[pt] Corrosão sob tensão (SCC), que consiste na iniciação e propagação de trincas devido ao efeito combinado de tensões mecânicas e o ambiente corrosivo, é um dano potencial para estruturas e componentes. Além do mais, SCC pode ser explicado por diferentes mecanismos dependendo do par material ambiente corrosivo considerado, o que dificulta o uso de um modelo geral para predizer o comportamento de trincas em SCC. Sendo assim, projetos frequentemente utilizam um critério conservativo que desqualifica materiais susceptíveis à SCC sem analisar de maneira apropriada a influência dos campos de tensão que a induzem. O objetivo deste trabalho é avaliar o efeito de tensões elastoplásticas na corrosão sob tensão. Esta abordagem mecânica considera que todos os efeitos corrosivos envolvidos na corrosão sob tensão podem ser apropriadamente quantificados pelas tradicionais resistências do material à iniciação e propagação de trincas para um ambiente corrosivo específico. Corpos de prova de flexão em Alumínio fragilizados por Gálio líquido serão utilizados para prever o efeito de tensões residuais induzidas por deformações plásticas na iniciação de trincas por corrosão sob tensão. Além disso, uma análise quantitativa baseada no comportamento de trincas não propagantes a partir de entalhes será usada para estimar a tensão necessária para iniciar e propagar trincas em corpos de prova entalhados em aço AISI 4140 sujeitos à corrosão por sulfeto de hidrogênio em ambiente aquoso. O comportamento de trincas curtas e a carga máxima suportada pelos corpos de prova entalhados são analisadas considerando campos de tensões lineares elástico e elastoplásticos através do modelo proposto que será validado através de dados experimentais. / [en] Stress Corrosion Cracking (SCC), which consist in the initiation and propagation of cracks due to the combined attack of mechanical stresses and a corrosive environment is a potential danger for structures and components. Moreover, SCC can be explained by different mechanisms depending on the metal environmental pair, what makes difficult to create a generalized analytical approach to predict the crack behavior in SCC. Therefore, projects often use an over-conservative design criteria that disqualify a material susceptible to SCC without properly evaluate the influence of the stress fields that drive them. The aim of this work is to evaluate the effect of elastic-plastic stress in SCC. This mechanical approach assumes that all chemical effects involved in SCC problems can be appositely described and quantified by traditional material resistances to crack initiation and propagation at under specific environment. Aluminum bending specimens in Gallium environment are used to predict the effect of the residual stress induced by plastic deformation in the crack initiation under SCC conditions. Furthermore, a quantitative analysis based on the non-propagating crack behavior departing from notch tips are used to calculate the necessary stress to initiate and propagate SCC in AISI 4140 steel notched specimens under aqueous hydrogen sulfide environment. The non-propagating crack behavior and the maximum load supported by notched specimens are analyzed under linear elastic and elastic-plastic stress field through the proposed model that will be validated by experimental data.

L'objectif de ce travail est la mise en oeuvre de la mécanique de la rupture et d'un modèle d'endommagement afin de vérifier l'intégrité du réservoir cryotechnique d'ARIANE 5 en présence de défauts. Ces derniers sont généralement assimilés à des fissures surfaciques semi-elliptiques. L'approche globale basée sur l'analyse FAD fournit une prédiction trop conservative lorsque cette méthode utilise le facteur d'intensité K et la ténacité KIc. Ce conservatisme peut toutefois être partiellement levé à condition d'introduire la notion d'intégrale J et d'utiliser une ténacité dérivée de la courbe JR - ∆a afin d'autoriser une légère avancée de la fissure dans le cas d'un matériau ductile. Cette courbe JR - ∆a s'obtient à partir d'essais sur des éprouvettes fissurées de différentes géométries (CT, SENT et SCT). L'approche locale de la rupture constitue cependant la seule alternative possible afin de statuer sur l'acceptabilité d'un défaut suffisamment important pour générer une plasticité étendue. Cette approche nécessite alors de décrire précisément les champs de contrainte et déformation en pointe de fissure. Par conséquent il est nécessaire de tenir compte du caractère anisotrope de la plasticité, lié au procédé de laminage, lors de la modélisation du comportement élasto-plastique del'alliage d'aluminium 2219 T87. Dans cette étude un critère phénoménologique est utilisé pour modéliser la plasticité dont l'anisotropie est décrite par différents coefficients. L'optimisation de ces paramètres repose sur la comparaison entre les résultats issus de simulations numériques et ceux obtenus par des essais sur des éprouvettes lisses et entaillées. L'approche local de la rupture repose également sur la compréhension des micromécanismes de rupture. L'alliage d'aluminium 2219 T87 étudié dans le cadre de cette thèse présenteune rupture ductile dont la phase de germination s'effectue sur les inclusions Al2Cu et constitue le mécanisme prépondérant de la rupture. L'endommagement est modélisé par le modèle de Gurson modifié par Needleman et Tvergaard (GTN). L'anisotopie de rupture est simulée par deux lois de germination différentes selon le sens de laminage et le sens transverse. / The purpose of this work is to use fracture mechanics and damage model to assess the structural integrity of the ARIANE 5 tank containing defects. These flaws are usually assumed to be semi-elliptical surface cracks.This situation can be analysed using the FAD (Failure Assessment Diagram) approach. This method is based on the stress intensity factor K and a material fracture toughness (Kmat) which can be the plane strain fracture toughness (KIC) for a conservative prediction. A more realistic prediction is achieved by employing the integral J and a material parameter derived from crack resistance curve JR - ∆a . This curve is obtained by using cracked test samples with different geometries (CT, SENT and SCT). The local approach to fractureis an alternative method to assess failure in particular in the case of large scale plasticity. In this case, the previous method is not able to give accurate predictions. Analyses based on local approach concepts requirean accurate evaluation of strain and stress fields near the crack tip. It is therefore important to take plastic anisotropy into account to model the plastic behavior of the rolled sheets. In this work this is done using amacroscopic phenomenological model. The parameters of this model are determined by minimizing of the difference between the simulation results and the test measurements for smooth and notched tensile test samples. The local approach to fracture is also based on the understanding of the failure micromechanismsof materials. Ductile fracture of metallic materials can be described as a three stage process. The first is void initiation at inclusions, the second is void growth and the third is void coalescence. Nucleation of defectsat Al2Cu inclusions is the main damage mechanism. In this work, the proposed model for ductile fracture is based on the Gurson model modified by Needleman and Tvergaard (GTN). This model is extended to account for fracture anisotropic by considering two nucleation gaussian laws respectively for rolling andtransverse directions.

The main goal of this work is the comparison of the size of the plastic zone at the crack tip for two analysis methods: an analytical linear method and an elastic-plastic analysis employing the Finite Element method (ANSYS software). All calculations were made for a crack loaded under pure shear modes. These types of loading are not sufficiently described in the literature. The first part of this work introduces the problem with the crack tip plastic zone using both linear and nonlinear fracture parameters. The second part is dedicated to the construction of the Finite Element model in the ANSYS software. The geometry of the samples and the loading levels were chosen to match an existing experimental test of the impact of shear modes on the crack behavior. In the third part of this thesis, the plastic zone radii for pure shear modes II and III are estimated using several methods and the results are compared. In the last part of this work, the same procedure as in the previous part is applied on a mixed-mode II+III loading. A result of this thesis is the assessment of the application limits of the linear analysis method used to estimate the size of the plastic zone at the crack tip for a specific geometry and material model.

The aim of this master thesis is to explore the influence of frictional forces to the stress and strain on the straight crack tip loaded in shear modes. The first section summarizes the most important things from the field of fracture mechanics. Especially theoretical knowledge about fracture parameters (stress intensity factor, J – integral) and their determination in computational environment ANSYS Workbench. The second part deals with computational modeling. At the beginning, is created the model of material, the model of geometry, the model of loads, etc. Then it is possible to solve the direct problem outlined in the introduction. A result of this thesis is the assessment of how the friction influences the fracture parameters in shear modes II and III.

Due to the increasing use of cyclically loaded cast aluminum components in automotive and aerospace applications, fatigue and fatigue crack growth characteristics of aluminum castings are of great interest. Despite the extensive research efforts dedicated to this topic, a fundamental, mechanistic understanding of these alloys' behavior when subjected to dynamic loading is still lacking. This fundamental research investigated the mechanisms active at the microstructure level during dynamic loading and failure of conventionally cast and SSM Al-Si-Mg alloys. Five model alloys were cast to isolate the individual contribution of constituent phases on fatigue resistance. The major constituent phases, alpha-Al dendrites, Al/Si eutectic phase, and Mg-Si strengthening precipitates were mechanistically investigated to relate microstructure to near-threshold crack growth (Delta Kth) and crack propagation regimes (Regions II and III) for alloys of different Si composition/morphology, grain size, secondary dendrite arm spacing, heat treatment. A procedure to evaluate the actual fracture toughness from fatigue crack growth data was successfully developed based on a complex Elastic-Plastic-Fracture-Mechanics (EPFM/J-integral) approach. Residual stress-microstructure interactions, commonly overlooked by researches in the field, were also comprehensively defined and accounted for both experimentally and mathematically, and future revisions of ASTM E647 are expected.

Les standards consacrés à la conception des oléoducs se concentrent principalement sur les chargements opérationnels, tels que les pressions internes et externes, et les procédures d'analyse de défauts actuelles n'exploitent pas les capacités d'écrouissage du matériau. Pourtant, dans des conditions extrêmes, les oléoducs peuvent être soumis à des contraintes au-delà de la limite d'élasticité jusqu'à atteindre 2.5% de déformations plastiques. Ici, les procédures proposées par ExxonMobil et PRCI basées sur des critères en déformation sont présentées, et l'utilisation de l'éprouvette SENT (Single Edge Notched Tension) pour caractériser la ténacité est étudiée, en comparant les différentes procédures d'essais recommandées. Puis, une importante campagne expérimentale a été réalisée pour caractériser deux aciers pour oléoducs à température ambiante et à basses températures. Les comportements mécaniques des matériaux de base et d'apport ont été identifiés grâce à l'utilisation de l'analyse inverse, et il est montré que le modèle d'endommagement GTN permet de modéliser finement les essais sur éprouvettes de laboratoire. Enfin, deux essais sur structures (pression et flexion, puis pression et traction) ont été réalisés de manière à comparer les approches globales et le modèle d'endommagement GTN. Ce dernier démontre une bonne transférabilité de l'éprouvette vers la structure. / Pipeline design codes and standards traditionally focus on the operational loadings such as internal and external pressures that are likely to exist over the entire lifetime of the pipeline. Existing Engineering Critical Assessments are mostly based on stress considerations, where the design margin is given as a percentage of the yield strength. In extrem environments, pipelines may experience stresses beyond the yield and plastic deformations up to 2.5 %. In such conditions, strain-based design procedures apply. In this work, a literature review of the existing strain based methods is proposed, including ExxonMobil and PRCI multi-tier approaches. The use of the Single Edge Notched Tension (SENT) specimen to measure the material toughness is then studied, benchmarking the recommended testing procedures from literature. A comprehensive experimental campaign was carried out to fully characterize two actual line pipes at room and low temperatures. The mechanical behavior of parent and weld materials are identified using an inverse analysis, and GTN damage model is shown to allow accurate modeling of the laboratory testings. Finally, two full scale tests (pressure + bending or pressure + tension) were carried out to benchmark the global approaches and GTN damage model. The latter showed a very good transferability from specimens to the structure.

Global-local finite element analyses were used to study the damage tolerance of curvilinearly stiffened panels; fabricated using the modern additive manufacturing process, the so-called unitized structures, and that of adhesive joints. A damage tolerance study of the unitized structures requires cracks to be defined in the vicinity of the critical stress zone. With the damage tolerance study of unitized structures as the focus, responses of curvilinearly stiffened panels to the combined shear and compression loadings were studied for different stiffeners' height. It was observed that the magnitude of the minimum principal stress in the panel was larger than the magnitudes of the maximum principal and von Mises stresses. It was also observed that the critical buckling load factor increased significantly with the increase of stiffeners' height. To study the damage tolerance of curvilinearly stiffened panels, in the first step, buckling analysis of panels was performed to determine whether panels satisfied the buckling constraint. In the second step, stress distributions of the panel were analyzed to determine the location of the critical stress under the combined shear and compression loadings. Then, the fracture analysis of the curvilinearly stiffened panel with a crack of size 1.45 mm defined at the location of the critical stress, which was the common location with the maximum magnitude of the principal stresses and von Mises stress, was performed under combined shear and tensile loadings. This crack size was used because of the requirement of a sufficiently small crack, if the crack is in the vicinity of any stress raiser. A mesh sensitivity analysis was performed to validate the choice of the mesh density near the crack tip. All analyses were performed using global-local finite element method using MSC. Marc, and global finite element methods using MSC. Marc and ABAQUS. Negligible difference in results and 94% saving in the CPU time was achieved using the global-local finite element method over the global finite element method by using a mesh density of 8.4 element/mm ahead of the crack tip. To study the influence of different loads on basic modes of fracture, the shear and normal (tensile) loads were varied differently. It was observed that the case with the fixed shear load but variable normal loads and the case with the fixed normal load but variable shear loads were Mode-I. Under the maximum combined loading condition, the largest effective stress intensity factor was very smaller than the critical stress intensity factor. Therefore, considering the critical stress intensity factor of the panel with the crack of size 1.45 mm, the design of the stiffened panel was an optimum design satisfying damage tolerance constraints. To acquire the trends in stress intensity factors for different crack lengths under different loadings, fracture analyses of curvilinearly stiffened panels with different crack lengths were performed by using a global-local finite element method under three different load cases: a) a shear load, b) a normal load, and c) a combined shear and normal loads. It was observed that 85% data storage space and the same amount in CPU time requirement could be saved using global-local finite element method compared to the standard global finite element analysis. It was also observed that the fracture mode in panels with different crack lengths was essentially Mode-I under the normal load case; Mode-II under the shear load case; and again Mode-I under the combined load case. Under the combined loading condition, the largest effective stress intensity factor of the panel with a crack of recommended size, if the crack is not in the vicinity of any stress raiser, was very smaller than the critical stress intensity factor. This work also includes the performance evaluation of adhesive joints of two different materials. This research was motivated by our experience of an adhesive joint failure on a test-fixture that we used to experimentally validate the design of stiffened panels under a compression-shear load. In the test-fixture, steel tabs were adhesively bonded to an aluminum panel and this adhesive joint debonded before design loads on the test panel were fully applied. Therefore, the requirement of studying behavior of adhesive joints for assembling dissimilar materials was found to be necessary. To determine the failure load responsible for debonding of adhesive joints of two dissimilar materials, stress distributions in adhesive joints of the nonlinear finite element model of the test-fixture were studied under a gradually increasing compression-shear load. Since the design of the combined load test fixture was for transferring the in-plane shear and compression loads to the panel, in-plane loads might have been responsible for the debonding of the steel tabs, which was similar to the results obtained from the nonlinear finite element analysis of the combined load test fixture. Then, fundamental studies were performed on the three-dimensional finite element models of adhesive lap joints and the Asymmetric Double Cantilever Beam (ADCB) joints for shear and peel deformations subjected to a loading similar to the in-plane loading conditions in the test-fixtures. The analysis was performed using ABAQUS, and the cohesive zone modeling was used to study the debonding growth. It was observed that the stronger adhesive joints could be obtained using the tougher adhesive and thicker adherends. The effect of end constraints on the fracture resistance of the ADCB specimen under compression was also investigated. The numerical observations showed that the delamination for the fixed end ADCB joints was more gradual than for the free end ADCB joints. Finally, both the crack propagation and the characteristics of adhesive joints were studied using a global-local finite element method. Three cases were studied using the proposed global-local finite element method: a) adhesively bonded Double Cantilever Beam (DCB), b) an adhesive lap joint, and c) a three-point bending test specimen. Using global-local methods, in a crack propagation problem of an adhesively bonded DCB, more than 80% data storage space and more than 65% CPU time requirement could be saved. In the adhesive lap joints, around 70% data storage space and 70% CPU time requirement could be saved using the global-local method. For the three-point bending test specimen case, more than 90% for both data storage space and CPU time requirement could be saved using the global-local method. / Ph. D.