The effect of crack tunneling on crack growth: experiments and CTOA analyses

This paper compares experimental crack-front shapes recorded at various stages of crack growth with area-average crack growth values during fracture tests conducted on 2024-T351 aluminum alloy plate. Crack-front shapes were determined by fracturing the specimen to a predetermined amount of crack growth and fatigue cycling the specimen for about 4000 cycles at a high stress ratio (Pmin/Pmax) to mark the crack-front location. For each shape, the area-average crack length was determined. The evolution of tunneling was used to create a calibration curve that could be used to adjust surface measured crack-length values, for a more representative comparison with analyses that use a straight crack-front approximation. The analysis compares much more favorably with the average crack growth than with the surface measured values near maximum load. However, the area-average technique tends to over correct crack growth near the crack initiation load. Crack tunneling results show that the area-average technique produces more representative crack-length measurements compared to optical based surface measurements.