The mechanisms of ductile rupture

Noell, Philip J.; Carroll, Jay D.; Boyce, Brad L.

doi:10.1016/j.actamat.2018.09.006

Title: The mechanisms of ductile rupture

Abstract

One of the most confounding controversies in the ductile fracture community is the large discrepancy between predicted and experimentally observed strain-to-failure values during shear-dominant loading. Currently presented solutions focus on better accounting for how the deviatoric stress state influences void growth or on measuring strain at the microscale rather than the macroscale. While these approaches are useful, they do not address a significant aspect of the problem: the only rupture micromechanisms that are generally considered are void nucleation, growth, and coalescence (for tensile-dominated loading), and shear-localization and void coalescence (for shear-dominated loading). Current phenomenological models have thus focused on predicting the competition between these mechanisms based on the stress state and the strain-hardening capacity of the material. However, in the present study, we demonstrate that there are at least five other failure mechanisms. Because these have long been ignored, little is known about how all seven mechanisms interact with one another or the factors that control their competition. These questions are addressed by characterizing the fracture process in three high-purity face-centered cubic (FCC) metals of medium-to-high stacking fault energy: copper, nickel, and aluminum. These data demonstrate that, for a given stress state and material, several mechanisms frequently work together inmore »« less

Authors:

Noell, Philip J. ^[1]; Carroll, Jay D. ^[1]; Boyce, Brad L. ^[1]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Publication Date:: 2018-09-06

Research Org.:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Org.:: USDOE National Nuclear Security Administration (NNSA)

OSTI Identifier:: 1524207

Report Number(s):: SAND-2018-5461J
Journal ID: ISSN 1359-6454; 663415

Grant/Contract Number:: AC04-94AL85000

Resource Type:: Accepted Manuscript

Journal Name:: Acta Materialia

Additional Journal Information:: Journal Volume: 161; Journal Issue: C; Journal ID: ISSN 1359-6454

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; Ductile fracture; Damage nucleation; Failure mechanism; Strain localization; Shear

Citation Formats


                    Noell, Philip J., Carroll, Jay D., and Boyce, Brad L. The mechanisms of ductile rupture.  United States: N. p., 2018. 
Web.  doi:10.1016/j.actamat.2018.09.006.

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                    Noell, Philip J., Carroll, Jay D., & Boyce, Brad L. The mechanisms of ductile rupture.  United States.  https://doi.org/10.1016/j.actamat.2018.09.006

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                    Noell, Philip J., Carroll, Jay D., and Boyce, Brad L. Thu .  
"The mechanisms of ductile rupture".  United States.  https://doi.org/10.1016/j.actamat.2018.09.006.  https://www.osti.gov/servlets/purl/1524207.

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@article{osti_1524207,

  title        = {The mechanisms of ductile rupture},

  author       = {Noell, Philip J. and Carroll, Jay D. and Boyce, Brad L.},

  abstractNote = {One of the most confounding controversies in the ductile fracture community is the large discrepancy between predicted and experimentally observed strain-to-failure values during shear-dominant loading. Currently presented solutions focus on better accounting for how the deviatoric stress state influences void growth or on measuring strain at the microscale rather than the macroscale. While these approaches are useful, they do not address a significant aspect of the problem: the only rupture micromechanisms that are generally considered are void nucleation, growth, and coalescence (for tensile-dominated loading), and shear-localization and void coalescence (for shear-dominated loading). Current phenomenological models have thus focused on predicting the competition between these mechanisms based on the stress state and the strain-hardening capacity of the material. However, in the present study, we demonstrate that there are at least five other failure mechanisms. Because these have long been ignored, little is known about how all seven mechanisms interact with one another or the factors that control their competition. These questions are addressed by characterizing the fracture process in three high-purity face-centered cubic (FCC) metals of medium-to-high stacking fault energy: copper, nickel, and aluminum. These data demonstrate that, for a given stress state and material, several mechanisms frequently work together in a sequential manner to cause fracture. The selection of a failure mechanism is significantly affected by the plasticity-induced microstructural evolution that occurs before tearing begins, which can create or eliminate sites for void nucleation. At the macroscale, failure mechanisms that do not involve cracking or pore growth were observed to facilitate subsequent void growth and coalescence processes. Even though the focus of this study is on damage accumulation in pure metals, these results are also applicable to understanding failure in engineering alloys.},

  doi          = {10.1016/j.actamat.2018.09.006},

  journal      = {Acta Materialia},

  number       = C,

  volume       = 161,

  place        = {United States},

  year         = {2018},

  month        = {9}

}

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Similar Records

Title: The mechanisms of ductile rupture

Abstract

Citation Formats

The Bending Stress Distribution at the Base of a Stationary Crack journal, March 1961

Plane strain deformation near a crack tip in a power-law hardening material journal, January 1968

The Sandia Fracture Challenge: blind round robin predictions of ductile tearing journal, January 2014

The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading journal, March 2016

On the ductile enlargement of voids in triaxial stress fields∗ journal, June 1969

Continuum Theory of Ductile Rupture by Void Nucleation and Growth: Part I—Yield Criteria and Flow Rules for Porous Ductile Media journal, January 1977

Shear band formation in plane strain journal, January 1981

Material failure by void coalescence in localized shear bands journal, January 1982

Analysis of the cup-cone fracture in a round tensile bar journal, January 1984

Two mechanisms of ductile fracture: void by void growth versus multiple void interaction journal, June 2002

On fracture locus in the equivalent strain and stress triaxiality space journal, January 2004

Rupture mechanisms in combined tension and shear—Micromechanics journal, August 2007

A Criterion for Ductile Fracture by the Growth of Holes journal, June 1968

On the mechanisms of ductile failure in high-strength steels subjected to multi-axial stress-states journal, June 1976

Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures journal, January 1985

Rupture mechanisms in combined tension and shear—Experiments journal, March 2007

Partially coupled anisotropic fracture model for aluminum sheets journal, May 2010

Ductile fracture: Experiments and computations journal, February 2011

Modification of the Gurson Model for shear failure journal, January 2008

On the predictive capabilities of the shear modified Gurson and the modified Mohr–Coulomb fracture models over a wide range of stress triaxialities and Lode angles journal, July 2011

Calibration and evaluation of seven fracture models journal, April 2005

Micromechanical analysis on the influence of the Lode parameter on void growth and coalescence journal, March 2011

Extension of a shear-controlled ductile fracture model considering the stress triaxiality and the Lode parameter journal, January 2013

Phase-field modeling of ductile fracture journal, April 2015

Evaluation of six fracture models in high velocity perforation journal, August 2006

Overview No. 1 journal, January 1979

Criteria for ductile fracture and their applications journal, April 1980

A complete Gurson model approach for ductile fracture journal, September 2000

New ductile fracture criterion for prediction of fracture forming limit diagrams of sheet metals journal, December 2012

Ductile failure behavior of polycrystalline Al 6061-T6 journal, March 2012

Ductile failure behavior of polycrystalline Al 6061-T6 under shear dominant loading journal, January 2013

Ductile failure under combined shear and tension journal, May 2013

On the deformation and failure of Al 6061-T6 at low triaxiality evaluated through in situ microscopy journal, February 2016

Ductile failure of aluminum alloy tubes under combined torsion and tension journal, October 2016

In situ 3-D observation of early strain localization during failure of thin Al alloy (2198) sheet journal, May 2014

Failure of metals I: Brittle and ductile fracture journal, April 2016

An investigation of the plastic fracture of AISI 4340 and 18 Nickel-200 grade maraging steels journal, June 1974

Fracture and strength of solids journal, January 1949

Compressive Properties of ⟨110⟩ Cu Micro-Pillars after High-Dose Self-Ion Irradiation journal, November 2013

The influence of hydrostatic pressure on the fracture mechanisms of sheet tensile specimens of copper and brass journal, April 1976

Ductile fracture in metals journal, August 1959

The effect of hydrostatic pressure on the tensile fracture of α-brass journal, November 1973

The influence of hydrostatic pressure on the tensile deformation and fracture of copper journal, April 1975

The effects of hydrostatic pressure on the mechanism of tensile fracture of aluminum journal, June 1975

The shear mode of ductile fracture in commercial copper journal, November 1977

The influence of iron content on the plane strain fracture behaviour of AA 5754 Al–Mg sheet alloys journal, February 2002

Ductile failure in polycrystalline OFHC copper journal, December 2011

The fracture of metals journal, January 1963

On localization and void coalescence as a precursor to ductile fracture journal, March 2015

Restoration mechanisms in large-strain deformation of high purity aluminum at ambient temperature and the determination of the existence of “steady-state” journal, September 1994

Room temperature recrystallization of 99.999 pct aluminum journal, February 1994

Dynamic recrystallization in high purity aluminum journal, December 1997

The role of heterogeneous deformation on damage nucleation at grain boundaries in single phase metals journal, September 2009

Do voids nucleate at grain boundaries during ductile rupture? journal, September 2017

An experimental methodology to relate local strain to microstructural texture journal, August 2010

Full-field 3D measurement using multi-camera digital image correlation system journal, September 2013

Slant strained band development during flat to slant crack transition in AA 2198 T8 sheet: in situ 3D measurements journal, November 2015

New discoveries in deformed metals journal, December 2001

Fracture mechanism maps in stress space journal, May 1988

Experimental investigation of void coalescence in metallic sheets containing laser drilled holes journal, May 2008

Observation of void nucleation, growth and coalescence in a model metal matrix composite using X-ray tomography journal, August 2008

Onset of void coalescence in uniaxial tension studied by continuous X-ray tomography journal, February 2013

Low energy dislocation structures associated with cracks in ductile fracture journal, August 1986

A model of ductile fracture based on the nucleation and growth of voids journal, August 1981

Anisotropic ductile fracture journal, September 2004

Influence of Ti on the Tensile Properties of the High-Strength Powder Metallurgy High Entropy Alloys journal, January 2020

Fatigue failure monitoring of 316L stainless steel coupons using optical fibre based distributed strain sensing journal, September 2019

Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects journal, July 2019

The Bending Stress Distribution at the Base of a Stationary Crack
journal, March 1961

Plane strain deformation near a crack tip in a power-law hardening material
journal, January 1968

The Sandia Fracture Challenge: blind round robin predictions of ductile tearing
journal, January 2014

The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading
journal, March 2016

On the ductile enlargement of voids in triaxial stress fields∗
journal, June 1969

Continuum Theory of Ductile Rupture by Void Nucleation and Growth: Part I—Yield Criteria and Flow Rules for Porous Ductile Media
journal, January 1977

Shear band formation in plane strain
journal, January 1981

Material failure by void coalescence in localized shear bands
journal, January 1982

Analysis of the cup-cone fracture in a round tensile bar
journal, January 1984

Two mechanisms of ductile fracture: void by void growth versus multiple void interaction
journal, June 2002

On fracture locus in the equivalent strain and stress triaxiality space
journal, January 2004

Rupture mechanisms in combined tension and shear—Micromechanics
journal, August 2007

A Criterion for Ductile Fracture by the Growth of Holes
journal, June 1968

On the mechanisms of ductile failure in high-strength steels subjected to multi-axial stress-states
journal, June 1976

Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures
journal, January 1985

Rupture mechanisms in combined tension and shear—Experiments
journal, March 2007

Partially coupled anisotropic fracture model for aluminum sheets
journal, May 2010

Ductile fracture: Experiments and computations
journal, February 2011

Modification of the Gurson Model for shear failure
journal, January 2008

On the predictive capabilities of the shear modified Gurson and the modified Mohr–Coulomb fracture models over a wide range of stress triaxialities and Lode angles
journal, July 2011

Calibration and evaluation of seven fracture models
journal, April 2005

Micromechanical analysis on the influence of the Lode parameter on void growth and coalescence
journal, March 2011

Extension of a shear-controlled ductile fracture model considering the stress triaxiality and the Lode parameter
journal, January 2013

Phase-field modeling of ductile fracture
journal, April 2015

Evaluation of six fracture models in high velocity perforation
journal, August 2006

Overview No. 1
journal, January 1979

Criteria for ductile fracture and their applications
journal, April 1980

A complete Gurson model approach for ductile fracture
journal, September 2000

New ductile fracture criterion for prediction of fracture forming limit diagrams of sheet metals
journal, December 2012

Ductile failure behavior of polycrystalline Al 6061-T6
journal, March 2012

Ductile failure behavior of polycrystalline Al 6061-T6 under shear dominant loading
journal, January 2013

Ductile failure under combined shear and tension
journal, May 2013

On the deformation and failure of Al 6061-T6 at low triaxiality evaluated through in situ microscopy
journal, February 2016

Ductile failure of aluminum alloy tubes under combined torsion and tension
journal, October 2016

In situ 3-D observation of early strain localization during failure of thin Al alloy (2198) sheet
journal, May 2014

Failure of metals I: Brittle and ductile fracture
journal, April 2016

An investigation of the plastic fracture of AISI 4340 and 18 Nickel-200 grade maraging steels
journal, June 1974

Fracture and strength of solids
journal, January 1949

Compressive Properties of ⟨110⟩ Cu Micro-Pillars after High-Dose Self-Ion Irradiation
journal, November 2013

The influence of hydrostatic pressure on the fracture mechanisms of sheet tensile specimens of copper and brass
journal, April 1976

Ductile fracture in metals
journal, August 1959

The effect of hydrostatic pressure on the tensile fracture of α-brass
journal, November 1973

The influence of hydrostatic pressure on the tensile deformation and fracture of copper
journal, April 1975

The effects of hydrostatic pressure on the mechanism of tensile fracture of aluminum
journal, June 1975

The shear mode of ductile fracture in commercial copper
journal, November 1977

The influence of iron content on the plane strain fracture behaviour of AA 5754 Al–Mg sheet alloys
journal, February 2002

Ductile failure in polycrystalline OFHC copper
journal, December 2011

The fracture of metals
journal, January 1963

On localization and void coalescence as a precursor to ductile fracture
journal, March 2015

Restoration mechanisms in large-strain deformation of high purity aluminum at ambient temperature and the determination of the existence of “steady-state”
journal, September 1994

Room temperature recrystallization of 99.999 pct aluminum
journal, February 1994

Dynamic recrystallization in high purity aluminum
journal, December 1997

The role of heterogeneous deformation on damage nucleation at grain boundaries in single phase metals
journal, September 2009

Do voids nucleate at grain boundaries during ductile rupture?
journal, September 2017

An experimental methodology to relate local strain to microstructural texture
journal, August 2010

Full-field 3D measurement using multi-camera digital image correlation system
journal, September 2013

Slant strained band development during flat to slant crack transition in AA 2198 T8 sheet: in situ 3D measurements
journal, November 2015

New discoveries in deformed metals
journal, December 2001

Fracture mechanism maps in stress space
journal, May 1988

Experimental investigation of void coalescence in metallic sheets containing laser drilled holes
journal, May 2008

Observation of void nucleation, growth and coalescence in a model metal matrix composite using X-ray tomography
journal, August 2008

Onset of void coalescence in uniaxial tension studied by continuous X-ray tomography
journal, February 2013

Low energy dislocation structures associated with cracks in ductile fracture
journal, August 1986

A model of ductile fracture based on the nucleation and growth of voids
journal, August 1981

Anisotropic ductile fracture
journal, September 2004

Influence of Ti on the Tensile Properties of the High-Strength Powder Metallurgy High Entropy Alloys
journal, January 2020

Fatigue failure monitoring of 316L stainless steel coupons using optical fibre based distributed strain sensing
journal, September 2019

Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects
journal, July 2019