PLANE-STRESS FRACTURE TOUGHNESS TESTING

USING A CRACK-LINE-LOADED SPEClMENt

R. H. HEYER and D. E. MCCABE
Armco Steel Corporation, Research and Technology, Middletown, Ohio, U.S.A.

Akhret-A crack-line-loaded specimen of modified WOL design was adapted for ioughness tesiing of high
strength sheet materials. A wedge-opening device was used to load the specimen and propagate the crack.
because of the specimen configuration and loading system. the crack never becomes unstabie. and full
crack growth resistance. R curves, can be developed for many materials.
When it can be shown that these R curves are characteristic of a material, and independent of specimen
configuration. they will be useful to predict instability conditions for other specimen types.

CRACK-fine-loaded specimens have proved useful for determining the plane-strain stress
intensity factors &, and k;,. These specimens are compact, require relatively low
loads, and are amenable to self-contained loading devices for environmental testing.
Clausing [ 1) has shown by analysis that crack growth in crack-line-loaded specimens
is stable over the entire range of crack extension provided a ‘stiff’ displacement con-
trolled loading system is used.
The compact tension specimen, CTS, now used in KI, testing and having H/W =
06. is also a crack-line-loaded (CLL) specimen and was derived from the Westingucrase
wedge-opening-loaded (WOL) specimen. The term double-cantilever beam (DCB) has
also been used to designate this family of specimens, including Ripling’s[2! tapered
version which can be designed for constant ii; independent of crack length.
Novak and Rolfe[31 reported using a compliance calibration of a self-loaded modi-
fied WOL-IT specimen to determine the applied load from the measured crack opening
displacement, COD. This technique was used with further modification of the specimen
in the present investigation to determine crack growth resistance. I?, curves for high
strength sheet materials.
A crack growth resistance concept was suggested by Irwin and Kies [4] in 1954, and
modified in 1960 [5.6] to show increasing resistance with crack extension. Krafft et ui.
171demonstrated that crack growth ins~bility, G,, could be predicted for various speci-
men sizes from the R curve for the material. Characteristics of R curves were exten-
sively treated by Srawley and Brown[8]. Experimental determinations of R for alum-
inum alloys, using center cracked tension specimens, were reported by Carman et al,
r91.

SPECIMENS, ~XTURES. PROCEDURE

The specimen configuration chosen was based on the Westinghouse WOL-T type
[lo] with specimen height to width ratio. H/W = O-486. The specimen sizesare shown
in Fig. I. Sheet thicknesses varied between 0,026 and 0.066 in. The small specimen
designated 2T is dimensioned. except for thickness, according to the Westinghouse
WOL-2T specimen for K,, dete~inations on 2-in-thick plate. The 4T specimen is
simifarly related to the 4-in.-thick K,, specimen, WOL-4T. To measure COD, diamond
indentation marks spaced at O-750 in. are impressed in the specimens 0.06 in. from the

+Presented at the National Symposium on Fracture Mechanics at Lehigh University, Augusr 25. 1969.
393

EFM. Vol. 4. No. 3-A

394 R. H. HEYER and D. E. MCCABE

I
!
WOL-ZT WOL-47
i!
0 j I n
--
2.48 4.96
1 W 5.1 IO.2
L 6.46 I I.56
2f-l s I-50 3.0

j
j

Fig. 1. Modified WOL-T specimens for plane stress toughness tests.

front edge. These points are l-3 in. from the specimen load line for both specimen sizes.?
Specimens are machined in packs up to 1.5 in. thick. The hole for the loading device
is precision bored with respect to the front edge. The g-in. slot is saw cut. Individual
specimens are then notched using a &-in-thick cut-off wheel. The end of the notch is
sharpened with a very light cut using a hack-saw blade ground to a 40” vee tooth con-
tour.
The specimens are precracked about &in. by cyclic tension loading in the apparatus
shown in Fig. 2. Backup plates &-in. thick are used to prevent buckling.
Figure 3 shows the die and wedge opening device used for the 2T specimens, with
the top cover plate removed. Lubricated Teflon sheets are placed on either side of the
specimen to reduce friction from the hold-down loads. The upper cover plate is bolted
on to the lower die with firm, but not heavy pressure. The wedge is hardened steel,
chromium plated and lubricated, with a total taper angle of 3”, or about 20 : 1 taper. The
wedge drives hardened steel dies contoured to fit the l*%n.-dia. hole in the specimen.
These dies operate in a slot cut into the bottom plate normal to the crack direction. The
wedge is forced downward through the die opening using a Universal testing machine
or a simple hydrauiic press. Crack propagation is observed during loading, and the
wedge is stopped at various increments of crack extension. The COD and crack length
are measured to the nearest +OWO2 in. with a stage micrometer, see Fig. 4. The die
shown in this figure and in Fig. 5 is for the 4T specimen. An auxiliary clamp provides
hold-down pressure over the central portion of the specimen. The view in Fig. 5 shows
the window through which the crack is observed.

CALIBRATION
Crack length and COD measurements are used to obtain the effective load through a
relationship established by a compliance calibration:

ERV,‘P =f‘(a/W)
E = modulus of elasticity, ksi
PFor caicuiation purposes the COD measurement for she WOL-4T specimen is linearly extrapolated from
the plastic zone corrected crack front to a position 2.6 in. forward of the specimen load line. This preserves
geometric similarity between the two specimen sizes.
 Fig. 2. Fatigue cracking machine.

Fig. 3. Die for 2T specimen (top piate removed).

[Facing page 3941

Fig. 4. Loading of4T specimen.

Fig. 5. Crack in 4T specimen.

 Plane-stress fracture toughness testing 395

B = thickness, inches
V= COD at the gage location. inches
P= effective load, kips
a = effective crack length, inches (1)
W= width, inches
K = stress intensity factor, Ksi-irY
R = crack growth resistance factor. Ksi-in”‘.

Two PH 14-8Mo specimens of the 2T size, 0.049 in. thick, were tension !oaded with-
in the elastic range between f-in-thick support plates. A NASA type clip gage mounted
between knife edges spaced at O-4 in. was used to measure COD. From COD-load
records, V/P ratios were obtained at 4 in. increments of crack length. The cracks were
about 0.020 in. wide produced by jeweier’s saw cuts. Test data in Fig. 6 include those

Fig. 6. Compliance calibration for WOL specimen, H/W = 0486.

of Novak and Rolfe[31. obtained from l-in-thick modified WOL-1T maraging steel
specimens. The polynomial obtained by least squares curve fit to the Armco data is:

EBVIP = 59.79-594.77 (a/W) +28&#.51 (@f’)’

-5208.8 (~/W)~+3803.85 (u/W)~=~$ (2)

CalcuIation of the stress intensity factor K is based on dispiacement at the load line,
V,, obtained by linear interpolation

V,=lV (3)
a+ I.3
396 R. H. HEYER and D. E. MCCABE

Using V, in equation ( 1)

&,(alW) = 177*23- 1629.0 (a/W) +5838*0 (a/W)*-89252 (~fW)~+5390.4 (a/W)”

(4)
K is obtained from

(5)

K = & [-814.5 (a/W) + 5838.0 (a/W)* - 13387.8 (t~/W)~i- 10780.8 (a/W)*]“*. (6)

Within the range of the calibration this agrees closely with Wilson’s relationship of
Ref. [ 101, Fig. 7, obtained analytically. Wilson’s equation is:

K =A r30.95 (a/W)--1956 (alW)‘+73@6 (c~jW)~-1186.3 (a/W)”

-t7546(a/W)7 (7)

=&*fL (a/W).

For stable cracks, the driving force K and the crack growth resistance R are equal
at the crack tip. In calculating R from wedge loading test data, equations (2) and (7)
are combined, relating R to I/ and a.

R = z .fL(atW’ where
(8)
+a f(ulW)‘
u= am-i-r, (9)
& = measured crack length

YS = 0.2 per cent offset yield strength in uniaxial tension. An iteration procedure on
a is used to solve for R,
A method of interpolating the load line displacement reported by Roberts [ 111 gives
slightly higher values of V, than obtained by the Iinear interpolation of equation (3).
The Irwin plastic zone correction, rP, is subject to verification for use in this applica-
tion where the magnitude of the correction on high toughness materials can be large
considering measured crack growth and specimen dimensions.
The plastic zone has been the subject of intensive study by many investigators, and
alternate plastic zone estimates have been suggested[ 12-161. However, the Irwin
concept was selected as the sting point in this investigation.

TEST DATA
Typical crack growth resistance curve data are shown in Figs. 7 and 8. Coincidence
of the curves for 4T and 2T specimens, having starting crack lengths of approximately
 Plane-stress fracture toughness testing 397

PH l4-BMo, onr melt

8*0.049 Ill
L,l WOL-4T
0 woi-2r

1 I I 1 t
0 o-5 I.0 I.5 2.0
Cmck extetwon, in.

Fig. 7. Crack growth tesistance curves for wedge ioaded WOL-T specimens.

PH 14-SMo, vacuum melt

0*OG46
_l WOL-4f (0
0 WOL -4T (2)
: WOL -2f f2)

55 ‘C :5 23
Cmk txtens10n. I"

Fig. 8. Crack growth resistance curves for wedge loaded WOL-T specimens.

3-f and 1*6 in.. demonstrates that R is independent of initial crack length. This is also
shown in Fig. 9, where the crack was started twice in the same 4T specimen from
starting lengths of 3.15 and 4.41 in.
Extremes in crack growth resistance curve characteristics are shown in Figs. 10 and
398 R. H. HEYER and D. E. MCCABE

400

300

$ 2oo
~

l
KG/+--
PH 14- 8Mo. SRH950,
YS = 208.5 ksi bOQ49
WOL-4T
m
l Stortmg truck length, 4.41 m
d
. 0 Starting Crack bngth, 3.15 in

100 j

Crack extension, I”.

Fig. 9. Crack growth resistance curves for WOL-4T specimen with two starting crack lengths.

-4T
+L.._ 2f

Aa,,,= measured ;/-.._.&

crock extension _c*--
.E
I;.I 100 -
P

u‘ /’
/
C
I/ Aa = effectwe
Al alloy 2024-T3
: crock extensbn
3OJ- YS a46.0 k¶l /9*0.066
/
I . . WOL -4T (2)
0 WOL-PT (2)
4

I.0 I.5 2.0

Crock extension. I”.

Fig. 10. Crack growth resistance curves for wedge loaded WOL-T specimens.

11 for aluminum alloys 2024-T3 and 7075-T%, and in Figs. 12 and 13 for stainless
steels 414 Ti and PH 157Mo. In Figs. 10 and 12 the difference between the curve for
measured crack length, a,, and for the plastic zone corrected crack length indicates a
very large plastic zone correction, compared to Figs. 11 and 13.
 Plane-stress fracture toughness testing 399

h - -3
#---
$0 00 Bt alloy 7O?S-T6
YS.75.6 ksi B-0066
-4T
K e -__2T . WOL-4T (2)
0 WOL-2T (4)

, ,
I-O ! .f 2.0

Crack extenston, in

Fig. 11. Crack growth resistance curve for wedge loaded WOL-T specimens.

500
t

Stainless steel type 4f4 Ti

-4t
YS=lO45 ksi B-@O38 hr.
Kc--,2T l WOL- 4-f (2)
o WOL-2T (2)

Crock exteniion. in.

Fig. 12. Crack growth resistance curve for wedge loaded WOL-T specimens.

The low toughness materials of Figs. 11 and 13 exhibit sudden bursts of crack exten-
sion at high loads, and replication is inferior to that for tougher materials.

It becomes increasingly apparent that toughness of sheet materials cannot be ex-

pressed as a single Kc value. independent of specimen size and geometry. Crack growth
resistance curves offer the possibility of determining a Kr value for specific specimens
400 R. H. HEYER and D. E. MCCABE

PH I!+7M0, RH1050
YS = 212.0 ksi B= 0.050
.WL-4Tf21
0 WOL-2T (21

0 0.2 0.4 0+3 0.8 I.0

Crack exknston. tn.

Fig. 13. Crack growth resistance curve for wedge loaded WOL-T specimens.

or structural elements, where Kc is the point of tangency of the crack driving force (K)
curve and the crack growth resistance (R) curve. Experimental proof of this concept
is difficult when strain rate effects are present and when the crack length at instability
cannot be accurately measured. These difficulties are not encountered in determining a
static crack growth resistance curve by the method reported here.
When the K and R curves are expressed in numeric terms. the tangent intercept can
be computed by simultaneous solution of the expressions for slopes of the curves. Both
curves can be expressed as polynomial functions of a/W, and this procedure was
followed in this report for Kc calculations.
A procedure which may prove more satisfactory was suggested by Irwin in a private
commu~cation. Irwin proposes that R be expressed in terms of ptastic zone size. crack
extension, and the plateau K value, K,.

Aa = (u, try) -a0

a, = actual crack length [= a, of equation (911 110)

rl, = &7r(K/YS)’
a@= initial crack length
a = parameter determined by measurement
F-m= ~~(~~iYS~~.

The function,& may be tanh (X)“‘, where

X = Aalar,,,.
 Plane-stress fracture toughness testing 401

Applying this model to several materials of this investigation, data fit was excellent
providing an adjustment, Co, was added to correct the fit near the origin of the R curve.

x = halffr;, + c,
The two methods of data fitting are compared in the following table on the basis of
predicted instability.
Table 1. Load control Kc predictions for WOL specimens

WOL Kc- ksi din.

specimen
Material size Polynomial Tanh

7075-T6 21 66 68
PH 14-8Mo CH900 2T 122 123
PH14-8Mo SRH950 2T 205 206
PH14-SMoSRH1050 2T 233 233
PHl4-3MoSRH~lOO 4T 310 3021
PH 14-8Mo SRH950 4T 349 343
Vacuum Melt
Ti-6AI-4V 2T 148 146

The tanh method is desirable in that material properties are used to define the R
curve. However, the K, value could not be developed in some of the high toughness
materials even using the 4T specimen.
The third order polynomial curve fitting procedure was applied only to data in the
region of the expected instability K value. in order to obtain an accurate fit in this
critical area. The tanh curve fitting procedure, on the other hand, includes all the data
except for values of R close to the origin.

METHODS OF LOADING WOL PLANE-STRESS SPECIMENS

Wedge loading provides displacement control of crack extension. wherein K and P
decrease with crack growth, as shown in Fig. 14(a). When displacement is increased at a
moderate rate from A to B, the K vs. a/W relationship departs from the static R curve,
then time dependent crack growth at constant displacement from B to C establishes
point C on the curve. As the plateau region of the R curve is approached, time depen-
dent crack growth after each increment of displacement increases. While 5 or 10 min is
su%icient to attain a practical equilibrium condition in early stages of time dependent
crack growth. measurable crack extension may be observed after an hour or more in
the plateau region.
Loading the specimen in a tension testing machine having load control capability, K
and V increase with crack extension at constant load, as shown in Fig. 14(b). When
load is increased incrementally, as from D to E, time dependent crack growth at the
attained load will follow a load controlled crack extension force curve such as EF to
the point F on the static R curve. With load control. specimen instability occurs at the
point of tangency between the K and R curve. When operating at very slow crosshead
movement the instability is observed as a definite fall-off of load with crack extension.
This limits the extent of the R curve which can be determined by the load control
method, whereas using displacement control and a su~ciently large specimen, the R
curve can be determined to a plateau value.
402 R. H. HEYER and D. E. MCCABE

K curves for
400 - constant displacemmt

300 -

cc
200 -
y’

IOO-

F!

I I I /
0 01 o-2 03 04 OS O-6

O/W

Fig. 14(a). Crack driving force K curves for WOL-4T specimen related to R curve for PH14-
8M0, SRH 950, vacuum melt. Displacement control test.

400 -

300 -

K curves for
constant load

0 0. I 0.2 03 0.4 O-5

o/W

Fig. 14(b). Crack driving force K curves for WOL-4T specimen related to R curve for PH14-
8M0, SRH 950. vacuum melt. Load control test.
 Plane-stress fracture toughness testing 403

An example of data obtained by both displacement and load control is given in

Fig. 15. Kc by termination of the R curve in the load control tests coincided with Kc
predicted from the R curve obtained with displacement control. The Instron load was
predicted within reasonable limits from displacement and the plastic zone corrected
crack length. using equation (2). This supports the accuracy of the plastic zone correc-
tion as applied to this material, which had r, = 0.33 in. and u, = 2.00 in. at the Kc in-
stability.
In the case of load controlled tests of 2024-T3, the Instron loads were considerably
higher than loads predicted from displacement and the plastic zone correct.ed crack
length. Furthermore, the Instron load and displacements give smaller effective crack
lengths. by equation (21, than those of Fig. 10 for displacement controlled tests. Using
these calculated crack lengths and the Instron loads. the values of R from equation (7)
yielded a curve only slightly to the right of the curve in Fig. 10 for measured crack
extension, a,. This R curve would result in Kc instability values higher than would be
obtained from the curve for wedge loading.
These results indicate that the caiculated plaaGc zone correction does not give the
correct effective crack length for 2024-T3. This subject is treated further m a later
section.
Data from load controlled tests of 2024-T3 resulted in an R curve coincident with
one from wedge tests when R was calculated from displacement and r, corrected crack
length. This curve terminated at the Kc predicted from the wedge loaded test, in the
manner of Fig. 15 for stainless steel.
Experimentally the sustained tension loading procedure is more difficult to carry
out than the wedge loading, displacement controlled procedure. The problems are in
maintaining alignment in the testing machine, in reducing holddown friction to obtain
accurate load readings, and in a less convenient setup for measuring crack length and

400-

3oo- ./??Tzzz

I
AT
d
zoo-
l
P
PH l4-9th. SRH It00
YS =180.0 ksl 8=0,049 tn.
o. WOL -2T load control

i / 1
0 05 I.0 15 2.0

Cmck extenston, I”.

Fig. 15. Crack growth resistance curves for displacement and load control.
404 R. H. HEYER and D. E. MCCABE

displacement. Two operators are needed, whereas the wedge loading procedure is read-
ily performed by a single operator.

Load controlled tension instability stress intensity, Kc, can be calculated using the
R curve and the load control K curve for the specimen. The Kc values for 2T and 4T
specimens in Figs. 7-13 were calculated from the solution for the point of tangency of
the crack driving force, K, and crack growth resistance, R, curves, using the Wilson
values forf; (a/W). Note that Kc for the 4T specimen is always slightly higher than for
the corresponding 2T specimen.
Assuming that an R curve developed with WOL specimens is characteristic of a
material, it should be possible to predict the appropriate Kc instability stress intensity
for other specimen types. Such predictions have not been adequately verified, and
remain a major objective of this investigation. Some hypothetical examples showing the
influence of fracture toughness, specimen width, and starting crack length on Kc of
center cracked tension specimens are shown in Figs. 16-19, where the K curves for the
center-cracked tension specimens were calculated using Isida’s [ 171 equation:

Pda
K = m Y, where
(11)
Y= 1.77+0~227 (2aiW) -0310 (2~f~)*i-27 (2&$q3.

In Fig. 16, a 20.4-in.-wide center cracked tension specimen (CCT) has a predicted
Kc. nearly equal to that of the WOL-47 specimen, with starting crack length a/W =
O-3 in both cases.

CCT

21-20.4

Fig. 16. Load controlled crack driving force K curves for WOL-4T and CCT specimens related
to R curve for PH 14”8Mo. SRH 950, vacuum melt.
 Plane-stress fracture toughness testing 405

In Figs. 17 and 18 predictions of the effect of width of CCT specimens on Kc are

shown for two levels of fracture toughness. The increase in Kc with specimen width
is greater at the higher toughness level, Fig. 18. The data shown in Fig. 17(a) are com-
pared with corresponding data for Fig. 18 and for aluminum alloy 2024-T3 in Table 2.
These calculated values predict general yielding for 10*2- and 20*4-in.-wide CCT speci-
mens of 2024-T3.
A rather small effect on Kc of starting crack !engths from 0.15 to 0.45 a/W is shown
in Fig. 19 and in Table 3, which also shows small change in net stress, with the expected
large drop in maximum load as the crack lengths increase.

It t t t t
K, ~233

Fig. 17(a). Effect of width of CCT specimens on predicted K,. Initial a/W = 0.3, test specimens.

4oo: /
/

300- /
L.f
.-
:
0:
200 -
Y’

I 1
0 O-i 02 0.3 0.4 O-5 CI.6

O/W
Fig. 17(b). Effect of width of CCT specimens on predicted K,. Initial a/W = 0.3. Crack growth
resistance and critical crack driving force curves.
 406 R. H. HEYER and D. E. MCCABE

PH 14 - SMo, SRH 950. vacuum meli

YS 9208.8 B -0.0458

I
I , I I
O-I 0.2 03 o-4 0:s 0
O/W
Fig. 18.Effect of width of CCT specimens on predicted K,.

Table 2. Characteristics of center cracked tension specimens cal-

culated from crack growth resistance curves. Specimen width
variable. Starting crack length constant at a/W = 0.3

PH 14-8Mo PHi4-8Mo
SRH950 SRH950
Width Air melt Vat. melt
2.w Fig. 17 Fig. 18 2024T3
oys. ksi 208.5 208.8 46.0
CT,,,,ksi 51.0 63.4 99.8 34.0
20.4 97-o 147.2 46-6
10.2 130.2 187.4 59.4

P,,,, ksi 51.0 105.2 148.3 67.3

20.4 60-9 806 34.4
10.2 38.3 48.2 19.2

Kc. k&in”* 51.0 233 371 123.7

20.4 228 349 1104
10.2 218 314 98-7

a,. in. 51.0 8-57 9.28 IO.20

20.4 3.79 4.22 1.6.5
10.2 2-10 2.30 267

ha, in. 51.0 o-92 1.63 2.55

20.4 0.73 1.16 1.59
IO.2 0.57 0.76 I-14

PLASTIC ZONE CORRECTION TO CRACK LENGTH

In plane stress testing the calculated contribution of local plastic deformation to the
effective crack length can be very large, as shown in Figs. 10 and 12. We have made
 Plane-stress fracture toughness testing 407

5::
rz
bi

0 01 02 03 04 0.5 0

O/W

Fig. 19. Effect of starting crack length of CCT specimens on predicted K,.

Table 3. Characteristics of center cracked ten-

sion specimens calculated from crack growth
resistance curve. Starting crack length variable.
Width constant at 20.4 in.

PH14-8Mo SRH950
Vacuum melt - Fig. I9
Starting al W 0.15 0.30 0.45

uy.<.ksi 208.8 208.8 208.8

cr,,,. ksi 151.4 147.2 150.2
P mal.ksi 107.5 80.6 61.2
Kc. ksi-in”* 330.0 349.0 350-o
a,. in 2.45 4-22 5.75
Au. in 0.92 1.16 1.16

some determinations of the length of plastic zones by strain gage methods, and com-
pared these to the corresponding calculated r, vafues.
Foil type strain gages iDX 4 in. were applied at 7 positions along the crack-line of a
4T specimen of 2024-T3. Strain measurements at increments of visible crack extension
are given in Fig. 20. Each curve represents uniaxial strain normal to the crack-line (y
direction) at the indicated length of the visible crack. As the load and crack length
increased, the neutral axis of the specimen shifted. However, at crack lengths F and G,
after the Kc critical stress intensity had been developed, a considerable portion of the
specimen was still under compressive strains.
The gage at &in. from the starting crack indicated plastic strain when the crack had
advanced only O-01 in. from the starting crack length of 3.10 in. In this preliminary
survey strain gage readings at 1 and 2 in. from the starting crack were discontinued
before the y direction strain equalled the 0.2 per cent offset uniaxial yield strength
408 R. H. HEYER and D. E. MCCABE

Strom patterns m
wedge loadiigof
2024-T3, WOL-4T

a, -startmg crack length

Dtstance from loadhe. m.

Fig. 20. Strain at seven pbsitions on the crack-line of a WOL-4T specimen of 2024-T3. wedge
loaded.

strain of 0.63 per cent. In subsequent tests crack length vs. strain readings up to and
above the uniaxial yield strain were obtained. The measured crack length, a,, coinci-
dent with development of this strain was used to obtain a measure of the length of the
plastic zone in advance of the crack. These values are compared to r, = 3m( Ki YS)* in
Table 4. They range from 101 to 117 per cent of r,, for the stainless steels and from 80
to 102 per cent of r, for 2024-T3.
Additional tests are being made using 90” rosette type gages to obtain both x and y
strains at a given gage location. These strains are used to obtain the actual y direction
stresses. The von Mises yield criterion is then used to obtain the elastic-plastic border.
On this basis the strain level for yielding is lowered, and the apparent plastic zone size
is increased beyond that indicated in Table 4. Thus the approximate agreement between
the plastic zone size based on y direction strains only and the Irwin r, value may be
fortuitous.
After the strain gage tests had been run a i’s in. wide slot was progressively milled
along the crack line to remove the deformed metal of the plastic zone so that the COD
would be restored to the before-test value. While the original measurement of O-750 in.
was not attained, Fig. 2 1 shows that the great& portion of the recovery had occurred
when the slot length was equal to r, = h(K/YS)‘.
Another means of determining plastic zone size was by measurements under sus-
tained loads in an Ins&on testing machine, calculating the effective total crack length
from the compliance relationship, equation (2). Subtracting the measured crack length,
 Plane-stress fracture toughness testing 409

Table 4. Length of plastic zone based on strain gage measurements

along the crackline

Strain gage
indication based on
uniaxial yield strength r, = f?r Strain
Material strain (KIYS )’ gage/r,

(1, PH15-7Mo 0.104 in 0.072 in. 144

RHIlOO

(2) PH14-8Mo 0.207 0.201 1.03

SRH950 0.209 0.201 1G4

(3) Ti-6A1-4V 0.215 0.220 0.98

0.240 0.263 0.91

(4) PH 14-8Mo 0.310 0.265 1.17

SRH I 050

(5) PH 14-8Mo 0.43 0.40 I.07

SRH 1 iOG 0.49 0.49 I.00
0.48 0.53 0.91

(6) PH 14-8Mo 064 0.59 I.08

Vacuum melt
SRH1050
(7) 2024~T3 0.71 0.68 1.04
0.03 15 in.
(8) 2024-T3 0.65 O-69 0.94
O-03!5 in. 0.75 0.79 o-95

(9) 2024-T3 0.76 0.95 0.80

0.066 in.
(10) Type414Ti 0.76 1.18 0.64
1.08 2.10 0.51
1.24 2.73 0.45

the effective plastic zone was determined. Table 5 compares r, values so obtained to
those predicted by r, = +7r(K/YV. Except at low R values the agreement obtained in
the steel specimens is good, considering the sensitivity of the compliance technique to
elastic modulus variations and errors in load measurement. In the case of the aluminum
specimen there is definite disagreement between the two methods. At first. it was
thought that friction of the retainer plates might account for the unexpected high ten-
sion loads. but this was disproved in a special friction test. in which 2024-T3 developed
less frictional resistance than the stainless steels. The fit of aluminum to the compliance
calibration curve, obtained with steel specimens, was also suspect, but this also was
disproved by a calibration test of 2024-T3.
Recapping, plastic zone size for 2024T3 is about 80-100 per cent of r, = trr(K/YW
when determined by the strain gage technique (Table 41, and under 28 per cent of r,
by the load-compliance calculation, (Table 5). .4 possible explanation of this anomaly
lies in the relatively high work-hardening in the plastically deformed metal ahead of the
crack in 2024-T3 compared with the higher strength materials. Strengthening in the
plastic zone could partially offset the expected relaxation. so that the effective crack
tip is moved towards the actual crack tip.
410 R. H. HEYER and D. E. MCCABE

4
A
0.75i I t
0 0.5 I .o I.5

Slot length/r,

Fig. 2 1. Recovery of displacement by removing deformed metal from the plastic zone.

Table 5. Effective length of plastix zone based on indicated load and dis-
placement (equation 2) compared to r, = +v(K/YS)~

Load, lb
Plastic zone: Length, rp, in.
Material R, ksiqin. Indicated Calc.* 47r(K/YS)**

PH 14-8Mo 110 2475 2556 0.118 0.045

SRH950 200 4275 4247 0.128 0.146
226 4475 4462 0.181 0.188

PH14-8Mo 112 2505 2582 0.124 0.061

SRHllOO 238 5005 5049 0,299 0.278
303 5605 5658 0.475 0.452

2024-T3 42 1102 923 0.054 0.161

63 1452 1182 0.050 0.354
74 1602 1269 0.111 o-419
a4 1702 1282 0.148 0.525

*Equation (8).
?Equation (2).
*By iteration using equations (8) and (9).

DISCUSSION
Major areas for future investigation are: (1) verification of predictions of load con-
trol instability Kc for various specimen types and structural elements using WOL
generated R curves; (2) determination of minimum specimen size limitations: (3)
 Plane-stress fracture toughness testing 411

determination of proper plastic zone size correction for the tougher materials. A solu-
tion is presently available in compliance determination of effective crack length by the
load control technique.
It is anticipated that the stress patterns now being determined by strain gauges
ahead of the crack will be useful in defining the plastic zone. and hopefully the effective
crack length.
Other likely areas for future work include variation of test temperature. strain rate,
environment, and specimen thickness.
We are presently developing correlations of center-notched wide panel test results
to the WOL developed R curves. Preliminary results have been quite favorable. Diffi-
culty is expected however, in the low strength, high toughness materials.

RESULTS AND CONCLUSIONS

(I) Crack growth resistance (R) curves for sheet metals were determined using a
modified WOL type crack-line-loaded specimen.
(2) Expe~men~l compliance calibration tests confo~ed to analytical and experi-
mentai determinations reported in the literature for WOL type specimens.
(3) Stiff, displacement controlled loading was attained using a tapered wedge. Stable
cracks were maintained throughout the test, from which complete R curves were devel-
oped for several materials.
(4) Using sustained tension controlled loading. stable R curves were produced only
up to the load instability stress intensity. Kc. This value was in agreement with Kc
calculated as the point of tangency of the K driving force and the stable R curve ob-
tained by wedge loading.
(5) The wedge loading procedure involves measurement of visible crack length and
crack opening displacement by microscope at spaced increments of crack extension. R
is then calculated using the compliance relationship and an iterative procedure to correct
the crack length for the term &T( KlYS)'.
(6) Loads calculated by the above procedure were consistent with testing machine
indicated loads within limits of experimental error in the case of load controlled tests of
stainless steels. Inconsistently high measured loads were obtained in load controlled
tests of 2024-T3, indicating plastic zone sizes much smaller than those obtained by other
means. High work-hardening in the plastic zone may reduce the effective crack length
in this material.
(7) Plastic zones defined by uniaxial 4’ direction strain measurements along the
crack line were approximately equal to Irwin’s r, = ip(K/YS)?.
(8) Progressive removal of plastically deformed metal along the crack line of tested
specimens tended to return the crack opening displacement to the unstressed value.
These results were consistent with the plastic zone size determinations by strain gages.
(9) The WOL-2T specimen yields a sufficiently complete R curve in most of the
materials tested so that instability Kc can be predicted for a wide range of specimen
types. Corresponding curves for WOL-4T specimens are coincident over the range of
the WOL-2T curves. but extend to higher crack lengths and R values. This suggests
that the 2T specimen size yields valid results within its limits of calibration. However,
further proof is needed that these R curves represent material properties. independent
of specimen shape and size.
Correlations between WOL type and center cracked tension tests of wide panels,
412 R. H. HEYER and D. E. MCCABE

now in progress, are expected to yield information on validity of R curves for the crack-
line loaded specimens.

~cknowfedge~~n~s-The authors are deeply appreciative of the many suggestions and comments from
members of the ASTM Committee E-24 during the course of this investigation, of the able assistance of
Mr. D. M. Hammonds in the mechanical tests and Mr. R. A. Brown in test fixture and specimen oremuation,
and of the support of this work by Armco Steel Corporation.

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(Received 5 November 197 1)