Fracture and Fatigue Testing for Structural Integrity and Fitness-for-Service Assessments

Understanding the fracture and fatigue behavior of metallic materials is fundamental to the safe design and continued operation of pressure-retaining and load-bearing assemblies. Ion Industrial Metallurgy R&D Inc. (Ion Metal MTL) provides accredited fracture toughness, fatigue crack propagation, and cyclic fatigue testing services that support engineering critical assessments (ECA), design qualification, and fitness-for-service (FFS) evaluations in accordance with international codes.

Fracture Toughness Testing

Fracture toughness quantifies a material’s resistance to crack initiation and unstable crack growth. Ion Metal conducts both linear-elastic (K_IC) and elastic-plastic (J-integral, CTOD) fracture mechanics tests in accordance with international standards including:

• ASTM E399, ASTM E1820, ASTM E561

• BS 7448-4, BS 8571, DNV GL RP-F108

• ISO 12135, ISO 12737, ISO 15653

These methods are applied to base metals, weldments, and heat-affected zones over a wide temperature range. Tests can be performed under inert, air, or special environments like pressurized hydrogen following ASTM E1681, and relevant design codes such as ASME BPVC Section VIII Division 3 and ASME B31.12 for hydrogen piping and containment systems.

Fracture fatigue testing image from one of our test in Ion Metal

Fatigue and Crack Propagation Testing

Fatigue performance defines service life under cyclic loading. Ion Metal offers:

• Low-cycle fatigue (LCF) and high-cycle fatigue (HCF) tests per ASTM E606, ASTM E466, ISO 12106, ISO 1099

• Fatigue crack growth rate (da/dN-ΔK) evaluations per ASTM E647 and ISO 12108

Our electro-mechanical and servo-hydraulic test systems provide precise load, strain, and displacement control, with options for elevated or cryogenic temperature conditioning. These data support design fatigue curves, weld qualification, and damage tolerance analyses of critical aerospace, energy, and transportation components.

Engineering and Fitness-for-Service Applications

Results obtained from Ion Metal’s mechanical characterization programs are integrated into ASME/API Fitness-for-Service (FFS) assessments, enabling quantitative evaluation of flaws, hydrogen-induced cracking, and defect tolerances in pressure vessels, pipelines, and structural assemblies.

Through combined expertise in fracture mechanics, fatigue behavior, and metallurgical evaluation, Ion Metal provides data and interpretation essential for safe design, failure prevention, and life-extension decisions in demanding industrial environments.