Nano-mechanics based modeling of lifetime distribution of quasibrittle structures

The statistics of structural lifetime under constant load are related to the statistics of structural strength. The safety factors applied to structural strength must ensure failure probability no larger than 10^-6, which is beyond the means of direct verification by histogram testing. For perfectly brittle materials, extrapolation from the mean and variance to such a small tail probability is no problem because it is known that the Weibull distribution applies. Unfortunately, this is not possible for quasibrittle materials because the type of cumulative distribution function (cdf) has been shown to vary with structure size and shape. These are materials with inhomogeneities and fracture process zones (FPZ) that are not negligible compared to structural dimensions. A probabilistic theory of strength of quasibrittle structures failing at macro-crack initiation, which can be experimentally verified and calibrated indirectly, has recently been deduced from the rate of jumps of atomic lattice cracks governed by activation energy barriers. This paper extends this nano-mechanics based theory to the distribution of structural lifetime. Based on the cdf of strength and a power law for subcritical crack growth rate, the lifetime cdf of quasibrittle structures under constant loads is derived. The lifetime cdf is shown to depend strongly on the structure size as well as geometry. It is found that, for the creep rupture case, the mean structural lifetime exhibits a very strong size effect, much stronger than the size effect on the mean structure strength. The theory also implies temperature dependence of the lifetime cdf. For various quasibrittle materials, such as industrial ceramics and fiber composites, it is demonstrated that the proposed theory correctly predicts the experimentally observed deviations of lifetime histograms from the Weibull distribution.     

Energetic–statistical size effect simulated by SFEM with stratified sampling and crack band model

The paper presents a model that extends the stochastic finite element method to the modelling of transitional energetic–statistical size effect in unnotched quasibrittle structures of positive geometry (i.e. failing at the start of macro‐crack growth), and to the low probability tail of structural strength distribution, important for safe design. For small structures, the model captures the energetic (deterministic) part of size effect and, for large structures, it converges to Weibull statistical size effect required by the weakest‐link model of extreme value statistics. Prediction of the tail of extremely low probability such as one in a million, which needs to be known for safe design, is made feasible by the fact that the form of the cumulative distribution function (cdf) of a quasibrittle structure of any size has been established analytically in previous work. Thus, it is not necessary to turn to sophisticated methods such as importance sampling and it suffices to calibrate only the mean and variance of this cdf. Two kinds of stratified sampling of strength in a finite element code are studied. One is the Latin hypercube sampling of the strength of each element considered as an independent random variable, and the other is the Latin square design in which the strength of each element is sampled from one overall cdf of random material strength. The former is found to give a closer estimate of variance, while the latter gives a cdf with smaller scatter and a better mean for the same number of simulations. For large structures, the number of simulations required to obtain the mean size effect is greatly reduced by adopting the previously proposed method of random property blocks. Each block is assumed to have a homogeneous random material strength, the mean and variance of which are scaled down according to the block size using the weakest‐link model for a finite number of links. To check whether the theoretical cdf is followed at least up to tail beginning at the failure probability of about 0.01, a hybrid of stratified sampling and Monte Carlo simulations in the lowest probability stratum is used. With the present method, the probability distribution of strength of quasibrittle structures of positive geometry can be easily estimated for any structure size. Copyright © 2007 John Wiley & Sons, Ltd.     

Efficient prediction of deterministic size effects using the scaled boundary finite element method

This paper develops an efficient numerical approach to predict deterministic size effects in structures made of quasi-brittle materials using the scaled boundary finite element method (SBFEM). Depending on the structure’s size, two different SBFEM-based crack propagation modelling methodologies are used for fracture analyses. When the length of the fracture process zone (FPZ) in a structure is of the order of its characteristic dimension, nonlinear fracture analyses are carried out using the finite element-SBFEM coupled method. In large-sized structures, a linear elastic fracture mechanics (LEFM)-based SBFEM is used to reduce computing time due to small crack propagation length required to represent the FPZ in an equivalent nonlinear analysis. Remeshing is used in both methods to model crack propagation with crack paths unknown a priori. The resulting peak loads are used to establish the size effect laws. Three concrete structures were modelled to validate the approach. The predicted size effect is in good agreement with experimental data. The developed approach was found more efficient than the finite element method, at least in modelling LEFM problems and is thus an attractive tool for predicting size effect.     

Size effect in shallow and deep notched quasi-brittle structures

The nominal strength of a quasi-brittle structure is known to vary with its size. If the structure undergoes large stable crack growth prior to failure or if it contains a large pre-existing crack, then the failure load is known to approach the asymptotic limit of linear elastic fracture mechanics (LEFM) for large structures from below. In this paper, the size effect is studied on a particular structural geometry containing a crack which can be relatively shallow or deep. The study is conducted within the framework of the fictitious crack model for the fracture of quasi-brittle materials. By allowing for the redistribution of the stresses in the fracture process zone (FPZ), the essential result of the size effect is confirmed. However, it is shown that this result can only be obtained from tests on specimens whose size exceeds a certain minimum value depending on the material, so that at failure the fully developed FPZ is contained wholly within the test specimen. Moreover, the minimum size of the test specimen is shown to increase as the depth of the pre-crack is reduced, thus requiring specimens of very large sizes to obtain valid results from tests on specimens with very shallow pre-cracks. This revised version was published online in July 2006 with corrections to the Cover Date.     

Scaling of quasibrittle fracture: hypotheses of invasive and lacunar fractality, their critique and Weibull connection

Considerable progress has been achieved in fractal characterization of the properties of crack surfaces in quasibrittle materials such as concrete, rock, ice, ceramics and composites. Recently, fractality of cracks or microcracks was proposed as the explanation of the observed size effect on the nominal strength of structures. This explanation, though, has rested merely on intuitive analogy and geometric reasoning, and did not take into account the mechanics of crack propagation. In this paper, the energy-based asymptotic analysis of scaling presented in the preceding companion paper in this issue [1] is extended to the effect of fractality on scaling. First, attention is focused on the propagation of fractal crack curves (invasive fractals). The modifications of the scaling law caused by crack fractality are derived, both for quasibrittle failures after large stable crack growth and for failures at the initiation of a fractal crack in the boundary layer near the surface. Second, attention is focused on discrete fractal distribution of microcracks (lacunar fractals), which is shown to lead to an analogy with Weibull's statistical theory of size effect due to material strength randomness. The predictions ensuing from the fractal hypothesis, either invasive or lacunar, disagree with the experimentally confirmed asymptotic characteristics of the size effect in quasibrittle structures. It is also pointed out that considering the crack curve as a self-similar fractal conflicts with kinematics. This can be remedied by considering the crack to be an affine fractal. It is concluded that the fractal characteristics of either the fracture surface or the microcracking at the fracture front cannot have a significant influence on the law of scaling of failure loads, although they can affect the fracture characteristics. Walter P. Murphy, Professor| of This revised version was published online in July 2006 with corrections to the Cover Date.     

Size effect and quasi-brittle fracture: the role of FPZ

Fracture process zone (FPZ), or the crack-tip damage zone created by crack-bridging and micro-cracking activities, in a specimen of a concrete-like material is comparable to the crack size and un-cracked ligament, so fracture is typically quasi-brittle. Increasing or decreasing the specimen size, quasi-brittle fracture transition occurs towards the toughness-controlled or strength-controlled fracture, which is known as size effect (SE). In this study it is shown that the “size-dependent” quasi-brittle fracture transition is actually due to the interaction of FPZ with the nearest structure boundary rather than the size variation, and the widely-accepted SE for geometrically-similar specimens of different sizes is only a special case of quasi-brittle fracture controlled by the FPZ/boundary interaction. Relevant SE relations are critically reviewed and explained by emphasizing the key SE mechanism, FPZ/boundary interaction.     

Statistics of strength of ceramics: finite weakest-link model and necessity of zero threshold

It is argued that, in probabilistic estimates of quasibrittle structure strength, the strength threshold should be considered to be zero and the distribution to be transitional between Gaussian and Weibullian. The strength histograms recently measured on tough ceramics and other quasibrittle materials, which have been thought to imply a Weibull distribution with nonzero threshold, are shown to be fitted equally well or better by a new weakest-link model with a zero strength threshold and with a finite, rather than infinite, number of links in the chain, each link corresponding to one representative volume element (RVE) of a non-negligible size. The new model agrees with the measured mean size effect curves. It is justified by energy release rate dependence of the activation energy barriers for random crack length jumps through the atomic lattice, which shows that the tail of the failure probability distribution should be a power law with zero threshold. The scales from nano to macro are bridged by a hierarchical model with parallel and series couplings. This scale bridging indicates that the power-law tail with zero threshold is indestructible while its exponent gets increased on each passage to a higher scales. On the structural scale, the strength distribution except for its far left power-law tail, varies from Gaussian to Weibullian as the structure size increases. For the mean structural strength, the theory predicts a size effect which approaches the Weibull power law asymptotically for large sizes but deviates from it at small sizes. This deviation is the easiest way to calibrate the theory experimentally. The structure size is measured in terms of the number of RVEs. This number must be convoluted by an integral over the dimensionless stress field, which depends on structure geometry. The theory applies to the broad class of structure geometries for which failure occurs at macro-crack initiation from one RVE, but not to structure geometries for which stability is lost only after large macro-crack growth. Based on tolerable structural failure probability of <10^?6, the change from nonzero to zero threshold may often require a major correction in safety factors.     

Size effect on strength and lifetime probability distributions of quasibrittle structures

Engineering structures such as aircraft, bridges, dams, nuclear containments and ships, as well as computer circuits, chips and MEMS, should be designed for failure probability ???6–10^???7 per lifetime. The safety factors required to ensure it are still determined empirically, even though they represent much larger and much more uncertain corrections to deterministic calculations than do the typical errors of modern computer analysis of structures. The empirical approach is sufficient for perfectly brittle and perfectly ductile structures since the cumulative distribution function (cdf) of random strength is known, making it possible to extrapolate to the tail from the mean and variance. However, the empirical approach does not apply to structures consisting of quasibrittle materials, which are brittle materials with inhomogeneities that are not negligible compared to structure size. This paper presents a refined theory on the strength distribution of quasibrittle structures, which is based on the fracture mechanics of nanocracks propagating by activation energy controlled small jumps through the atomic lattice and an analytical model for the multi-scale transition of strength statistics. Based on the power law for creep crack growth rate and the cdf of material strength, the lifetime distribution of quasibrittle structures under constant load is derived. Both the strength and lifetime cdf’s are shown to be size- and geometry-dependent. The theory predicts intricate size effects on both the mean structural strength and lifetime, the latter being much stronger. The theory is shown to match the experimentally observed systematic deviations of strength and lifetime histograms of industrial ceramics from the Weibull distribution.     

Indirect determination of size effect on strength of asphalt mixtures at low temperatures

Low temperature cracking of asphalt pavements is a major distress in cold regions. Accurate assessment of strength of asphalt mixtures at low temperatures is of great importance for ensuring the structural integrity of asphalt pavements. It has been shown that asphalt mixtures behave in a quasibrittle manner at low temperatures and consequently its nominal strength strongly depends on the structure size. The size effect on the strength of asphalt mixtures can be directly measured by testing geometrically similar specimens with a sufficiently large size range. Recent studies have shown in theory that for quasibrittle structures, which fail at the macrocrack initiation from one representative volume element, the mean size effect curve can also be derived from the scaling of strength statistics based on the finite weakest link model. This paper presents a comprehensive experimental investigation on the strength statistics as well as the size effect on the mean strength of asphalt mixtures at ?24 °C. It is shown that the size effect on mean structural strength can be obtained by strength histogram testing on specimens of a single size. The present study also indicates that the three-parameter Weibull distribution is not applicable for asphalt mixtures.     

Eigenvalue analysis of size effect for cohesive crack model

The paper analyses the effect of structure size on the nominal strength of the structure that is implied by the cohesive (or fictitious) crack model proposed for concrete by Hillerborg et al. A new method to calculate the maximum load of geometrically similar structures of different sizes without calculating the entire load-deflection curves is presented. The problem is reduced to a matrix eigenvalue problem, in which the structure size for which the maximum load occurs at the given (relative) length of the cohesive crack is obtained as the smallest eigenvalue. Subsequently, the maximum load, nominal strength and load-point displacement are calculated from the matrix equilibrium equation. The nonlinearity of the softening stress-displacement law is handled by iteration. For a linear softening law, the eigenvalue problem is linear and independent of the matrix equilibrium equation, and the peak load can then be obtained without solving the equilibrium equation. The effect of the shape of the softening law is studied, and it is found that the size effect curve is not very sensitive to it. The generalized size effect law proposed earlier by Baant, which describes a transition between the horizontal and inclined asymptotes of strength theory and linear elastic fracture mechanics, is found to fit the numerical results very well. Finally some implications for the determination of fracture energy from the size effect tests are discussed. The results are of interest for quasibrittle materials such as concrete, rocks, sea ice and modern tough ceramics.     

A review of the J and I integrals and their implications for crack growth resistance and toughness in ductile fracture

The application of the J and the I-integrals to ductile fracture are discussed. It is shown that, because of the finite size of the fracture process zone (FPZ), the initiation value of the J-integral is specimen dependent even if the plastic constraint conditions are constant. The paradox that the I-integral for steady state elasto-plastic crack growth is apparently zero is examined. It is shown that, if the FPZ at the crack tip is modelled, the I-integral is equal to the work performed in its fracture. Thus it is essential to model the fracture process zone in ductile fracture. The I-integral is then used to demonstrate that the breakdown in applicability of the J-integral to crack growth in ductile fracture is as much due to the inclusion in the J-integral of progressively more work performed in the plastic zone as it is to non-proportional deformation during unloading behind the crack tip. Thus J _R -curves combine the essential work of fracture performed in the FPZ with the plastic work performed outside of the FPZ. These two work terms scale differently and produce size and geometry dependence. It is suggested that the future direction of modelling in ductile fracture should be to include the FPZ. Strides have already been made in this direction.     

Fully-developed FPZ length in quasi-brittle materials

This paper studies the development of fracture processes in quasi-brittle materials. We propose to use the length of the fracture process zone (FPZ) once it is fully developed as a material parameter. This assumption allows us to build an analytical formulation that reproduces the mechanical behavior of any specimen as a cohesive crack advances. Extensive comparisons with experimental results lead us to define a new characteristic length that commensurates with the fully-developed FPZ and that together with the new analytical model, is used to provide a complete and consistent study on the fracture process. In particular, the size-effect deriving from our formulation coincides with the statistical size-effect law of Ba?ant for small and medium sizes, whereas it smoothly converges to size-independent results as size increases. The analytical cohesive formulation developed here is validated against experimental results on various types of normal and high-strength concretes as well as construction ceramics for several experimental set-ups and test scales. Because of its simplicity as compared with numerical models for fracture, this analytical formulation constitutes a powerful tool for studying fracture processes in a wide variety of mechanical configurations. Meanwhile, analytical expression for a fully-developed FPZ length is given for a general type of cohesive law.     

用能量方法研究混凝土断裂过程区的力学性能

准脆性混凝土自由裂缝前缘断裂过程区的发展与其非线性断裂特征及尺寸效应现象密切相关。它的物理力学行为的量化分析对理解混凝土断裂破坏机理和建立适用于混凝土结构裂缝稳定分析和安全评估断裂准则尤为重要,一直是混凝土断裂力学研究的核心问题。该文依据Hillerborg给出的断裂能定义,给出了计算单位长度断裂过程区发展能量耗散的通用表达式。以三点弯曲梁为例,采用非线性软化本构关系,进一步给出了计算此平均能量耗散的具体步骤及对应的公式。在根据实测的三点弯曲梁的断裂能回归拟合了特征裂缝张开位移w0后,计算了每个试件整个断裂全过程中不同荷载时刻断裂过程区耗能的平均值。结果表明:随着裂缝扩展,断裂过程区能量耗散的变化和试件尺寸无关,可描述断裂过程区混凝土材料的力学性能。     

Numerical and analytical investigation of the size-dependency of the FPZ length in concrete

The main objective of this paper is to study the size effect on the fracture characteristics in concrete structures. The numerical investigation is based on a mesoscale modeling approach. Analytically, two size effect laws are investigated: the classical Ba?ant SEL and a new size effect law based on the enrichment of the stress field on the crack tip. The mesoscopic approach is used to study the evolution of the tangential stress along the crack path in order to investigate the fracture process zone variation during the cracking process. In addition, different analytical governing equations are used to evaluate the size-dependency of the FPZ length.     

II型III型动态裂纹尖端断裂过程区近似评估方法

动态裂纹尖端断裂过程区轮廓的确定问题仍然是一个没有得到完全解决的问题。基于弹性动力学的理论和复应力函数方法,提出一种伪应力函数方法,用于近似评估动态裂纹尖端应力场。通过与已知应力场计算结果对比,验证了伪应力函数的正确性。利用此近似方法通过Von Mises强度准则和Tresca强度准则,分别确定了不同强度准则条件下、不同裂纹扩展速度下断裂过程区的轮廓。计算结果表明:II型和III型动态裂纹尖端断裂过程区关于裂纹面对称分布,随着裂纹扩展速度增大而增大。当裂纹传播速度接近瑞利波速时,断裂过程区变化加剧。利用Tresca强度准则计算得到的动态裂纹尖端断裂过程区面积比利用Von Mises强度准则计算得到的断裂过程区的面积大。     

Scaling of quasibrittle fracture: asymptotic analysis

Fracture of quasibrittle materials such as concrete, rock, ice, tough ceramics and various fibrous or particulate composites, exhibits complex size effects. An asymptotic theory of scaling governing these size effects is presented, while its extension to fractal cracks is left to a companion paper [1] which follows. The energy release from the structure is assumed to depend on its size D, on the crack length, and on the material length c _f governing the fracture process zone size. Based on the condition of energy balance during fracture propagation and the condition of stability limit under load control, the large-size and small-size asymptotic expansions of the size effect on the nominal strength of structure containing large cracks or notches are derived. It is shown that the form of the approximate size effect law previously deduced [2] by other arguments can be obtained from these expansions by asymptotic matching. This law represents a smooth transition from the case of no size effect, corresponding to plasticity, to the power law size effect of linear elastic fracture mechanics. The analysis is further extended to deduce the asymptotic expansion of the size effect for crack initiation in the boundary layer from a smooth surface of structure. Finally, a universal size effect law which approximately describes both failures at large cracks (or notches) and failures at crack initiation from a smooth surface is derived by matching the aforementioned three asymptotic expansions. Walter P. Murphy Professor of This revised version was published online in July 2006 with corrections to the Cover Date.     

Experimental and numerical investigations on fracture process zone of rock–concrete interface

A crack propagation criterion for a rock–concrete interface is employed to investigate the evolution of the fracture process zone (FPZ) in rock–concrete composite beams under three‐point bending (TPB). According to the criterion, cracking initiates along the interface when the difference between the mode I stress intensity factor at the crack tip caused by external loading and the one caused by the cohesive stress acting on the fictitious crack surfaces reaches the initial fracture toughness of a rock–concrete interface. From the experimental results of the composite beams with various initial crack lengths but equal depths under TPB, the interface fracture parameters are determined. In addition, the FPZ evolution in a TPB specimen is investigated by using a digital image correlation technique. Thus, the fracture processes of the rock–concrete composite beams can be simulated by introducing the initial fracture criterion to determine the crack propagation. By comparing the load versus crack mouth opening displacement curves and FPZ evolution, the numerical and experimental results show a reasonable agreement, which verifies the numerical method developed in this study for analysing the crack propagation along the rock–concrete interface. Finally, based on the numerical results, the effect of ligament length on the FPZ evolution and the variations of the fracture model during crack propagation are discussed for the rock–concrete interface fracture under TPB. The results indicate that ligament length significantly affects the FPZ evolution at the rock–concrete interface under TPB and the stress intensity factor ratio of modes II to I is influenced by the specimen size during the propagation of the interfacial crack.     

General size effect on strength of bimaterial quasibrittle structures

This paper presents a general size effect equation for the strength of hybrid structures, which are made of two dissimilar quasibrittle materials with a thin and weak bimaterial interface. Depending on the material mismatch and structure geometry, a singular stress field could occur at the bimaterial corner. For structures with strong stress singularities, an energetic size effect is derived based on the equivalent linear elastic fracture mechanics and asymptotic matching. For structures without stress singularities, a finite weakest link model is adopted to derive the size effect. A general scaling equation that bridges the limits of strong and zero stress singularities is formulated by combining the energetic scaling of fracture of the bimaterial corner and the finite weakest link model.     

The fracture process zone in asphalt mixture at low temperature

The fracture process zone (FPZ) is a key factor to mechanistically characterize material fracture. This study investigates the FPZ of asphalt mixture at low temperature. The fracture process under a semi-circular bend (SCB) test of seven asphalt mixtures that represent a combination of different factors was monitored using an acoustic (AE) system with eight piezoelectric sensors. The size of FPZ was estimated by locating micro-cracks that correspond to 95% AE energy before peak load in the vicinity of the initial crack tip. The experimental data illustrates the significant influence of test temperature on the behavior of the asphalt mixture. Comparison results showed that the size of the FPZ significantly depends on air voids and aggregate type, but is less depend on the asphalt content. It was found that at a very low temperature, different loading rates produced very close FPZ, both for the width and length. No obvious difference was observed on the width of the FPZ for the three different initial notch lengths, whereas the length of the FPZ was found significantly increases with the decrease of the notch length. The size of FPZ was also numerically estimated for one case with the cohesive zone model (CZM) calibrated by experimental data from the same SCB test. The FPZ size obtained with both methods agrees reasonably with each other.     

Size effect on strength of laminate-foam sandwich plates: Finite element analysis with interface fracture

Recent three-point bend tests of size effect on the strength of geometrically scaled sandwich beams of three types – with no notches, and with notches at the upper or lower skin–foam interface, which were previously evaluated using simplified sandwich beam theory and equivalent linear elastic fracture mechanics, are now reanalyzed more accurately by finite elements. Zero-thickness interface elements with a softening cohesive law are used to model fractures at the skin–foam interface, in the fiber composite skins, and in the foam. The fracture energy and fracture process zone length of a shear crack in foam near the interface are deduced by fitting an analytical expression for size effect to the test data. Numerical simulations reveal that small-size specimens with notches just under the top skin develop plastic zones in the foam core near the edges of the loading platen, and that small-size specimens with notches just above the bottom skin develop distributed quasibrittle fracture in the foam core under tension. Both phenomena, though, are found to reduce the maximum load by less than 6%. Further it is shown that, in notch-less beams, the interface shear fracture is coupled with compression crushing of the fiber–polymer composite skin. For small specimens this mechanism is important because, when it is blocked in simulations, the maximum load increases. The size effect law for notch-less beams is calibrated such that beams of all sizes fail solely by interface shear fracture.