Master of Science / Department of Mechanical and Nuclear Engineering / Kevin Lease / Over the past several years the crack tip opening angle (CTOA) has been identified as one of the key fracture parameters to characterize low constraint stable tearing and instability in structural metallic alloys. This document presents the results of experimental stable tearing characterizations. Characterization methods include optical microscopy and marker band measurements of crack front tunneling. Specific attention is given to the measurement methods used, and also the correlation between CTOA and Delta-5. The effect of tunneling and comparisons with computational results are discussed, and the effect of material and measurement method on CTOA is observed and a clear relationship is seen. Preliminary work on future studies into internal features and behavior is also presented.

A computer-based parametric study of the effect of reinforcement architectures on fracture response of aluminum compact-tension (CT) specimens was performed using the finite element code ABAQUS. A three-dimensional crack propagation procedure based on the crack tip opening angle (CTOA) was developed using Python. Eleven different reinforcement architectures consisting of rectangular and triangular cross-section reinforcements were evaluated. Reinforced specimens produced between 13 and 28 percent higher fracture load than achieved with the non-reinforced case. Reinforcements with blunt leading edges (rectangular reinforcements) exhibited superior performance relative to the triangular reinforcements with sharp leading edges. Relative to the rectangular reinforcements, the most important architectural feature was reinforcement thickness. At failure, the reinforcements carried between 58 and 85 percent of the load applied to the specimen, suggesting that there is considerable load transfer between the base material and the reinforcement. The amount of load transfer is linked to strains experienced by the reinforcement ahead of the crack tip. / Master of Science

A two-parameter fracture criterion (TPFC) is used to correlate and predict failure loads on cracked configurations made of ductile materials. The current study was conducted to validate the use of the fracture criterion on more brittle materials, using elastic-plastic finite-element analyses with the critical crack-tip-opening angle (CTOA) failure criterion. Forman generated fracture data on middle-crack tension, M(T), specimens made of thin-sheet 7075-T6 aluminum alloy, which is a quasi-brittle material. The fracture data included a wide range of specimen widths (2w) ranging from 3 to 24 inches. A two-dimensional (2D) finite-element analysis code (ZIP2D) with a ''plane-strain core" option was used to model the fracture process. Fracture simulations were conducted on M(T), single-edge-crack tension, SE(T), and single-edge-crack bend, SE(B), specimens. The results supported the TPFC equation for net-section stresses less than the material proportional limit. However, some discrepancies were observed among the numerical results of the three specimen types. Thus, more research is needed to improve the transferability of the TPFC from the M(T) specimen to both the SE(T) and SE(B) specimens.

The Two-Parameter-Fracture-Criterion (TPFC) was validated using an elastic-plastic two-dimensional (2D) finite-element code, ZIP2D, with the plane-strain-core concept. Fracture simulations were performed on three crack configurations: (1) middle-crack-tension, M(T), (2) single-edge-crack-tension, SE(T), and (3) single-edge crack-bend, SE(B), specimens. They were made of 2014-T6 (TL) aluminum alloy. Fracture test data from Thomas Orange work (NASA) were only available on M(T) specimens (one-half width, w = 1.5 to 6 in.) and they were all tested at cryogenic (-320oF) temperature. All crack configurations were analysed over a very wide range of widths (w = 0.75 to 24 in.) and crack-length-to-width ratios ranged from 0.2 to 0.8. The TPFC was shown to fit the simulated fracture data fairly well (within 6.5%) for all crack configurations for net-section stresses less than the material proportional limit. For M(T) specimens, a simple approximation was shown to work well for net-section stresses greater than the proportional limit. Further study is needed for net-section stresses greater than the proportional limit for the SE(T) and SE(B) specimens.