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the setup shown in figure 6 and 7 is an ideal setup for in situ tomography experiments. the experiment uses 4 ft load frames mounted on top of a linear actuator which is preload balanced. the top load frame is designed with an x-ray transparent material, which also allows for direct observation of the crack front. the specimen is mounted to the stages using a load bearing sleeve so that the load can be applied by the linear actuator. the sleeve allows the applied load to be applied evenly about the rotational axis, to which the specimen is attached. the axial movement of the linear actuator as well as rotation of the specimen along the rotational axis is controlled via a servo system. the x-ray scanner is mounted directly above the specimen stage and thus, all mechanical movement is confined to the specimen stage with the x-ray scanner. a small set of accessories, such as holder for ct scanner and sample scanner was provided to connect the specimen stages to the ct and x-ray scanners respectively.

figure 8 shows the fully loaded specimen with central notch, mounted on its load bearing sleeve. the hole is placed in the center of the sleeve and is drilled to a depth of 1mm. two axial load directions (x and y) are used to cover the full cross-sectional area of the specimen, but for the z-direction, only the top half (1/2 z) is scanned. the notch is machined to dimensions of 1.5mm × 1.5mm × 1mm, with a central hole of 1.5mm diameter. an outline of the specimen and a laterally patterned region of the specimen at low loads are shown in figure 8. figure 9 shows the crack growth front at different applied loads. the crack propagates both in the x- and y-direction at the same time. with applied loads of about 18 n, the crack grew to about 1mm in height. the in situ tomography data of this crack propagation were validated with an out-of-focus bucky correction (fig. 10).

in order to accurately measure fatigue crack growth rates, the crack path is preferably measured accurately and consistently. this can be achieved using sen specimens or a larger mt specimen. however, sen specimens are more practical for testing a larger number of specimens in a short period of time (3 days). to accurately measure the crack path of a sen specimen, the crack must be in the center of the specimen. this is because the notch shape or the notch orientation can affect the crack path. therefore, the cracks are preferably nucleated on the edges of the specimen or at the center of the specimen (with an appropriate notch shape and orientation). in this study, we have used an edge-notched specimen and a notch was machined to the center of the specimen using a two-axis milling machine. the crack was then nucleated on the notch with a prescribed crack length (3.5mm). the fatigue crack growth rates (da/dn) were measured at a constant strain ratio of 0.6 using both sen and sen+mt specimens. results are shown in figure 12. the fracture toughness k as a function of crack length is plotted in figure 12 (a). a linear relationship between k and the crack length was obtained for the sen specimen. the value of k for sen+mt specimens (3.34mpa·m0.5, measured in mt stage) was slightly higher than that of the sen specimen. the fatigue crack growth rates for sen and sen+mt specimens were found to be 15.2±0.4% and 15.8±0.4% per million cycles, respectively. the crack growth rate was slightly higher for sen+mt specimen because of a notch in the center of the specimen.
the design of the third stage (figure 6 ) included the ability to automatically control the actuator using feedback from the load cell. additionally, the sample was inserted from the top of the stage rather than from the cut outs in the sleeve. the reason for this was that small cracks were observed over time near cut outs due to the combination of the applied load and the use of pink beam (used in corrosion-fatigue). thus, a wider, shorter sleeve was used to facilitate sample loading and to increase load frame stiffness to perform fatigue tests at high r-ratios. the actuators stroke length was also increased to 25mm to provide more clearance during sample loading.
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