A unified potential drop calibration function for common crack growth specimens

Calibration functions, used to determine crack extension from potential drop measurements, are not readily available for many common crack growth specimen types. This restricts testing to a limited number of specimen types, typically resulting in overly conservative material properties being used in residual life assessments. This paper presents a unified calibration function which can be applied to all common crack growth specimen types, mitigating this problem and avoiding the significant costs associated with the current conservative approach. Using finite element analysis, it has been demonstrated that Johnson’s calibration function can be applied to the seven most common crack growth specimen types: C(T), SEN(T), SEN(B), M(T), DEN(T), CS(T) and DC(T). A parametric study has been used to determine the optimum configuration of electrical current inputs and PD probes. Using the suggested configurations, the error in the measurement of crack extension is <6% for all specimen types, which is relatively small compared to other sources of error commonly associated with the potential drop technique.