Application of Automation Technology in Fatigue and Fracture Testing and Analysis 6th Volume

Transcription

1 McKeighan Braun Helping our world work better ASTM International ISBN: Stock #: STP1571 Application of Automation Technology in Fatigue and Fracture Testing and Analysis: 6th Volume STP 1571 ASTM INTERNATIONAL ASTM INTERNATIONAL Selected Technical Papers Application of Automation Technology in Fatigue and Fracture Testing and Analysis 6th Volume STP 1571 Editors: Peter McKeighan Arthur Braun

2 SELECTED TECHNICAL PAPERS STP1571 Editors: Peter C. McKeighan, Arthur A. Braun Application of Automation Technology in Fatigue and Fracture Testing and Analysis ASTM Stock #STP1571 ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA Printed in the U.S.A.

3 Library of Congress Cataloging-in-Publication Data Application of automation technology in fatigue and fracture testing and analysis / Peter C. McKeighan, Arthur A. Braun, editors. pages cm. -- (STP ; 1571) Includes bibliographical references. ISBN Fatigue testing machines. 2. Materials--Fatigue--Testing. 3. Strains and stresses--testing. 4. Fracture mechanics. I. McKeighan, P. C. (Peter C.) II. Braun, Arthur A., TA413.A dc ISSN: Copyright 2014 ASTM INTERNATIONAL, West Conshohocken, PA. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film, or other distribution and storage media, without the written consent of the publisher. Photocopy Rights Authorization to photocopy items for internal, personal, or educational classroom use, or the internal, personal, or educational classroom use of specific clients, is granted by ASTM International provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: (978) ; The Society is not responsible, as a body, for the statements and opinions expressed in this publication. ASTM International does not endorse any products represented in this publication. Peer Review Policy Each paper published in this volume was evaluated by two peer reviewers and at least one editor. The authors addressed all of the reviewers comments to the satisfaction of both the technical editor(s) and the ASTM International Committee on Publications. The quality of the papers in this publication reflects not only the obvious efforts of the authors and the technical editor(s), but also the work of the peer reviewers. In keeping with long-standing publication practices, ASTM International maintains the anonymity of the peer reviewers. The ASTM International Committee on Publications acknowledges with appreciation their dedication and contribution of time and effort on behalf of ASTM International. Citation of Papers When citing papers from this publication, the appropriate citation includes the paper authors, paper title, STP title, STP number, book editor(s), page range, Paper doi, ASTM International, West Conshohocken, PA, year listed in the footnote of the paper. A citation is provided on page one of each paper. Printed in Bay Shore, NY November, 2014

4 Foreword This compilation of Selected Technical Papers, STP1571, Application of Automation Technology in Fatigue and Fracture Testing and Analysis, contains eleven peerreviewed papers that were presented at a symposium held May 23, 2013 in Indianapolis, IN, USA. The symposium was sponsored by the ASTM International Committee E08 on Fatigue and Fracture and Subcommittee E08.03 on Advanced Apparatus and Techniques. The Symposium Chairmen and STP Editors are Peter C. McKeighan, Exponent - Failure Analysis Associates, Warrenville, IL, USA and Arthur A. Braun, Chapel Wood Engineering LLC, Columbia, MO, USA.

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6 Contents Overview vii Constant-Amplitude Versus K-Control in Fatigue Crack Growth Rate Testing 1 M. A. Adler Automated Real Time Correction of Motion Induced Dynamic Load Errors in the Force Readout of a Test Apparatus 18 D. Dingmann, A. White, and T. Nickel Application of Automation Methods for Nonlinear Fracture Test Analysis 31 P. A. Allen and D. N. Wells A Novel Shear Test Procedure for Determination of Constitutive Behavior of Automotive Aluminum Alloy Sheets 50 J. Kang and G. Shen In-Plane Biaxial Fatigue Testing Machine Powered by Linear Iron-Core Motors 63 M. Freitas, L. Reis, B. Li, I. Guelho, V. Antunes, J. Maia, and R. A. Cláudio Automation in Strain and Temperature Control on VHCF with an Ultrasonic Testing Facility 80 Y. Lage, A. M. R. Ribeiro, D. Montalvão, L. Reis, and M. Freitas Evaluation of Fracture Toughness Test Methods for Linepipe Steels 101 J. Kang, G. Shen, J. Liang, K. Brophy, A. Mendonca, and J. Gianetto Analysis Round Robin Results on the Linearity of Fracture Toughness Test Data 116 P. C. McKeighan and M. A. James Uncertainty in Ductile Fracture Initiation Toughness (J lc ) Resulting From Compliance Measurement 134 S. M. Graham

7 Combining Visual and Numeric Data to Enhance Understanding of Fatigue and Fracture Properties and Mechanisms 153 E. A. Schwarzkopf Software Tools for a Materials Testing Curriculum 163 C. Leser, F. Kelso, A. P. Gordon, and S. Ohnsted

8 Overview Automation in the testing laboratory has resulted in exciting new capabilities in the general areas of test control, data acquisition, data analysis and interpretation, modeling, and the integration of testing into mechanical design. As automated computer-based technology has become entrenched in the laboratory, our ability to record more meaningful and precise data has increased dramatically. The ever increasing capability of computers integrated into materials testing has allowed us to investigate some of the more unique and difficult problems in the materials testing world. This Symposium is the fifth in a series of symposia concerned with documenting and advancing the state of the art in automated fatigue and fracture testing. This series of symposia was initiated in 1989 with STP 1092 held in Kansas City, Missouri. Over the nearly 25 years since that time, the tools in the laboratory, including both sensors and computers, have evolved markedly. The evolution of automation systems was well described in Keith Donald s keynote paper presented at this most recent symposium. A key graphic from this invited presentation, reproduced below in Figure 1, describes the capability increase and cost decrease over three generations of the Fracture Technology Associates automation systems. The challenge facing the test engineer today differs from the initial phase of computer involvement in the test laboratory when computer processing technology limited the capabilities of our automation tools. The challenges today are at the opposite end of the spectrum: managing the enormous amount of data that can now be generated and stored by the newest and most robust computer systems. In a sense, the issues today are developing the appropriate smart algorithms and tools that can distill vast amounts of information in a rapid and meaningful manner. Our computer automation systems are becoming increasingly more sophisticated for interpreting different material behavior and effects. This symposium, and the eleven papers contained in it, emphasizes refined experimental methods, new methods and techniques, data analysis, and software development. The enhanced processing capabilities available with our test lab computers are highlighted in the first two papers contained herein. More specifically, Adler discusses an automated K-control method for fatigue crack growth testing that is only available given the processing speed and capability of our current data acquisition tools in the laboratory. Dynamic issues associated with high cyclic rate testing are addressed in the next paper by Dingmann, White, and Nickel; where a novel method is implemented and used to correct for force readout error in the testing system due to moving mass. vii

9 Figure 1. Evolution in automation system capability and cost over time (from J. K. Donald s keynote presentation A Personal Perspective on 40 years of Automated Fatigue Crack Growth Testing ). The next five papers address new methods and techniques developed to investigate a variety of technical issues. Allen and Wells introduce an analysis method, developed from extensive experimental results and full-scale test simulation analyses, where a database is developed to assist in the interpretation of surface crack fracture testing in the elastic-plastic regime. The enhanced processing capabilities of test laboratory computers are emphasized in the next four papers, addressing unusual and non-traditional experimental setups. A new shear specimen geometry and test is proposed in the next paper by Kang and Shen that uses full-field digital image correlation methods to interpret the shear behavior of automotive aluminum alloy sheets. Another unique experimental setup is then discussed and described in detail by de Freitas et al. concerning an in-plane biaxial fatigue testing machine powered by linear iron core motors. Lage et al. discuss the automation of strain and temperature measurements and control in a high cycle, ultrasonic fatigue testing application. A final paper by Kang et al. in this section examines automation of J- and CTOD-based fracture test methods as applied to linepipe steel. The remaining four papers in the symposium address data analysis and software developments. McKeighan and James present results from a fracture toughness inter-laboratory study with nine participants analyzing fracture toughness results and highlighting the importance of a consistent and systematic linearity assessment when interpreting linear elastic fracture toughness test results. The subsequent paper continues along the same general theme of test uncertainty where Graham examines viii

10 how compliance measurements can affect the measurement of ductile fracture initiation toughness JIc. The next paper in this section by Schwarzkopf addresses the issue of how automation software can effectively represent information (in visual graphic or numeric form) and provide an efficient interface between the actual test and the technician in the laboratory. Finally, Leser et al. address the practical challenges associated with integrating mechanical testing into a teaching curriculum using both physical test methods and virtual test simulation environments. The common theme evident with all the papers in this symposium is the increasing role of computer automation while actually performing a test and then interpreting the results once testing is complete. Without question, test automation remains a critical area for developing the tools and techniques required to understand the more difficult problems that face the materials engineer and designer today. It is the intent of Automation Task Group within ASTM E08.03 to revisit the automation research every five years to report and track how testing methods, techniques, and tools evolve. This is a developmental area that continues to flourish in the fatigue and fracture testing world. Recent efforts within the Task Group on algorithm development promise to provide useful tools to the analyst for interpreting material behavior and coping with the vast amount of data that is typically recorded in the laboratory today. In closing, the editors would like to express their sincere appreciation to all of the authors and co-authors responsible for the papers included in this STP and the presentations made during the symposium. This STP would not have been possible without your fine technical work and contributions. We also appreciate the tireless efforts provided by the numerous reviewers who assisted in the technical vetting and provided a high degree of professionalism and a timely response to ensure the quality of this publication. Finally, the editors would also like to express their sincere gratitude to the ASTM planning and editorial staff for their assistance in making this symposium a great success. Peter C. McKeighan Arthur A. Braun ix

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12 McKeighan Braun Helping our world work better ASTM International ISBN: Stock #: STP1571 Application of Automation Technology in Fatigue and Fracture Testing and Analysis: 6th Volume STP 1571 ASTM INTERNATIONAL ASTM INTERNATIONAL Selected Technical Papers Application of Automation Technology in Fatigue and Fracture Testing and Analysis 6th Volume STP 1571 Editors: Peter McKeighan Arthur Braun