Development of residual strength evaluation tool based on stress-strain approximation

To allow for a safe design of metallic structures, it must be considered that, as a result of the manufacturing and processing operations, cracks or flaws below the NDI (Non-Destructive Inspection) detectability level always exist in the component after inspection. Further problems originate from the defect geometry. Failure of engineering structural components and structures have been mostly traced to surface cracks. Especially for a surface crack containing structure that is thin, the limit collapse of a ligament is usually the main cause of structure rupture. Study of the evaluation procedure relating to the limit load of the surface crack ligament is, therefore, an important project for conventional fracture assessment, particularly for pressure vessel (LBB) assessment. For this purpose, novel more accurate residual strength prediction method based on the Elasto-Plastic Fracture Mechanics (EPFM) has been developed and tested. Laboratory tests on tensile plate specimens with surface cracks were performed considering two different materials. In the final part of the work, effort was directed toward the verification and justification of selected analytical methods by adequate component testing. The most significant results of this work deal with residual strength evaluation for the thin wall pressure containing components. The important finding is that there is a potential for improvement in comparison to the current methods that may be used to increase payoff of the lightweight structures. The presented very robust analysis method and the useful structure integrity evaluation procedure should significantly contribute to the state-of-the-art structure optimisation and being applied to the design of the light-weight structures should ease the effort of the structure engineer to develop the successful and reliable hardware and to keep in place with advancing technologies. This revised version was published online in August 2006 with corrections to the Cover Date.