Numerical Modelling of Plasticity Induced Crack Closure with Rough Fracture Surfaces

A two-dimensional elastic-plastic finite element model was built to simulate the closure of a long fatigue crack with arbitrarily shaped crack faces. The model growth is simulated by the successive mesh splitting along the crack path defined by element edges. To obtain a realistic morphology of the fracture surface, fatigue crack growth experiments with CT specimen made from AISI 304 stainless steel were performed and fracture surface topology was determined using a single camera and a depth-from-focus method. Simulated closing loads and closure lengths for the cracks with rough and smooth faces and for plane-stress and plane-strain conditions are compared. A mismatch of rough crack faces, resulting in an additional contact, is visualized.

Fatigue Crack Growth in Maraging Steel Obtained by Selective Laser Melting

Selective Laser Melting (SLM) is an additive manufacturing technology, ideal for the production of complex-shaped components. Design against fatigue is fundamental in the presence of cyclic loads, particularly for these materials which typically have significant porosity, high surface roughness and residual stresses. The main objective here is to study fatigue crack growth (FCG) in the 18Ni300 steel obtained by SLM. Typical da/dN-ΔK curves were obtained in C(T) specimens, indicating that cyclic plastic deformation may be the controlling mechanism. A complementary analysis, based on plastic CTOD range, showed a relatively low level of crack tip plastic deformation, and consequently a reduced level of plasticity induced crack closure. The curve da/dN versus plastic CTOD range is clearly above the curves for other materials.