Fracture Mechanics in Failure Analysis

Structural failure may occur when the overall structural cross-section cannot support the applied load or, when the critical flaw size ac is exceeded by preexisting discontinuity or by reaching the critical crack size through fatigue, stress corrosion cracking or creep mechanisms. Using fracture mechanics the stress at a crack tip can be calculated by a stress-intensity parameter K as, 

Structural failures in general occur by a combination of crack initiation followed by subcritical crack growth mechanism such as stress corrosion, fatigue, and creep until a critical crack size is reached. Thus, fracture mechanics is useful in evaluating ac that leads to failure by fracture. The application of fracture mechanics in failure analysis throws light on the progress from subcritical crack growth to fracture, the amount of load 

In the case of thin sections the measure of toughness is given by plane-stress fracture toughness, Kc and elastic-plastic fracture mechanics (EPFM) are used. It is also necessary to bear in mind that plane-stress fracture toughness Kc is higher than plane-strain fracture toughness Xlc. 

Determination of residual stress of a failed component is one of the most important steps in failure analysis. The determination of residual stress is useful when failed components experience stress concentration, overload, distortion or the formation of cracks in the absence of applied loads, subjected to corrosive environments as in stress corrosion, mechanical or thermal fatigue due to cyclic loading, or when faults in processing such as shot peening, grinding, milling and improper heat treatment such as stress relief, induction hardening, thermal strains, exposure temperature are involved. 

The measurement of d-spacing under unstressed d() and stressed conditions d is used to calculate the strain, e 

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