Brittle fracture in structural steels: perspectives at different size-scales

This paper describes characteristics of transgranular cleavage fracture in structural steel, viewed at different size-scales. Initially, consideration is given to structures and the service duty to which they are exposed at the macroscale, highlighting failure by plastic collapse and failure by brittle fracture. This is followed by sections describing the use of fracture mechanics and materials testing in carrying-out assessments of structural integrity. Attention then focuses on the microscale, explaining how values of the local fracture stress in notched bars or of fracture toughness in pre-cracked test-pieces are related to features of the microstructure: carbide thicknesses in wrought material; the sizes of oxide/silicate inclusions in weld metals. Effects of a microstructure that is 'heterogeneous' at the mesoscale are treated briefly, with respect to the extraction of test-pieces from thick sections and to extrapolations of data to low failure probabilities. The values of local fracture stress may be used to infer a local 'work-of-fracture' that is found experimentally to be a few times greater than that of two free surfaces. Reasons for this are discussed in the conclusion section on nano-scale events. It is suggested that, ahead of a sharp crack, it is necessary to increase the compliance by a cooperative movement of atoms (involving extra work) to allow the crack-tip bond to displace sufficiently for the energy of attraction between the atoms to reduce to zero.