Fatigue Precracking of
Spin-burst Toughness Specimens
Paper describes a hydrostatic pressure-cycling technique
developed to permit controlled fatigue precracking of large
spin-burst fracture-toughness specimens
by W. G. Clark, Jr., and L. J. Ceschini
ABSTRAET--A hydrostatic pressure-cycling technique
developed to permit controlled fatigue precracking of
large spin-burst fracture-toughness specimens (disks in
excess of 12 in. in diameter and 3 in. long) is described.
The procedure involves localized internal-pressure cycl-
ing of the specimens by varying the hydrostatic pressure
within a small "notched" hole. The technique is capable
of generating hydrostatic pressures in excess of 40,000 psi
at an operating frequency of one pressure cycle per
second. In addition, the cyclic stresses are independent of
specimen size, provided thick-wall pressure-vessel condi-
tions exist. An ultrasonic flaw-detection technique used
to measure the extent of fatigue-crack growth during
cyclic loading is also described.
The pertinent data associated with the fatigue pre-
cracking of eight alloy steel (~ys ~ 85,000 psi) spin-burst
specimens approximately 13 in. in diameter and 10 in.
long are presented. The effectiveness of pressure cycling
and the accuracy of the crack-monitoring technique are
discussed. At a cyclic load range of 8000 to 40,000 psi,
fatigue cracks on the order of 0.3 in. long were developed
in approximately 60,000 cycles (17 hr). The ultrasonic
crack-length-measurement technique was found to
exhibit a sensitivity of 0.030 in.
Introduction
Spin-burst fracture testing of large center-bored
disks was developed specifically to reproduce, under
controlled conditions, the stress situation encoun-
tered in large rotating components. 1 More recently,
s i m i l a r tests involving internally notched (0.001-
0.005-in. root radius) disks have been used to esti-
mate the plane strain (brittle) crack-notch fracture
characteristics of low-strength, high-toughness fer-
rous alloys. 2,3 Although such tests provide a
realistic approach to laboratory duplication of plane-
strain loading conditions, it has long been desirable
to replace the machined notches with actual cracks
of sufficient notch acuity representative of severe
natural defects.
W . G. Clark, Jr., and L. J . Ceschini are Research Engineers, Westinghouse
R & D Center, Pittsburgh, Pc.
Paper was presented at 1968 S E S A Spring Meeting held in Albany, N . Y.,
on M a y 7-10.
Y u k a w a and McMullin have shown t h a t the
fracture strength of an alloy steel measured with
slow-bend toughness specimens is approximately 35
percent lower in the presence of an actual crack as
compared to a machined 0.005-in. root-radius
notch. ~ Additional tests on other ferrous alloys
have shown t h a t even more sharply notched speci-
mens (0.001-in. root radius) fail to yield fracture
strengths as low as those encountered with cracked
specimens.S. 5.0 F r o m these data, it is apparent
t h a t sharply machined notches cannot be considered
truly representative of the most severe defect which
can be encountered in an actual application. There-
fore, in order to establish a conservative measure of
a material's resistance to failure in the presence of
a defect (fracture toughness) and ultimately, to
provide realistic fracture-toughness data suitable for
design purposes, toughness specimens must contain
crack-like defects. Current A S T M recommendations
for plane-strain fracture-toughness testing require
t h a t machined notches be extended to fatigue-crack
severity b y low-stress cyclic loading. 7 I n addition,
these criteria require t h a t the fatigue crack be of
sufficient length such t h a t the crack-tip stresses a r e
not influenced by the starter-notch geometry. Gen-
erally, fatigue precracking of crack-notch toughness
specimens is relatively simple and involves conven-
tional fatigue-testing equipment. Also, the crack
length can usually be measured b y visual observa-
tion. However, due to the size and configuration
of spin-burst toughness specimens (disks in excess
of 12-in. in diameter and 3-in. long), conventional
fatigue-precracking techniques are not applicable.
Early attempts to improve the effective "sharp-
ness" o f machined notches involved nitriding the
notch to produce a layer of brittle material at the
notch tip. 3 This procedure was based upon the
assumption that, during loading, the brittle nitrided
layer would crack at a low nominal stress resulting
in a stress concentration of sufficient sharpness to
Experimental Mechanics ] 123
 ~ Specimen
Blank
LrTInspection
Surface ,, '.

s D.M. Slot
suitable technique of precracking spin-test specimens
is needed to accurately establish minimum precrack
length and in turn, to assure realistic test results.
This report describes a hydrostatic pressure-
cycling technique developed to permit controlled
fatigue precracking of large spin-burst fracture-
toughness specimens. An ultrasonic flaw-detection
procedure used to continuously monitor and control
crack growth during the pressure-cycling operation
FatigueCrack
Crack
91" -. 3" Long is also described.
Starter
Specimen Preparation
13" "1 Figure 1 presents a schematic representation of
]]16" Wide lit
;;i @ the pertinent steps involved in the preparation of
Sawcut 7 hi
h~ fatigue-precracked spin-burst toughness specimens.
hf
11, A 88 hole is gun-bored in the axial direction
Iii
through the specimen blank at a position correspond-
L-l]16"~deSawcut I j hi
I ill

/E.D.M.
SlOt(0. 0]")
J
i
I I
Spin-BurstToughness
Specimen
Fig. 1--Details of specimen preparation of fatigue-
precracked spin-burst specimens
simulate a crack-like fracture origin. However, con-
ventional nitriding procedures yield a brittle layer
of about 0.025-in. in depth which m a y not be long
enough to avoid the influence of the starter notch.
In addition, nitriding m a y affect the material beyond
the brittle layer such t h a t the test is not representa-
tive of the actual component. As a result, a more
'h
ing to 89 in. less t h a n the radial distance to the
desired crack-tip location. A ~-in.-long, 0.010-in.-
wide slot is then machined outward radially from the
hole by means of a "traveling wire" electric-arc
discharge machining (EDM) technique. The E D M
slot serves as the stress raiser necessary to induce
low-stress fatigue-crack propagation during subse-
quent pressure cycling of the disk. I n order to
accommodate the high-pressure fittings required for
hydrostatic pressure loading, the ~-in.-diam hole is
counterbored to ~-in. diameter, ~-in. deep on each
end. In addition, a 4-in.-wide flat surface (125-~ in.
finish) is machined on the circumference of the rotor
blank over the ~-in.-diam hole and parallel to the
~-in.-long slot as shown in Fig. 1. This surface is
used to permit ultrasonic measurement of crack
growth encountered during cyclic loading.

High PressureGage
-------] RecycleTimer Bridge
Amplifier Oscilloscope
HydraulicPressure
ReducingValve

Hydraulic Supply ~-'Transducer PressureRelief

SolenoidValve
High Pressure
CheckValve LowSide
Displacement ~ PressureGage
Fig. 2--Pressure-cycling Hydraulic Piston I\ ~ ' ~ / I~.\~,1
system used to fatigue Cylinder
crack spin-burst ,/ / / /
toughness specimens Accumulator

II \ I~" / L / ~ C ~ C ~ C ~ \ ~ I~\~---~//, ~,~

~ow

/ Leat ~'~'~ Sp~?;nBRU

rst
Packing Packing
Nut
High PressureSystem LowPressureSystem

124 I March 1969

 hydrostatic pressure. Moving the piston in and out
of the hole permits cyclic loading at a frequency of
one pressure cycle per second. In order to induce
fatigue-crack growth at relatively low stresses, the
maximum pressure is limited to 40,000 psi. This
pressure level corresponds to fatigue precracking at
a stress intensity level on the order of 30 ksiV~n.
Figure 3 shows the fixture and associated equipment
used to fatigue precrack large spin-burst fracture-
toughness specimens.

Measurement of Crack Growth

Fig. 3--Test fixture and associated equipment used to
fatigue precrack spin-burst specimen blanks
Fatigue Cracking
Figure 2 presents a schematic illustration of the
pressure-cycling system used to fatigue crack the
spin-burst-specimen blanks. The procedure, essen-
tially, involves hydrostatic loading of the "notched
hole" b y means of an oil-displacement technique.
The low-pressure control portion of the system is
used to maintain a minimum hydrostatic pressure
of approximately 8000 psi and also to make up any
oil loss through the packing. A 0.245-in.-diam
hardened-steel piston connected to a hydraulic
cylinder is driven into the pressurized "notched-
hole," displacing oil and, in turn, increasing the
The technique developed to measure fatigue-crack
growth during the pressure-cycling operation in-
volves conventional ultrasonic flaw-detection instru-
mentation; in particular, a ~-in.-diam, 10-MHz
(megahertz) ceramic SFZ transducer (supplied b y
Automation Industries) is used in conjunction with
a Sperry Model 721 reflectoscope. T h e essence of the
technique is to relate the position of the transducer
on the inspection surface to the extent of crack
growth b y moving the transducer to maintain a
constant-flaw signal from the propagating crack.
Figure 4 presents a schematic illustration of the
crack-following procedure involved.
T h e ultrasonic-instrumentation sensitivity level
is adjusted such that, with the transducer positioned
at mid-length on the inspection surface directly
above the ~-in.-diam hole (Fig. 4, position A), the
peak flaw signal from the hole is 1.2-in. s/p (sweep
to peak). At this gain setting, the transducer is
moved along the inspection surface in the direction
of the E D M slot until a 0.2-in. s/p signal is obtained
from the tip of the slot (Fig. 4, position B). This
position represents the "zero-crack-growth" trans-
ducer location and provides a reference for measure-
ment of subsequent fatigue-crack growth. The exact
location of the transducer a t position B is measured
and recorded prior to cyclic loading. When cracking

]/4"SDiiagHole
.na,~ / E.SlotD.M. Fatigue
Signal
SiCrack
gnal~ ) \

Fig. 4--Schematic Transducer

representations of the \

•
ultrasonic technique
used to monitor fatigue Inspection
precracking in spin-burst -/t//~//
Surface ii iiill[[

disks

\
I~1/4 DnaHole E,DM,
, Slot
Position "A" PositioGrowt
"B"
n h" Position "C"
Instrument atCalibration
ion "Zero
Crack EndofPrecracUng

Experimental Mechanics I 125


Fig. 5--Transverse section through crack starter in Cr-Mo-V
alloy-steel spin-burst toughness specimen
the transducer is m o v e d in the direction of crack
propagation (Fig. 4, position C). F r o m a predeter-
mined relationship between actual crack length and
the distance the transducer is m o v e d from position
B (zero-crack growth) in order to maintain a 0.2-in.-
s / p flaw signal from the growing crack, it is possible
to determine accurately the fatigue-crack length.
The necessary crack length--transducer location
relationship was established b y removing a i-in.-
thick transverse slice from several precracked speci-
men blanks, visually measuring the extent of crack
growth (see Fig. 5), and comparing the actual crack
length with the distance the ultrasonic transducer
was m o v e d during precracking. The actual crack
length was consistently 0.200-in. less t h a n the
distance the transducer was m o v e d from position B
to position C (Fig. 4). As a result, the ultrasonic
crack-growth measurements m u s t be corrected
accordingly: fatigue-crack length = transducer
location at position C - transducer location at
position B -- 0.200 in.
In order to measure transducer location accurately
and to m a i n t a i n adequate coupling of the transducers
to the inspection surface, the fixture shown in Fig. 6
was developed. T h e fixture consists of a mounting
bracket, spring-loaded transducer holder, screw-
driven micrometer positioner, and a dial gage. T h e
fixture is clamped on the specimen blank as shown
in Fig. 6 such t h a t the spring-loaded transducer can
accurately traverse the inspection surface during
cyclic loading without affecting the ultrasonic
tuning level.

Final Specimen Preparation

occurs, the flaw area within the scanning beam of Once the specimen blank has been precracked to
the transducer increases resulting in an increase in the desired crack length, the spin-burst specimen is
the flaw-signal amplitude. I n order to maintain a cut from the blank and machined as illustrated in
constant signal (0.2-in. s/p) from the growing crack, Fig. 1. Final machining involves center boring the

TABLE 1--SUMMARY OF FATIGUE-PRECRACKING RESULTS

Predicted Actual
fatigue* fatigue-
Cyclic- Transducer Location No. of crack crack
Disk Dia., Length, load range, Position B,* Position C,? elapsed length,l length, L Deviation,
No. in. in. Ib in. in. cycles in. in. in.

Ni-Mo-V alloy steel

(84.ksi yield strength)
4 13 9 4,000-30,000 1.365 1.565 131,000 0.000 0.013 --0.013
5 12.6 9 0-30,000 1.400 1.630 57,000 0.030 0.040 --0.010
Cr-Mo-V alloy steel
(88-ksi yield strength)
1 13.4 10.8 8,000-40,000 1.450 1.990 50,900 0.340 0.360 --0.020
2 12.4 12.4 6,000-40,000 1.530 2.000 48,395 0.270 0.300 --0.030
3 13.5 9.2 8,000-40,000 1.490 1.990 60,000 0.300 0.300 0.000
4 13.5 10.3 7,000-40,000 1.495 1.96511 57,000 0.270 0.410 --0.130Jl
5 13.5 12.4 8,000-40,000 1.550 2.000 56,875 0.250 0.250 0200
6 13.5 12.4 4,000-40,000 1.177 1.650 45,000 0.273 0.300 --0.027
* Transducer position at start of cyclic loading.
t Transducer position at end of cyclic loading.
$ Transducer position C-- transducer position B -- 0.200 in.
w Measured at center of fractured specimens.
I] Double-flaw signal indicating crack branching.

126 I March 1969


Fig. 7--Fracture
appearance of a Cr-Mo.V
alloy-steel spin-burst
specimen tested at 207~ F
disk to approximately 1.5-in. diameter and notching
the bore with two saw cuts approximately 1 ~ - i n .
long, one from the bore to the fatigue crack and the
other diametrically opposite. T h e latter saw cut is
extended b y electrical-discharge machining to yield
a symmetrical, full-length test notch approximately
4-in. long. T h e specimens are then spun to failure at
the test t e m p e r a t u r e of interest and the pertinent
fracture p a r a m e t e r s established.
Results of Fatigue Precracking
Table I presents a s u m m a r y of the pertinent data
associated with the fatigue precracking of eight
alloy-steel spin-burst fracture-toughness specimens.
T h e actual fatigue-crack lengths reported in Table 1
were determined from visual measurements made at
the mid-length location on the disks after spinning
to failure. N o t e t h a t with the exception of Cr-Mo-V
Disk No. 4, the crack length predicted from ultra-
Fig. 6--Fixture used to monitor fatigue-crack
growth in spin-burst toughness specimens
sonic measurements is within 0.030-in. of the actual
crack length.
During the fatigue precracking of Cr-Mo-V Disk
No. 4, two independent flaw signals were observed
indicating crack branching and thus, crack propaga-
tion along a plane not parallel to the inspection
surface. Since the accuracy of the ultrasonic crack-
length-measurement technique depends upon crack
growth being parallel to the inspection surface, the
inability to accurately predict the crack length in
Cr-Mo-V Disk No. 4 was not unexpected.
Figure 7 shows the fatigue crack a n d resulting
fracture appearance of a Cr-Mo-V alloy-steel spin-
burst specimen tested at 207 ~ F. N o t e the uniformity
of the fatigue crack length t h r o u g h o u t the body of
the disk. This appearance is typical of all the speci-
mens precracked using the pressure-cycling tech-
nique. Also note t h a t the extent of fatigue cracking
decreases within 89 of the ends of the disk. Such
Experimental Mechanics ] 127
 behavior is attributed to the variation in the stress
field at the ends of the disk as compared to the
interior. For this reason, the fatigue-crack length
could not be measured visually from the ends of
the disk.
Discussion
T h e p r i m a r y a d v a n t a g e of the fatigue-precracking
technique described in this paper is the ability to
develop cyclic stresses which are independent of
specimen size. F r o m thick-wall pressure-vessel stress
analysis, the nominal tangential stress associated
with the ~ - i n . - d i a m drilled hole is equivalent to the
hydrostatic pressure and independent of the diam-
eter and length of the disks. 8 As a result, unlike
other precracking techniques involving mechanical
loading where larger test specimens require higher
loads and, in turn, equipment of higher capacity, a
single hydrostatic pressure-cycling system is appli-
cable to a wide range of specimen sizes. Although the
hydrostatic fatigue-cracking technique was devel-
oped specifically for spin-burst toughness specimens,
such a procedure can be used to permit controlled
precracking of other heavy-section test specimens.
T h e 0.200-in. discrepancy between actual fatigue-
crack length and the distance the ultrasonic trans-
ducer is moved during crack propagation is attrib-
uted to the change in flaw configuration from an
E D M slot to a fatigue crack. F r o m an evaluation of
a similar crack-following technique used to measure
fatigue-crack growth in wedge-opening-loading
(WOL) toughness specimens, it was found t h a t when
crack growth is measured from an existing fatigue
crack, the distance the transducer is m o v e d corre-
sponds directly to the extent of crack growth, and
no correction factor is required2 However, as in the
case of the spin-burst specimens, crack-growth mea-
surements made from the starter notch require an
adequate correction factor. I t is conceivable t h a t
sound energy is trapped at the junction of the slot
and the fatigue crack (Fig. 5), yielding a signal
amplitude not directly related to the extent of
fatigue cracking; however, the actual cause of the
discrepancy has not been established. Regardless of
the reason, the consistency of the results (Table 1)
clearly indicate t h a t the discrepancy can adequately
be compensated for by means of a suitable correction
factor.
I n addition, since the ultrasonic crack-length-
m e a s u r e m e n t technique is based upon a relative-
flaw-signal response, the technique is independent
of test distance (provided the sound energy can
adequately penetrate the specimen). Changing the
test distance changes only the reflecting area within
the sound b e a m necessary to yield a given flaw
signal. T h e relationship between transducer location
at the beginning and end of precracking and the
extent of crack growth remains the same.
Fracture data, generated with spin-burst speci-
mens precracked in accordance with the technique
described in this paper, provide considerable insight
128 I March 1969
into the o p t i m u m notch design required to produce
effectively notched test rotors. Sankey has s h o w n
that, for the notch geometry described in Fig. 1, it
is necessary to extend the fatigue crack from the
machined notch to a m i n i m u m of 0.10-in. (prefer-
ably 0.2-in.) in order to provide realistic test data. 1~
Comparison of test results associated with ade-
quately fatigue-cracked specimens and specimens
both ~'as-notched" (0.001-in. root radius) and '~as-
nitrided," show t h a t fatigue-cracked specimens yield
fracture-toughness values (stress-intensity factors)
as m u c h as 60 percent lower than "as-notched"
specimens. F r o m these data, it is apparent t h a t spin-
burst toughness specimens m u s t be adequately
precracked to provide realistic design information.
Conclusions
1. Localized internal-pressure cycling permits the
controlled-fatigue precracking of large spin-burst
toughness specimens.
2. T h e cyclic stresses associated with the pre-
cracking technique are independent of specimen size
and geometry as long as thick-wall pressure-vessel
analyses apply.
3. The:extent of crack growth encountered during
the precracking operation can be measured with
conven~tional ultrasonic flaw-detection instrumenta-
tion ~ i t h i n a sensitivity of 0.030 in.
4. F a t i g u e cracks of about 0.300 in. in length c a n
be generated in alloy steel (%~ = 85,000 psi) speci-
mens in approximately 60,000 cycles (17 hr) at
applied stresses less t h a n one-half the yield strength.
Acknowledgments
The authors are indebted to their m a n y associates
at the Westinghouse Research Laboratories who
contributed to the development of the fatigue-pre-
cracking technique described. Particular acknowl-
edgment is given G. O. Sankey of Mechanics R&D,
for his support and helpful comments during the
course of the work.
References
1. Winne, D. H., and Wundt, B. M., "Application of the Gri[fith-lrwin
Theory of Crack Propagation to the Bursting Behavior of Disks, Including
Analytical and Experimental Studies," A S M E Paper 57-A-249 (December,
1957).
2. Sankey, G. 0., '~Spin Fracture Tests of N i - M o - V Rotor Steels in She
Brittle Fracture Range," Proc. A S T M , 60, 721-736 (1960).
3. Brothers, A. J., Newhouse, D. L., and Wundt, B. M., ~'Results of
Bursting Tests of Allay Steel Disks and Their Application to Design
Against Brittle Fracture," General Electric Corporation Report GER-2218,
presented at the 68th Annual Meeting of A S T M (June, 1965).
4. Yukawa, S., and McMullin, J . G., ~'Effects of Specimen Size and
Notch Acuity on the Brittle Fracture Strength of a Heat-Treated Steel,'"
A S M E Paper 61-Met-2, presented at the Metals Engineering Conference
(April, 1961).
5. Wessel, E. T., "The Influence of Pre-Existing Sharp Cracks on
Brittle Fracture of a N i - M a - V Forging Steel," Trans. A S M , 52, 277 (1960).
6. Srawley, J. E., and Beachem, C. D., '~Crack Prapagation Tests of
Some High-Strength Sheet Steels," N R L Report 5263 (Jan. 10, 1959).
7. Brown, W. F., Jr., and Srawley, J . E., "Plane Strain Crack
Toughness Testing of High Strength Metall& Materials," A S T M Special
Technical Publication No. 410 (December, 1966).
8. Roark, R. J., "Formulas far Stress and Strain," 4th Ed., McGraw-
Hill, 377 (1965).
9. Clark, W. G., Jr., Unpublished Westinghouse Research Laboratories
Data.
10. Sankey, G. 0., "Spin Tests To Determine Brittle Fracture Under
Plane Strain," E X P E R I M E N T A L MECHANICS, 8, (12), 529-538 (1968).