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Fatigue crack is one of the most common damage forms for aeronautical aluminum alloy. With crack propagation, the strain fields of the whole object surface and plastic zone (PZ) ahead of the crack tip are changing continuously. For most metallic materials, the behavior of PZ around the crack tip and continuous strain variation play a vital role in crack propagation. In this work, the “continuous” strain information at and in front of the crack tip on the specimen surface was obtained quantitatively and the PZ size ahead of crack tip was in situ measured quantitatively with crack propagation by using the digital image correlation (DIC) method, which overcomes the difficulty for the in situ measurement of mechanical variables. Moreover, the method of specimen preparation was simplified by using a white matt paint with strong adhesion, but also resulted in a higher resolution being shown, even for such a large area. Furthermore, the experimental results of the PZ size from the proposed method had good agreement with the theoretical values, which overcomes the limitation that the conventional approaches only consider the quasi-static crack. Finally, the continuous strain variation behavior was analyzed from the experimental results in detail with the consideration of crack propagation.

In Situ Measurements for Plastic Zone Ahead of Crack Tip and Continuous Strain Variation under Cyclic Loading Using Digital Image Correlation Method