in aid of the repeated observation. As a result, it was found that the synchrotron radiation μCT imaging with 70 keV was useful for non-destructive observation of inclusions of more than 10 μm, one of which may be an internal fatigue origin. No identifiable damage was observed around every inclusion, and in the base metal, at least up to 70% of fatigue life was observed in the imaging volume. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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15 pages, 6506 KiB  
Article
Research on Fatigue Strength for Weld Structure Details of Deck with U-rib and Diaphragm in Orthotropic Steel Bridge Deck
by Yixin Chen, Pengmin Lv and Datao Li
Metals 2019, 9(5), 484; https://doi.org/10.3390/met9050484 - 26 Apr 2019
Cited by 14 | Viewed by 3546
Abstract
The orthotropic steel bridge deck weld structure would easily cause fatigue cracking under the repeated action of vehicle load. This paper took the steel box girder in a bridge as a research object, researched the mechanical properties of the steel plate and the [...] Read more.
The orthotropic steel bridge deck weld structure would easily cause fatigue cracking under the repeated action of vehicle load. This paper took the steel box girder in a bridge as a research object, researched the mechanical properties of the steel plate and the microstructure of the welded joint, then designed the fatigue specimens of the deck plate and did the fatigue test. The Δσ-N curves and stress amplitudes of the weld details of the deck plate with U-rib and diaphragm under different probabilities of survival were obtained. After extended the Δσ-N curves to the long life range, the fatigue damage calculation equation of the detail was proposed, and the cut-off limit under the 50% and 97.7% probability of survival were 81.50 MPa and 53.11 MPa, respectively. Based on the actual vehicle load spectrum and simplified finite element model of the steel box girder section, the stress amplitude of the details of the weld joint was calculated. The calculation result shows that the maximum stress amplitude of the concerned point was 38.29 MPa, less than the cut-off limit. It means that the fatigue strength of the details of the weld joint meet the requirement of the fatigue design. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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16 pages, 1627 KiB  
Article
Effect of Repetitive Collar Replacement on the Residual Strength and Fatigue Life of Retained Hi-Lok Fastener Pins
by David F. Hardy and David L. DuQuesnay
Metals 2019, 9(4), 445; https://doi.org/10.3390/met9040445 - 16 Apr 2019
Cited by 2 | Viewed by 5300
Abstract
Hi-Lok fasteners were subjected to multiple collar replacements, and were tested under static loading and constant-amplitude fatigue loading, to determine the effect of repetitive collar replacement on the residual strength and fatigue life of a retained Hi-Lok-type fastener pin. Hi-Lok-type fasteners are typically [...] Read more.
Hi-Lok fasteners were subjected to multiple collar replacements, and were tested under static loading and constant-amplitude fatigue loading, to determine the effect of repetitive collar replacement on the residual strength and fatigue life of a retained Hi-Lok-type fastener pin. Hi-Lok-type fasteners are typically used in aircraft structural joints, and are loaded mainly in shear. Tests were conducted for clamping force, static shear strength, static tensile strength, and shear fatigue life for collars subjected to five collar replacements. The static shear results showed no decrease in the ultimate shear strength of the fastener pin as a function of collar replacement. Static tensile results showed no decrease in the ultimate tensile strength of the fastener as a function of collar replacement, with failure of the aluminum collar remaining the critical failure mode. Similarly, shear fatigue results showed no decrease in the shear fatigue life of the fastened joint as a result of collar replacement, with fracture of the aluminum substrate remaining the critical failure mode. For static shear, static tension, and shear fatigue tests, estimated clamping force was highly consistent between specimens and no decrease in clamping force was observed as a function of collar replacement. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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11 pages, 4294 KiB  
Article
Fatigue Life Prediction of Steam Generator Tubes by Tube Specimens with Circular Holes
by Qiwei Wang, Junfeng Chen, Xiao Chen, Zengliang Gao and Yuebing Li
Metals 2019, 9(3), 322; https://doi.org/10.3390/met9030322 - 12 Mar 2019
Cited by 9 | Viewed by 4047
Abstract
Heat exchangers manufactured from Inconel 690 tubes are widely used for steam generators in nuclear power plants. Inconel 690 tubes have suffered failures of fatigue fracture due to flow induced vibration. It is difficult to obtain the fatigue life of the tube directly [...] Read more.
Heat exchangers manufactured from Inconel 690 tubes are widely used for steam generators in nuclear power plants. Inconel 690 tubes have suffered failures of fatigue fracture due to flow induced vibration. It is difficult to obtain the fatigue life of the tube directly since the conventional fatigue test would potentially cause end fatigue failure due to the stress concentration at the clamp end. In this study, a thin-walled Inconel 690 tube with circular hole is designed to deduce the fatigue life of smooth tube based on the notch fatigue life prediction technology. Firstly, the local stress and strain distributions around the hole based on the finite element analysis are discussed. Local stress-strain is calculated and compared with Neuber’s ruler. Meanwhile, fatigue life tests using tube specimens with circular holes are carried out. Finally, based on the best-fitted fatigue life curve of Inconel 690 alloy, the fatigue life of tube specimen is estimated from the local strain according to Neuber’s ruler. The results show that the local stress and strain estimated by Neuber’s ruler are basically consistent with those obtained by finite element analysis. Compared with the average fatigue life of nickel-based alloy, the new predicted equivalent fatigue life of heat Inconel 690 transfer tube with a hole is higher. The Inconel 690 heat transfer tube has better fatigue performance. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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13 pages, 5081 KiB  
Article
Retardation of Fatigue Crack Growth in Rotating Bending Specimens with Semi-Elliptical Cracks
by Martin Leitner, David Simunek, Jürgen Maierhofer, Hans-Peter Gänser and Reinhard Pippan
Metals 2019, 9(2), 156; https://doi.org/10.3390/met9020156 - 1 Feb 2019
Cited by 6 | Viewed by 4339
Abstract
This work investigates overload-induced retardation effects for semi-elliptically cracked steel round bars. The specimen geometry equals the shaft area of a 1:3 down-scaled railway axle and the material is extracted from railway axle blanks made of EA4T steel. Rotating bending tests under constant [...] Read more.
This work investigates overload-induced retardation effects for semi-elliptically cracked steel round bars. The specimen geometry equals the shaft area of a 1:3 down-scaled railway axle and the material is extracted from railway axle blanks made of EA4T steel. Rotating bending tests under constant amplitude loading as well as overload tests considering overload ratios of ROL = 2.0 and ROL = 2.5 are conducted. The experimental results are compared to a crack growth assessment based on a modified NASGRO equation as well as the retardation model by Willenborg, Gallagher, and Hughes. The evaluated delay cycle number due to the overload by the experiments and the model shows a sound agreement validating the applicability of the presented approach. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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14 pages, 6214 KiB  
Article
Fatigue Limit Improvement and Rendering Defects Harmless by Needle Peening for High Tensile Steel Welded Joint
by Ryutaro Fueki, Koji Takahashi and Mitsuru Handa
Metals 2019, 9(2), 143; https://doi.org/10.3390/met9020143 - 28 Jan 2019
Cited by 23 | Viewed by 3862
Abstract
The effects of needle peening (NP) on the bending fatigue limit of a high tensile steel (HTS) HT780 (JIS-SHY685)-welded joint containing an artificial semicircular slit on the weld toe were investigated. Three-point bending fatigue tests were conducted at a stress ratio of R [...] Read more.
The effects of needle peening (NP) on the bending fatigue limit of a high tensile steel (HTS) HT780 (JIS-SHY685)-welded joint containing an artificial semicircular slit on the weld toe were investigated. Three-point bending fatigue tests were conducted at a stress ratio of R = 0.05 for NP-treated welded specimens with and without a slit. The fatigue limits of all specimens increased by 9–200% due to the NP treatment. Furthermore, NP-treated specimens with slit depths of a = 1.0 mm exhibited high fatigue limits that were equal to those of NP-treated specimens without a slit. Therefore, a semicircular slit of less than a = 1.0 mm could be rendered harmless through NP treatment. This result indicates that the reliability of HTS-welded joints can be significantly improved via NP for surface defects with depths that are less than 1 mm, which are not detected through non-destructive inspection (NDI). Therefore, the problem regarding the reliability of HTS-welded joints that restricts the industrial utilization of HTS can be solved by performing both NDI and NP. The dominant factor that contributed to the improvement of the fatigue limit and increase in the acceptable defect size was the introduction of large and deep compressive residual stress with non-propagating cracks. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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10 pages, 2110 KiB  
Article
Critical Distance Default Values for Structural Steels and a Simple Formulation to Estimate the Apparent Fracture Toughness in U-Notched Conditions
by Sergio Cicero, Juan Diego Fuentes, Isabela Procopio, Virginia Madrazo and Pablo González
Metals 2018, 8(11), 871; https://doi.org/10.3390/met8110871 - 24 Oct 2018
Cited by 8 | Viewed by 2889
Abstract
The structural integrity assessment of components containing notch-type defects has been the subject of extensive research in the last few decades. The assumption that notches behave as cracks is generally too conservative, making it necessary to develop assessment methodologies that consider the specific [...] Read more.
The structural integrity assessment of components containing notch-type defects has been the subject of extensive research in the last few decades. The assumption that notches behave as cracks is generally too conservative, making it necessary to develop assessment methodologies that consider the specific nature of notches, providing accurate safe predictions of failure loads or defect sizes. Among the different theories or models that have been developed to address this issue the Theory of Critical Distances (TCD) is one of the most widely applied and extended. This theory is actually a group of methodologies that have in common the use of the material toughness and a length parameter that depends on the material (the critical distance; L). This length parameter requires calibration in those situations where there is a certain non-linear behavior on the micro or the macro scale. This calibration process constitutes the main practical barrier for an extensive use of the TCD in structural steels. The main purpose of this paper is to provide, through a set of proposed default values, a simple methodology to accurately estimate both the critical distance of structural steels and the corresponding apparent fracture toughness predictions derived from the TCD. Full article
(This article belongs to the Special Issue Fracture, Fatigue and Structural Integrity of Metallic Materials)
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