Fatigue crack propagation in functionally graded materials
Propagation of cracks in functionally graded materials (FGMs) under cyclic loading was investigated via experiments and finite element (FE) analysis. Alumina-epoxy composites with an interpenetrating-network structure and tailored spatial variation in composition were produced via a multi-step infiltration technique. Compressed polyurethane foam was infiltrated with alumina slip. After foam burn-out and sintering, epoxy was infiltrated into the porous alumina body. Non-graded specimens with a range of compositions were produced, and elastic properties and fatigue behaviour were characterised. An increase in crack propagation resistance under cyclic loading was quantified via a novel analytical approach. A simulation platform was developed with the commercial FE package ANSYS. Material gradient was applied via nodal temperature definitions. Stress intensity factors were calculated from nodal displacements near the crack-tip. Deflection criteria were compared and the local symmetry criterion provided the most accurate and efficient predictions. An automated mesh-redefinition algorithm enabled incremental simulation of crack propagation. Effects of gradient and crack-geometry parameters on crack-tip stresses were investigated, along with influences of crack-shape, crack-bridging, residual stresses and plasticity. The model provided predictions and data analysis for experimental specimens. Fatigue cracks in graded specimens deflected due to elastic property mismatch, concordant with FE predictions. In other FGMs, thermal or plastic properties may dominate deflection behaviour. Weaker step-interfaces influenced crack paths in some specimens; otherwise effects of toughness variation and gradient steps on crack path were negligible. Crack shape has an influence, but this is secondary to that of elastic gradient. Cracks in FGM specimens initially experienced increase in fatigue resistance with crack-extension followed by sudden decreases at step-interfaces. Bridging had a notable effect on crack propagation resistance but not on crack path. Similarly, crack paths did not differ between monotonic and cyclic loading, although crack-extension effects did. Recommendations for analysis and optimisation strategies for other FGM systems are given. Experimental characterization of FGMs is important, rather than relying on theoretical models. Opportunities for optimization of graded structures are limited by the properties of the constituent materials and resultant general crack deflection behaviour.
Functionally graded materials (FGMs), composites, fracture, fatigue, finite element analysis, R-curve
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