A novel semi-empirical technique for improving API X70 pipeline steel fracture toughness test data

Accurate measurement of KIC values for gas pipeline steels is important for assessing pipe safety using failure assessment diagrams. As direct measurement of KIC was impossible for the API X70 pipeline steel, multi-specimen fracture tests were conducted to measure JIC using three-point bend geometry. The J values were calculated from load-displacement (F-δ) plots, and the associated crack extensions were measured from the fracture surface of test specimens. Valid data points were found for the constructed J-Δa plot resulting in JIC=356kN/m. More data points were added analytically to the J-Δa plot to increase the number of data points without performing additional experiments for different J-Δa zones where test data was unavailable. Consequently, displacement (δ) and crack-growth (Δa) from multi-specimen tests (with small displacements) were used simultaneously, resulting in the variation of Δa-δ (crack growth law) and δ-Δa obtained for this steel. For new Δa values, corresponding δ values were first calculated from δ-Δa. Then, corresponding J values for the obtained δ values were calculated from the area under the F-δ record of a full-fractured specimen (with large displacement). Given Δa and J values for new data points, the developed J-Δa plot with extra data points yielded a satisfactory estimation of JIC=345kN/m with only a -3.1% error. This is promising and showed that the developed technique could ease the estimation of JIC significantly and reduce the time and cost of expensive extra fracture toughness tests.