On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant-amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant-amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In each case the marker loading was selected so as to have minimal influence on the growth rate under the primary loading. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information.