Architected crack tip stress field

Abstract

A method for improving apparent fracture toughness of a crack tip is disclosed herein. The method can include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material. The method can further include determining a plurality of parameters associated with material. The method can further include performing finite element analysis (FEA) based on at least one of a geometry of a component for which the surface is disposed, a geometry of the crack, or the plurality of parameters associated with the material. The method can further include determining a design comprising at least one of a hole or a slot to be selectively removed from the surface based on the performed FEA. The method can further include selectively removing the at least one of the hole or the slot from the surface.

Description

Attorney Docket No. WEC-2024-169-PCTTITLEARCHITECTED CRACK TIP STRESS FIELDCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Serial No. 63 / 691,821 filed September 6, 2024, entitled “ARCHITECTED CRACK TIP STRESS FIELD,” the contents of which is hereby incorporated by reference in its entirety herein.FIELD

[0002] The present disclosure is generally related to architected crack tip stress fields, and more particularly, is directed to improved methods for increasing apparent fracture toughness of cracks.SUMMARY

[0003] The following summary is provided to facilitate an understanding of some of the innovative features unique to the aspects disclosed herein, and is not intended to be a full description. A full appreciation of the various aspects can be gained by taking the entire specification, claims, and abstract as a whole.

[0004] In various aspects, a method for improving apparent fracture toughness of a crack tip is disclosed. The method can include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material. The method can further include determining a yield stress and a stress intensity factor associated with the material. The method can further include calculating a radius of a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor. The method can further include determining a design including at least one of a hole or a slot to be selectively removed from the surface within or adjacent to the radius. The method can further include selectively removing the at least one of the hole or the slot from the surface.

[0005] In various aspects, a method for improving apparent fracture toughness of a crack tip is disclosed. The method can include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material. The method can further include determining a plurality of parameters associated with material. The method can further include performing finite element analysis (FEA) based on at least one of a geometry of a component for which the surface is disposed, a geometry of the crack, or the plurality of parameters associated with the material. The method can further include determining a design including at least one of a hole or a slot to be selectively removed from the surfaceAttorney Docket No. WEC-2024-169-PCT based on the performed FEA. The method can further include selectively removing the at least one of the hole or the slot from the surface.

[0006] In various aspects, a method for improving apparent fracture toughness of a crack tip is disclosed. The method can include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material. The method can further include determining a yield stress and a stress intensity factor associated with the material. The method can further include identifying a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor. The method can further include selectively removing at least one portion of the material of the surface within or adjacent to the plastic zone based on a determined crack treatment that increases apparent fracture toughness of the crack.

[0007] These and other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various features of the aspects described herein are set forth with particularity in the appended claims. The various aspects, however, both as to organization and methods of operation, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

[0009] FIG. 1 is a surface representation of a crack in a plate, including plastic zone shapes for plane stress and plane strain conditions, in accordance with at least one nonlimiting aspect of the present disclosure.

[0010] FIG. 2 illustrates a crack with multiple holes located on either side of the crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0011] FIG. 3 illustrates a crack with a hole located on either side of the crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0012] FIG. 4 illustrates a crack with multiple slots located on either side of the crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0013] FIG. 5 illustrates a crack with a slot located on either side of the crack, in accordance with at least one non-limiting aspect of the present disclosure.Attorney Docket No. WEC-2024-169-PCT

[0014] FIG. 6 illustrates two adjacent cracks with multiple holes located on either side of each crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0015] FIG. 7 illustrates two adjacent cracks with a hole located on either side of each crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0016] FIG. 8 illustrates two adjacent cracks with multiple slots located on either side of each crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0017] FIG. 9 illustrates two adjacent cracks with a slot located on either side of each crack, in accordance with at least one non-limiting aspect of the present disclosure.

[0018] FIG. 10 illustrates a method for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure.

[0019] FIG. 11 illustrates a method for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure.

[0020] FIG. 12 illustrates a method for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure.

[0021] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various aspects of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION

[0022] Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the aspects as described in the disclosure and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the aspects described in the specification. The reader will understand that the aspects described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims. Furthermore, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms. Furthermore, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.

[0023] Before explaining various aspects of the architected crack tip stress field in detail, it should be noted that the illustrative examples are not limited in application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative examples may be implemented or incorporated in otherAttorney Docket No. WEC-2024-169-PCT aspects, variations, and modifications, and may be practiced or carried out in various ways. Further, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative examples for the convenience of the reader and are not for the purpose of limitation thereof. Also, it will be appreciated that one or more of the following-described aspects, expressions of aspects, and / or examples, can be combined with any one or more of the other following-described aspects, expressions of aspects, and / or examples.

[0024] The present disclosure is directed to architected crack tip stress fields and improved methods for increasing apparent fracture toughness of cracks. Recently, in nuclear reactor applications, for example, cracks have been identified in both pressurized water reactor (PWR) and boiling water reactor (BWR) core barrels. In order to address such cracks when they exceed the allowable flaw size, one option is to drill a through hole at a tip of the crack (e.g., a crack tip) to blunt the crack tip and to increase the apparent fracture toughness of the crack. As is well known to those having ordinary skill in the art, such through holes may be considered to be crack-arrest holes. However, as is also well known to those having ordinary skill in the art, through holes, or crack-arrest holes, are disadvantageous as coolant may leak through the through holes, or crack-arrest holes, thereby creating a bypass flow. As a result, and because there is typically a limit to allowable bypass flow, it is often necessary to install a plug to prevent such bypass flow. Additionally, drilling through holes, or crack-arrest holes, also results in a significant amount of material being removed.

[0025] The present disclosure provides various methods and techniques for increasing fracture toughness of one or more cracks with, or without, the use of a through hole. In aspects where a through hole or through slot are used, the present disclosure provides various methods and techniques for increasing fracture toughness of one or more cracks without the use of a plug. In aspects where a through hole or slot is not used, the present disclosure provides various methods and techniques for increasing fracture toughness of one or more cracks, and specifically a crack tip associated with the one or more cracks, by selectively removing one or more portions of material adjacent to, or in the vicinity of, the crack tip without creating a through hole or through slot. For example, various methods and techniques are disclosed that selectively remove one or more small holes or slots of material in the vicinity of a crack tip to increase the apparent fracture toughness of a crack.

[0026] The present disclosure also provides that it may be beneficial to selectively remove a single, large hole or slot of material in the vicinity of a crack tip to increase the apparent fracture toughness of a crack. In all aspects, it shall be appreciated that the series of small holes or slots, or the single, large hole or slot, may be through wall or may not be through wall. In other words, it may or may not be necessary to selectively remove material through the wall to change a stress field and thus increase the apparent fracture toughness.Attorney Docket No. WEC-2024-169-PCT

[0027] The present disclosure even further provides that Finite Element Analysis (FEA) may be performed to design and optimize a specific hole, slot, etc. location, pattern, size, and number to optimize the increased apparent fracture toughness depending on the applied stress field, the geometry, and the material mechanical behavior of the core barrel, plate, or the like for which the crack is observed. In addition to FEA, a physical fracture toughness test may be performed to validate the design and optimization solution provided by the FEA.

[0028] There are many benefits provided by the present disclosure. For example, the apparent toughness may be tailored (e.g., increased) for a specific situation by changing the location, pattern, size, and number of holes, slots, etc. Additionally, the amount of material being removed is expected to be far less than that of a typical through hole, or crack-arrest hole, being drilled, or machined, at the crack tip. Additionally, the solutions of the present disclosure may be used in unique situations where there are several parallel cracks (e.g., a situation where through holes, or crack-arrest holes, are impractical). Additionally, the solutions of the present disclosure reduce, or eliminate, bypass flow and no longer require the installation of a plug to prevent such bypass flow.

[0029] Referring now to the figures, FIG. 1 is a surface representation 100 of a crack 102 in a plate, including plastic zone shapes 104, 106 for plane stress and plane strain conditions, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the plastic zone shapes 104, 106 represent the plane stress and the plane strain conditions, respectively, at a crack tip 108 of the crack. Most notably, the plane stress and the plane strain conditions extend laterally on either side of the crack and / or the crack tip, as well as ahead of the crack and / or the crack tip. Furthermore, as shown by the equation of FIG. 1, r = - 7T (— ( yS)2, wherein r is the radius of the plastic zone,is the stress intensity factor, and oysis the yield stress. As such, the radius, r, of the plastic zone may be calculated so long as the stress intensity factor, K and the yield stress, ays, are known.

[0030] Now, with respect to FIGS. 2-9, a crack, or two adjacent cracks, is, or are, shown according to several non-limiting aspects of the present disclosure. It shall be appreciated that the geometry of the crack(s) shown is not to be construed as limiting. Rather, such solutions as provided in the present disclosure may be applicable to any such geometry of any such crack(s). Furthermore, although a hole, a slot, multiple holes, multiple slots, or the like, may be illustrated according to various positions (e.g., adjacent to the crack tip, surrounding the crack tip, a specified distance from and / or beyond the crack tip, etc.), sizes, numbers, patterns, or the like, it shall be appreciated that the position, size, number, pattern, or the like, of any hole(s) or slot(s) is not to be construed as limiting. Rather, such solutions as provided in the present disclosure are for illustration purposes only and any hole(s) or slot(s) may include any position, size, number, pattern, or the like. It shall be furtherAttorney Docket No. WEC-2024-169-PCT appreciated that any hole(s) or slot(s) may not necessarily be symmetrical among an axis defined by the crack and / or the crack tip. Even further, it shall be appreciated that any hole(s) or slot(s) may or may not necessarily extend through the surface (e.g., any hole(s) or slot(s) may or may not be through hole(s) or through slot(s)).

[0031] FIG. 2 illustrates a crack 200 with multiple holes 202 located on either side of the crack 200, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the multiple holes 202 may be located, specifically, near a crack tip 204 of the crack 200. Additionally, the multiple holes 202 may be located beyond a length of the crack 200.

[0032] FIG. 3 illustrates a crack 300 with a hole 302 located on either side of the crack 300, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the hole 302 located on either side of the crack 300 may be located, specifically, near a crack tip 304 of the crack 300. Additionally, the hole 302 located on either side of the crack 300 may be located beyond a length of the crack 300, though not shown in FIG. 3.

[0033] FIG. 4 illustrates a crack 400 with multiple slots 402 located on either side of the crack 400, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the multiple slots 402 may be located, specifically, near a crack tip 404 of the crack 400. Additionally, the multiple slots 402 may be located beyond a length of the crack 400. Although shown in a configuration nearly parallel to the crack, the multiple slots 402 may be positioned in any orientation with respect to the crack 400 and / or the crack tip 404.

[0034] FIG. 5 illustrates a crack 500 with a slot 502 located on either side of the crack 500, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the slot 502 located on either side of the crack 500 may be located, specifically, near a crack tip 504 of the crack 500. Additionally, the slot 502 located on either side of the crack 500 may be located beyond a length of the crack 500. Although shown in a configuration nearly parallel to the crack, the slot 502 located on either side of the crack 500 may be positioned in any orientation with respect to the crack 500 and / or the crack tip 504.

[0035] Although FIGS. 2-3 illustrates a crack treated with holes and FIGS. 4-5 illustrates a crack treated with slots, it shall be appreciated that other embodiments may treat a crack with any combination of holes and slots or other geometries arranged to increase a fracture toughness of the crack.

[0036] FIG. 6 illustrates two adjacent cracks 600 with multiple holes 602 located on either side of each crack 600, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the multiple holes 602 may be located, specifically, near a crack tip 604 of each crack 600. Additionally, the multiple holes 602 may be located beyond a length of each crack 600.

[0037] FIG. 7 illustrates two adjacent cracks 700 with a hole 702 located on either side of each crack 700, in accordance with at least one non-limiting aspect of the presentAttorney Docket No. WEC-2024-169-PCT disclosure. As shown, the hole 702 located on either side of each crack 700 may be located, specifically, near a crack tip 704 of each crack 700. Additionally, the hole 702 located on either side of each crack 700 may be located beyond a length of each crack 700, though not shown in FIG. 7.

[0038] FIG. 8 illustrates two adjacent cracks 800 with multiple slots 802 located on either side of each crack 800, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the multiple slots 802 may be located, specifically, near a crack tip 804 of each crack 800. Additionally, the multiple slots 802 may be located beyond a length of each crack 800. Although shown in a configuration nearly parallel to each crack, the multiple slots 802 may be positioned in any orientation with respect to each crack 800 and / or the crack tip 804.

[0039] FIG. 9 illustrates two adjacent cracks 900 with a slot 902 located on either side of each crack 900, in accordance with at least one non-limiting aspect of the present disclosure. As shown, the slot 902 located on either side of each crack 900 may be located, specifically, near a crack tip 904 of each crack 900. Additionally, the slot 902 located on either side of each crack 900 may be located beyond a length of each crack 900. Although shown in a configuration nearly parallel to the crack, the slot 902 located on either side of each crack 900 may be positioned in any orientation with respect to each crack 900 and / or the crack tip 904.

[0040] Although FIGS. 6 and 7 illustrate two adjacent cracks treated with holes and FIGS. 8 and 9 illustrate two adjacent cracks treated with slots, it shall be appreciated that other embodiments may treat two or more adjacent cracks with any combination of holes and slots arranged to increase a fracture toughness of the crack.

[0041] FIG. 10 illustrates a method 1000 for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure. The method may include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material (1002); determining a yield stress and a stress intensity factor associated with the material (1004); calculating a radius of a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor (1006); determining a design including at least one of a hole or a slot to be selectively removed from the surface within or adjacent to the radius (1008); and selectively removing the at least one of the hole or the slot from the surface (1010). According to at least one aspect, the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and the rectangular geometry includes at least one of sharp or rounded corners. According to at least one aspect, the design may include at least one of a location, a pattern, a size, a number, or the like, of the at least one of the hole or the slot. According to at least one aspect, selectively removing the at least one of the hole or the slotAttorney Docket No. WEC-2024-169-PCT from the surface may include selectively removing the at least one of the hole or the slot through the surface. According to at least one different aspect, selectively removing the at least one of the hole or the slot into the surface may not include selectively removing the at least one of the hole or the slot through the surface. According to at least one aspect, the radius may be calculated according to r = - 7T (— (7yS)2, wherein r is the radius, K, is the stress intensity factor, and aysis the yield stress.

[0042] FIG. 11 illustrates a method 1100 for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure. The method may include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material (1102); determining a plurality of parameters associated with the material (1104); performing finite element analysis (FEA) based on at least one of a geometry of a component for which the surface is disposed, a geometry of the crack, or the plurality of parameters associated with the material (1106); determining a design including at least one of a hole or a slot to be selectively removed from the surface based on the performed FEA (1108); and selectively removing the at least one of the hole or the slot from the surface (1110). According to at least one aspect, the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and the rectangular geometry includes at least one of sharp or rounded corners. According to at least one aspect, the design may include at least one of a location, a pattern, a size, a number, or the like, of the at least one of the hole or the slot. According to at least one aspect, selectively removing the at least one of the hole or the slot from the surface may include selectively removing the at least one of the hole or the slot through the surface.According to at least one different aspect, selectively removing the at least one of the hole or the slot from the surface may not include selectively removing the at least one of the hole or the slot through the surface. According to at least one aspect, the plurality of parameters may include at least one of a yield stress or a stress intensity factor associated with the material.

[0043] FIG. 12 illustrates a method 1200 for improving apparent fracture toughness of a crack tip, in accordance with at least one non-limiting aspect of the present disclosure. The method may include determining a crack is present on a surface, the crack including a crack tip, and the surface including a material (1202); determining a plurality of parameters associated with the material (1204); identifying a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor (1206); and selectively removing at least one portion of the material of the surface within or adjacent to the plastic zone based on a determined crack treatment that increases apparent fracture toughness of the crack (1208). According to at least one aspect, the at least one of the hole or the slotAttorney Docket No. WEC-2024-169-PCT define at least one of a circular, elliptical, or rectangular geometry, and the rectangular geometry includes at least one of sharp or rounded corners. According to at least one aspect, selectively removing the at least one portion of the material of the surface may include forming one or more through holes, non-through holes, though slots, non-through slots, or combinations thereof within or adjacent to the plastic zone. According to at least one aspect, forming the one or more through holes, non-through holes, through slots, non- through slots, or combinations thereof may include drilling into the surface. According to at least one aspect, the method may further include performing finite element analysis (FEA) to determine at least one of a position, an orientation, a shape, a number, or a depth of the one or more though holes, non-through holes, through slots, non-through slots, or combinations thereof. According to at least one aspect, identifying a plastic zone may include calculating a radius of the plastic zone associated with the crack, and selectively removing at least one portion of the material may include selectively removing at least one portion of the material within or adjacent to the calculated radius. According to at least one aspect, the crack may be a first crack and the crack tip may be a first crack tip, and the method may further include determining at least a second crack is present adjacent to the first crack on the surface, the second crack may include a second crack tip, the plastic zone may be associated with the first and second crack tips, and selectively removing at least one portion of the material at the surface within the plastic zone may increase apparent fracture toughness of the first and second cracks. According to at least one aspect, selectively removing at least one portion of the material may include selectively removing a plurality of discrete portions, a continuous portion, or combinations thereof at or about the crack tip.

[0044] Various aspects of the subject matter described herein are set out in the following numbered clauses:

[0045] Clause 1 : A method for improving apparent fracture toughness of a crack tip, the method including: determining a crack is present on a surface, the crack including a crack tip, and the surface including a material; determining a yield stress and a stress intensity factor associated with the material; calculating a radius of a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor; determining a design including at least one of a hole or a slot to be selectively removed from the surface within or adjacent to the radius; and selectively removing the at least one of the hole or the slot from the surface.

[0046] Clause 2: The method according to Clause 1 , wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry includes at least one of sharp or rounded corners.Attorney Docket No. WEC-2024-169-PCT

[0047] Clause 3: The method according to either of Clauses 1 or 2, wherein the design includes at least one of a location, a pattern, a size, or a number of the at least one of the hole or the slot.

[0048] Clause 4: The method according to any of Clauses 1-3, wherein selectively removing the at least one of the hole or the slot from the surface includes selectively removing the at least one of the hole or the slot through the surface.

[0049] Clause 5: The method according to any of Clauses 1-3, wherein selectively removing the at least one of the hole or the slot from the surface does not include selectively removing the at least one of the hole or the slot through the surface.

[0050] Clause 6: The method according to any of Clauses 1-5, wherein the radius is calculated according to r = - 7T (— ( yS)2, wherein r is the radius, KIis the stress intensity factor, and aysis the yield stress.

[0051] Clause 7: A method for improving apparent fracture toughness of a crack tip, the method including: determining a crack is present on a surface, the crack including a crack tip, and the surface including a material; determining a plurality of parameters associated with the material and component; performing finite element analysis (FEA) based on at least one of a geometry of a component for which the surface is disposed, a geometry of the crack, or the plurality of parameters associated with the material; determining a design including at least one of a hole or a slot to be selectively removed from the surface based on the performed FEA; and selectively removing the at least one of the hole or the slot from the surface.

[0052] Clause 8: The method according to Clause 7, wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry includes at least one of sharp or rounded corners.

[0053] Clause 9: The method according to either of Clauses 7 or 8, wherein the design includes at least one of a location, a pattern, a size, or a number of the at least one of the hole or the slot.

[0054] Clause 10: The method according to any of Clauses 6-9, wherein selectively removing the at least one of the hole or the slot from the surface includes selectively removing the at least one of the hole or the slot through the surface.

[0055] Clause 11: The method according to any of Clauses 6-9, wherein selectively removing the at least one of the hole or the slot from the surface does not include selectively removing the at least one of the hole or the slot through the surface.

[0056] Clause 12: The method according to any of Clauses 6-11, wherein the plurality of parameters includes at least one of a yield stress or a stress intensity factor associated with the material.Attorney Docket No. WEC-2024-169-PCT

[0057] Clause 13: A method for improving apparent fracture toughness of a crack tip, the method including: determining a crack is present on a surface, the crack including a crack tip, and the surface including a material; determining a yield stress and a stress intensity factor associated with the material; identifying a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor; and selectively removing at least one portion of the material of the surface within or adjacent to the plastic zone based on a determined crack treatment that increases apparent fracture toughness of the crack.

[0058] Clause 14: The method according to Clause 13, wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry includes at least one of sharp or rounded corners.

[0059] Clause 15: The method according to either of Clauses 13 or 14, wherein selectively removing the at least one portion of the material of the surface includes forming one or more through holes, non-through holes, through slots, non-through slots, or combinations thereof within the plastic zone.

[0060] Clause 16: The method according to Clause 15, wherein forming the one or more through holes, non-through holes, through slots, non-through slots, or combinations thereof includes drilling into the surface.

[0061] Clause 17: The method according to either of Clauses 15 or 16, further including performing finite element analysis (FEA) to determine at least one of a position, an orientation, a shape, a number, or a depth of the one or more through holes, non-through holes, through slots, non-through slots, or combinations thereof.

[0062] Clause 18: The method according to any of Clauses 13-17, wherein identifying a plastic zone includes calculating a radius of the plastic zone associated with the crack, and wherein selectively removing at least one portion of the material includes selectively removing at least one portion of the material within or adjacent to the calculated radius.

[0063] Clause 19: The method according to any of Clauses 13-18, wherein the crack is a first crack and the crack tip is a first crack tip, and wherein the method further includes determining at least a second crack is present adjacent to the first crack on the surface, the second crack including a second crack tip, wherein the plastic zone is associated with the first and second crack tips, and wherein selectively removing at least one portion of the material at the surface within or adjacent to the plastic zone is to increase apparent fracture toughness of the first and second cracks.

[0064] Clause 20: The method according to any of Clauses 13-18, wherein selectively removing at least one portion of the material includes selectively removing a plurality of discrete portions, a continuous portion, or combinations thereof about the crack tip.Attorney Docket No. WEC-2024-169-PCT

[0065] All patents, patent applications, publications, or other disclosure material mentioned herein, are hereby incorporated by reference in their entirety as if each individual reference was expressly incorporated by reference respectively. All references, and any material, or portion thereof, that are said to be incorporated by reference herein are incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as set forth herein supersedes any conflicting material incorporated herein by reference and the disclosure expressly set forth in the present application controls.

[0066] The present invention has been described with reference to various exemplary and illustrative aspects. The aspects described herein are understood as providing illustrative features of varying detail of various aspects of the disclosed invention; and therefore, unless otherwise specified, it is to be understood that, to the extent possible, one or more features, elements, components, constituents, ingredients, structures, modules, and / or aspects of the disclosed aspects may be combined, separated, interchanged, and / or rearranged with or relative to one or more other features, elements, components, constituents, ingredients, structures, modules, and / or aspects of the disclosed aspects without departing from the scope of the disclosed invention. Accordingly, it will be recognized by persons having ordinary skill in the art that various substitutions, modifications or combinations of any of the exemplary aspects may be made without departing from the scope of the invention. In addition, persons skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the various aspects of the invention described herein upon review of this specification. Thus, the invention is not limited by the description of the various aspects, but rather by the claims.

[0067] Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductoryAttorney Docket No. WEC-2024-169-PCT phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.

[0068] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”

[0069] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although claim recitations are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are described, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

[0070] It is worthy to note that any reference to “one aspect,” “an aspect,” “an exemplification,” “one exemplification,” and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in one aspect,” “in an aspect,” “in an exemplification,” and “in one exemplification” in various places throughout the specification are notAttorney Docket No. WEC-2024-169-PCT necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.

[0071] As used herein, the singular form of “a”, “an”, and “the” include the plural references unless the context clearly dictates otherwise.

[0072] Directional phrases used herein, such as, for example and without limitation, top, bottom, left, right, lower, upper, front, back, and variations thereof, shall relate to the orientation of the elements shown in the accompanying drawing and are not limiting upon the claims unless otherwise expressly stated.

[0073] The terms “about” or “approximately” as used in the present disclosure, unless otherwise specified, means an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain aspects, the term “about” or “approximately” means within 1 , 2, 3, or 4 standard deviations. In certain aspects, the term “about” or “approximately” means within 50%, 200%, 105%, 100%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0074] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term “about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0075] Any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of “1 to 100” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 100, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 100. Also, all ranges recited herein are inclusive of the end points of the recited ranges. For example, a range of “1 to 100” includes the end points 1 and 100. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein.Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0076] Any patent application, patent, non-patent publication, or other disclosure material referred to in this specification and / or listed in any Application Data Sheet isAttorney Docket No. WEC-2024-169-PCT incorporated by reference herein, to the extent that the incorporated materials is not inconsistent herewith. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0077] The terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as "has" and "having"), "include" (and any form of include, such as "includes" and "including") and "contain" (and any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, a system that "comprises," "has," "includes" or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that "comprises," "has," "includes" or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

Claims

Attorney Docket No. WEC-2024-169-PCTCLAIMSWHAT IS CLAIMED IS:

1. A method for improving apparent fracture toughness of a crack tip, the method comprising: determining a crack is present on a surface, the crack comprising a crack tip, and the surface comprising a material; determining a yield stress and a stress intensity factor associated with the material; calculating a radius of a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor; determining a design comprising at least one of a hole or a slot to be selectively removed from the surface within or adjacent to the radius; and selectively removing the at least one of the hole or the slot from the surface.

2. The method of Claim 1 , wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry comprises at least one of sharp or rounded corners.

3. The method of Claim 1 , wherein the design comprises at least one of a location, a pattern, a size, or a number of the at least one of the hole or the slot.

4. The method of Claim 1 , wherein selectively removing the at least one of the hole or the slot from the surface comprises selectively removing the at least one of the hole or the slot through the surface.

5. The method of Claim 1 , wherein selectively removing the at least one of the hole or the slot from the surface does not comprise selectively removing the at least one of the hole or the slot through the surface.

6. The method of Claim 1 , wherein the radius is calculated according to r = - re (— ays)'2, wherein r is the radius,is the stress intensity factor, and aysis the yield stress.

7. A method for improving apparent fracture toughness of a crack tip, the method comprising: determining a crack is present on a surface, the crack comprising a crack tip, and the surface comprising a material;Attorney Docket No. WEC-2024-169-PCT determining a plurality of parameters associated with the material; performing finite element analysis (FEA) based on at least one of a geometry of a component for which the surface is disposed, a geometry of the crack, or the plurality of parameters associated with the material; determining a design comprising at least one of a hole or a slot to be selectively removed from the surface based on the performed FEA; and selectively removing the at least one of the hole or the slot from the surface.

8. The method of Claim 7, wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry comprises at least one of sharp or rounded corners.

9. The method of Claim 7, wherein the design comprises at least one of a location, a pattern, a size, or a number of the at least one of the hole or the slot.

10. The method of Claim 7, wherein selectively removing the at least one of the hole or the slot from the surface comprises selectively removing the at least one of the hole or the slot through the surface.

11. The method of Claim 7, wherein selectively removing the at least one of the hole or the slot from the surface does not comprise selectively removing the at least one of the hole or the slot through the surface.

12. The method of Claim 7, wherein the plurality of parameters comprises at least one of a yield stress or a stress intensity factor associated with the material.

13. A method for improving apparent fracture toughness of a crack tip, the method comprising: determining a crack is present on a surface, the crack comprising a crack tip, and the surface comprising a material; determining a yield stress and a stress intensity factor associated with the material; identifying a plastic zone associated with the crack tip based on at least one of the yield stress or the stress intensity factor; and selectively removing at least one portion of the material of the surface within or adjacent to the plastic zone based on a determined crack treatment that increases apparent fracture toughness of the crack.Attorney Docket No. WEC-2024-169-PCT14. The method of Claim 13, wherein the at least one of the hole or the slot define at least one of a circular, elliptical, or rectangular geometry, and wherein the rectangular geometry comprises at least one of sharp or rounded corners.

15. The method of Claim 13, wherein selectively removing the at least one portion of the material of the surface comprises forming one or more through holes, non-through holes, though slots, non-through slots, or combinations thereof within the plastic zone.

16. The method of Claim 15, wherein forming the one or more through holes, non- through holes, through slots, non-through slots, or combinations thereof comprises drilling into the surface.

17. The method of Claim 15, further comprising performing finite element analysis (FEA) to determine at least one of a position, an orientation, a shape, a number, or a depth of the one or more though holes, non-through holes, through slots, non-through slots, or combinations thereof.

18. The method of Claim 13, wherein identifying a plastic zone comprises calculating a radius of the plastic zone associated with the crack, and wherein selectively removing at least one portion of the material comprises selectively removing at least one portion of the material within or adjacent to the calculated radius.

19. The method of Claim 13, wherein the crack is a first crack and the crack tip is a first crack tip, and wherein the method further comprises determining at least a second crack is present adjacent to the first crack on the surface, the second crack comprising a second crack tip, wherein the plastic zone is associated with the first and second crack tips, and wherein selectively removing at least one portion of the material at the surface within or adjacent to the plastic zone is to increase apparent fracture toughness of the first and second cracks.

20. The method of Claim 13, wherein selectively removing at least one portion of the material comprises selectively removing a plurality of discrete portions, a continuous portion, or combinations thereof at or about the crack tip.

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