ASTM INTERNATIONAL Selected Technical Papers

Application of Automation Technology in Fatigue and Fracture Testing and Analysis6th Volume

STP 1571Editors:Peter McKeighanArthur Braun

ASTM INTERNATIONAL Helping our world work better

ISBN: 978-0-8031-7587-7Stock #: STP1571

www.astm.org

Application of A

utomation Technolog

y in Fatigue and Fracture Testing and Analysis: 6

th Volum

e STP 1571

McKeighan | B

raunA

STM

International

SELECTED TECHNICAL PAPERSSTP1571

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 19438-2959.Printed in the U.S.A.

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 978-0-8031-7587-7

1. 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., 1953-

TA413.A67 2014620.1’1260287--dc23 2014041031

ISSN: 1537-7407

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Printed in Bay Shore, NYNovember, 2014

Th is compilation of Selected Technical Papers, STP1571, Application of Automation Technology in Fatigue and Fracture Testing and Analysis, contains eleven peer-reviewed papers that were presented at a symposium held May 23, 2013 in Indi-anapolis, IN, USA. Th e symposium was sponsored by the ASTM International Committee E08 on Fatigue and Fracture and Subcommittee E08.03 on Advanced Apparatus and Techniques.

Th e 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.

Foreword

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 (Jlc) Resulting From Compliance Measurement 134

S. M. Graham

Contents

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

vii

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 com-puter-based technology has become entrenched in the laboratory, our ability to record more meaningful and precise data has increased dramatically. Th e ever increasing capability of computers integrated into materials testing has allowed us to investigate some of the more unique and diffi cult problems in the materials testing world.

Th is Symposium is the fi ft h in a series of symposia concerned with document-ing and advancing the state of the art in automated fatigue and fracture testing. Th is 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. Th e 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.

Th e challenge facing the test engineer today diff ers from the initial phase of com-puter involvement in the test laboratory when computer processing technology lim-ited the capabilities of our automation tools. Th e challenges today are at the oppo-site 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 diff erent material behavior and eff ects.

Th is symposium, and the eleven papers contained in it, emphasizes refi ned ex-perimental methods, new methods and techniques, data analysis, and soft ware devel-opment. Th e enhanced processing capabilities available with our test lab computers are highlighted in the fi rst two papers contained herein. More specifi cally, Adler dis-cusses 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.

Overview

viii

Th e next fi ve papers address new methods and techniques developed to investi-gate a variety of technical issues. Allen and Wells introduce an analysis method, de-veloped from extensive experimental results and full-scale test simulation analyses, where a database is developed to assist in the interpretation of surface crack frac-ture testing in the elastic-plastic regime. Th e 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-fi eld 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 fi nal paper by Kang et al. in this section examines automation of J- and CTOD-based fracture test methods as applied to linepipe steel.

Th e remaining four papers in the symposium address data analysis and soft ware developments. McKeighan and James present results from a fracture toughness in-ter-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. Th e subsequent paper con-tinues along the same general theme of test uncertainty where Graham examines

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”).

ix

how compliance measurements can aff ect the measurement of ductile fracture initia-tion toughness JIc. Th e next paper in this section by Schwarzkopf addresses the issue of how automation soft ware can eff ectively represent information (in visual graphic or numeric form) and provide an effi cient interface between the actual test and the technician in the laboratory. Finally, Leser et al. address the practical challenges as-sociated with integrating mechanical testing into a teaching curriculum using both physical test methods and virtual test simulation environments.

Th e common theme evident with all the papers in this symposium is the in-creasing role of computer automation while actually performing a test and then interpreting the results once testing is complete. Without question, test automa-tion remains a critical area for developing the tools and techniques required to un-derstand the more diffi cult 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 fi ve years to report and track how testing methods, techniques, and tools evolve. Th is is a developmental area that continues to fl ourish in the fatigue and fracture testing world. Recent eff orts within the Task Group on al-gorithm 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. Th is STP would not have been possible without your fi ne technical work and contributions. We also appreciate the tireless eff orts 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 qual-ity 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. McKeighanArthur A. Braun

ASTM INTERNATIONAL Selected Technical Papers

Application of Automation Technology in Fatigue and Fracture Testing and Analysis6th Volume

STP 1571Editors:Peter McKeighanArthur Braun

ASTM INTERNATIONAL Helping our world work better

ISBN: 978-0-8031-7587-7Stock #: STP1571

www.astm.org

Application of A

utomation Technolog

y in Fatigue and Fracture Testing and Analysis: 6

th Volum

e STP 1571

McKeighan | B

raunA

STM

International