Establishing a methodology to predict the crack initiation load in through-wall cracked components using tensile specimen test data

Among several other definitions, the crack initiation fracture toughness (Ji) based on critical stretch zone width (SZWc), called JSZWc, is being considered as a geometry independent material property. The problem in SZWc experimental evaluation is in identifying the size of stretch zone on a blunted crack front as this requires a high degree of precision and expertise in measuring the SZW. The present study addresses finite element determination of SZWc value using tensile test data. The role of stress tri-axiality in standard fracture specimens and the smooth round tensile specimen is also studied. Based on the ASTM-E1820 standard, the present study also showed that fracture specimen thickness greater than the specified size is to be used for numerical prediction of valid SZWc value. The numerically predicted SZWc that leads to JSZWc matches well with experimental values. Using JSZWc, the crack initiation load is also determined in circumferentially through-wall cracked (TWC) elbows and compares well with experimental results. Thus the paper establishes the methodology to predict crack initiation in cracked piping components using numerically obtained valid JSZWc from material’s tensile test data.