DOI: 10.5281/zenodo.11945904
title: Digital image correlation displacements and strains around a growing fatigue crack in an AA2024-T3 aluminium alloy

description: This repository contains the data used in the research article:

Strohmann, Melching, Paysan, Dietrich, Requena, Breitbarth. Next generation fatigue crack growth experiments of aerospace materials. Scientific Reports, 2024, https://doi.org/10.1038/s41598-024-63915-x.

 

General DescriptionThe dataset contains digital image correlation (DIC) data of a growing fatigue crack in an AA2024-T3 alloy. For the experiment, two independent DIC measurement devices were used – a global full-field DIC and a local microscopic DIC. Thus, the dataset consists of two main directories. One for the 3D DIC data ("global_3d_dic") and a second one for the 2D microscopic DIC data ("local_2d_dic"). Both of these are described and connected by rich metadata.The 3D DIC data directory contains two subdirectories (a "Nodemaps" directory and a "Connections" directory). Both of them contain 797 '.txt'-files. The "Nodemaps" give the DIC results (i.e. coordinates, displacement and strains) for every timestep throughout the experiment. These are usually maximum, minimum, and mean load of a certain load cycle. However, for few crack lengths, we obtained DIC data for a higher number (ca. 100) of images within one load cycle. The nodemaps' format and structure is optimized for data processing in the open-source Python package CrackPy. The last integer number of each filename can be interpreted as a 'timestep' throughout the experiment. The "Connection" files represent the connections of the DIC facet center coordinates. These are necessary to export the "Nodemap" data to any mesh like dataset, e.g. for VTK. The 2D microscopic DIC directory contains 3 subdirectories ("80", "90", "95") for predefined positions with respect to the specimen coordinate system. For each location, a number of DIC data are stored, again within two subdirectories "Nodemaps" and "Connections" as '.txt'-files. For the 2D DIC data, the last integer of each name cannot be correlated to a timestep. Instead, we provide a descriptive file "local_2d_microscopic_coordinates_by_nodemaps.csv" linking each and every "Nodemap"-file to its respective coordinates and timestep (i.e. the load cycles).

To describe the data, we distinguish between1.    Higher-level metadata - these data contain information about the experiment and material. The data do not change between timesteps and are given within this description.2.    Timestep metadata - these data contain information about one timestep of the experiment and are stored in the header of each "Nodemap"-file.

 

Higher-level MetadataThe experiment is described in detail in the reference publication by Strohmann et al. (2024) and a summary is given below. Moreover, we provide a dictionary in javascript object notation explaining terms which are used in the higher-level metadata. We use such a dictionary since no standardized ontology is currently available. This dictionary is stored in the main directory as "higher_level_metadata_dictionary.json".

Material A commercially available AA2024-T3 aluminum alloy was tested in L-T orientation, i.e. rolling direction, L, parallel to the load axis. The specimen had a width W = 160 mm cut from a rolled sheet of 2 mm.

Digital image correlationFor 3D DIC, we used a GOM Aramis 12M system with a facet size of 20 x 20 pixels and a 16 pixels facet distance. One facet, therefore, covers ~0.614 x 0.614 mm². For the 2D microscopic DIC we captured images using a Zeiss STEMI 206C light optical microscope (LOM), equipped with a Basler a2A5320-23µmPro global shutter CMOS camera. One image has a size of 10.2 x 5.7 mm², 5328 x 3040 Pixels and a facet size of 40x40 pixels (distance of facet center points 30 pixels). The LOM was mounted to a robotic arm, a KUKA lbr Iiwa Cobot.

Fatigue crack growthWe used a standard uniaxial servo-hydraulic testing rig. We applied a cyclic load ranging from Fmin = 4.5 kN to Fmax = 15 kN, i.e. R=Fmin/Fmax = 0.3. Throughout the experiment, we measured the crack length using direct current potential drop (DCPD).

Image acquisition during fatigue crack growthWe acquired reference images for the DIC calculations before the experiment. For the global DIC, this is simply an image of the unloaded specimen. For the local microscopic DIC, the reference images are acquired in a checker board pattern with an overlap of 70 %. The depth of focus was calibrated for each image individually following (see Paysan et al. (2023)). Images were acquired every 0.5 mm of crack extension at minimum, maximum and 0.5(Fmax- Fmin).

 

Timestep MetadataThe timestep-wise metadata is stored in the individual DIC output files, "Nodemaps". We explain the terms used in a second dictionary, "timestep_level_metadata_dictionary.json". For all DIC data, we stored all data coming from the machine controller, i.e. number of cycles, force, displacement of the cylinder and also potential and crack length calculated from the potential as well as current values for back face strain gauges at both back faces of the MT specimen. In addition, for the local microscopic DIC data, we also store the current location of the center point of the image with respect to the global coordinate system provided by the current position of the robot carrying the LOM.