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The crack growth paths of two different samples of nuclear reactor tubing were examined. The crack paths reported on in the literature show substantial differences between identical samples. The samples were different in geometry and had different coating conditions. The crack growth paths were studied using standard plasticity theory, as well as by using crack propagation and opening models. The results showed that significant differences in crack paths could occur due to the differences in geometry, sample condition, and testing technique. It was also found that the mechanical properties of the tubing may be a major influence on the crack path selection. By using general crack propagation models and a range of material parameters, the model was able to predict the evolution of the crack path for the two samples. The lack of reproducibility of the crack path data in the literature is due to the lack of agreement on the method employed. The current study shows the importance of having a common approach when testing cracking models and the need to re-assess the current methods used in cracking models to ensure reproducibility of the data and to ensure that the crack path is being measured consistently in the literature.

The fracture behaviour of the rock sample was investigated using the finite element method (FEM) in conjunction with the Morris and Rice (MR) plasticity model. The MR model was found to produce crack paths which closely matched the microstructure and stress wave propagation. The material properties were parameterized using the results of a small-scale uniaxial compression test on a grain-size sized test specimen. The results were validated against the published experimental data on the rock sample.

Grain boundary evolution due to crack propagation is a complex, non-linear process. The fracture behaviour of a standard polycrystalline rock sample was investigated in a 1/16 by 1/16 by 12 in. section. The test was conducted using a low strain rate tensile machine with a 50 kN load cell. The microstructure of the sample consisted of elongated grains, for which a tensile stress wave propagated from grain to grain, causing the failure to progress along the wave. The microstructural features and the stress wave progression were measured using 3-D laser scanning and imaging techniques.

The severity of a crack's effect upon the tensile strength of a material is a function of its length, its orientation, and the magnitude of the stress it experiences. The effect of cracks on tensile strength is examined, using various crack lengths and orientations, for superplastic nickel and superplastic aluminum. The results show that the effect of a crack on the tensile strength of superplastic nickel and superplastic aluminum is larger than that of superplastic copper. The effect of a crack on tensile strength appears to be greater for aluminum than for nickel.

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