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Article history: The main aim of this paper is to investigate the effect of yield strength mismatch of parent
Received 19 October 2006 and weld metal on the fracture behavior of plain and heat-treated welded nodular cast iron.
Received in revised form 7 June 2007 For this, experimental and theoretical studies were performed. Nickel electrode, which has
Accepted 28 June 2007 lower yield strength value than that of the parent material, was used to join nodular cast
iron by cold arc welding method. In experimental study, fracture toughness (J-integral) val-
ues were determined for various crack locations including base, weld metal and heat affected
Keywords: zone. In theoretical study, finite element analyses were performed for the same crack loca-
J-integral tions with different crack lengths. Stress triaxiality and equivalent plastic strain values were
Undermatching determined for all crack locations and various crack lengths. Finally, fracture toughness val-
Stress triaxiality ues of the base metal were determined as lower than those of the other regions including the
CMOD weld metal and the heat affected zones. Stress triaxiality and equivalent plastic strain val-
Nodular iron ues used to clarify the effect of yield strength mismatch on the constraint around crack tip
increased with growing crack length in annealed and under-matched models. In annealed
models, stress triaxiality values became slightly lower but equivalent plastic strain values
appeared higher than those of under-matched models.
© 2007 Published by Elsevier B.V.
∗
Corresponding author. Tel.: +90 236 2412144; fax: +90 236 2412143.
E-mail address: hakan.cetinel@bayar.edu.tr (H. Cetinel).
0924-0136/$ – see front matter © 2007 Published by Elsevier B.V.
doi:10.1016/j.jmatprotec.2007.06.081
184 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 8 ( 2 0 0 8 ) 183–190
Table 1 – Chemical composition of the nodular iron and the weld metal (mass percent)
Element Fe Ni C Cu Si Mn P S
Table 2 – Mechanical properties of the nodular iron and the weld metal
P0.2 (MPa) m (MPa) E (MPa) K (MPa) n ε (%)
Table 4 – Microhardness and yield strengths of different regions of the plain and the annealed models
Weld metal Base metal HAZ1 HAZ2 HAZ3
Annealed
Microhardness (80 g) (HV) 81 120 130 220 130
Yield strength (MPa) 104 263 273 355 273
Plain
Microhardness (80 g) (HV) 170 190 220 390 210
Yield strength (MPa) 218 325 351 504 342
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 8 ( 2 0 0 8 ) 183–190 187
4.2. Numerical results Fig. 6 – (a) Stress triaxiality and (b) equivalent plastic strain
values along y-axis around crack tip in the center and on
In Eq. (2), stress triaxiality (h) resulting from crack tip con- the surface of the under-matched, annealed and
straint is given by the ratio of the hydrostatic stress ( h ) over even-matched models for 5.2 mm crack length on the
the von Mises effective stress ( e ) location 2.
√
h (r, , z) 2
ST = h(r, , z) = = √ kk{ { (2)
e (r, , z) 3 3 ij ij
in the center than that of on the surface of the models. On in stress triaxiality values with crack length arises from differ-
the surfaces of the annealed model, equivalent plastic strain ent regions with various work hardening exponents. Strengths
values become higher than those of under-matched and even- of different regions increase by plastic deformation or crack
matched models. growth. This increase is higher in the HAZ than these of the
Fig. 8 depict the variation of stress triaxiality values with base metal and the weld metal. Thus, mismatch between HAZ
crack length at 0.01 mm away from the crack tip in the center and other regions increased by deformation, so constraint at
of the even-matched, under-matched and annealed models crack tip increased by plastic deformation or crack growth.
comparing with even-matched specimens for different crack Fig. 9 depict the variation of equivalent plastic strain val-
locations. As seen in Fig. 8a, even-matched models have the ues with crack length at 0.01 mm ahead of crack tip in the
higher stress triaxiality values for all crack lengths. In under- center of the even-matched, under-matched and annealed
matched models with different crack lengths on different models for different crack locations. As seen in Fig. 9a, for
crack locations, higher stress triaxiality values occur on the shorter crack lengths, there is no significant difference in
crack location 2 placed between base metal and weld metal, equivalent plastic strain values among even-matched and
because this crack location is the nearest one to HAZ where under-matched models including all crack locations, but with
plastic strain flow confined. This hindrance is more effec- increasing crack length, equivalent plastic strain values in
tive than those of other crack locations. In location 4, there crack locations 1 and 2 on under-matched models get higher
is a small volume between the crack tip and HAZ region. than those of even-matched models and under-matched mod-
Lower stress triaxiality values take place on the location 4 els with cracks in other location. In Fig. 9b, the same situation
for shorter crack lengths but this situation changes with can be observed for annealed models. There is no signifi-
growing crack length and the lowest stress triaxiality values cant difference in equivalent plastic strain values for shorter
occur on the crack location 1. Fig. 8b shows the similar sit- crack lengths. Equivalent plastic strain values get lower with
uation for annealed models. Lower stress triaxiality values increasing crack length for location 3 and 4 on annealed and
occur in annealed models for all crack locations than those even-matched models. The increase in plastic deformation at
of even-matched models. On locations 2 and 3, higher stress crack tip reduces the stress triaxiality. Plastic deformation at
triaxiality values take place than those of locations 1 and 4. crack tip may be exhausted if increase in equivalent plastic
In shorter crack lengths, stress triaxiality values on location 4 strain becomes extensive due to the lack of extension into the
are lower than that of location 1. This situation changes with material. In even-matched models, these equivalent plastic
the growing crack length for crack locations 1 and 4. Increase strain values do not change significantly. Equivalent plastic
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 8 ( 2 0 0 8 ) 183–190 189
Fig. 10 – Equivalent plastic strain distribution (a) on the Fig. 11 – Equivalent plastic strain distribution (a) on the
surface and (b) in the center of the under-matched model surface and (b) in the center of the annealed model for
for 5 mm crack length in the crack location 3. 5 mm crack length in the crack location 3.
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