Equations and a fast algorithm for determining the probability of failure initiated by flaws

Powerful equations and an efficient algorithm are proposed for determining the probability of failure of loaded components with complex shape, containing multiple types of flaws. The equations are based on the concept ‘conditional individual probability of initiating failure’ characterising a single flaw given that it is in the stressed component. The proposed models relate in a simple fashion the conditional individual probability of failure characterising a single flaw (estimated by a Monte Carlo simulation) to the probability of failure characterising a population of flaws. The derived equations constitutes the core of a new statistical theory of failure initiated by flaws in the material, with important applications in optimising designs by decreasing their vulnerability to failure initiated by flaws during overloading or fatigue cycling.Methods have also been developed for specifying the maximum acceptable level of the flaw number density and the maximum size of the stressed volume which guarantee that the probability of failure initiated by flaws remains below a maximum acceptable level. An important parameter referred to as ‘detrimental factor’ is also introduced. Components with identical geometry and material, with the same detrimental factors are characterised by the same probability of failure. It is argued that eliminating flaws from the material should concentrate on types of flaws characterised by large detrimental factors.The equations proposed avoid conservative predictions resulting from equating the probability of failure initiated by a flaw in a stressed region with the probability of existence of the flaw in that region.     

用二维逆Born近似法对杆中圆形缺陷的反演

在三维弹性波散射问题的Born近似解基础上,进一步分析了在纵波入射条件下二维散射问题的Born近似解,对铝质长杆中的椭圆形空穴缺陷的散射场情况进行了对比分析;最后,提出了在低频下识别缺陷几何特征的二维逆Born近似法,并用此法对铝质长杆中的圆形空穴缺陷作了计算机模拟。     

A 3-D ellipsoidal flaw model for brittle fracture in compression

Engineering materials are rarely free of flaws. Mode I cracking from pre-existing flaws is the major cause of the brittle fracture in compression of materials such as concrete and rock. A 3-D ellipsoidal flaw model is used to show the significant influence of flaw geometry on crack initiation in uniform uniaxial, biaxial and triaxial compression. The model shows that the governing criterion for crack initiation may change from energy to stress with increasing crack size, and that for voids of similar size a spherical void is the most critical shape for crack initiation. The model thus provides a basis for a better understanding of both the phenomenon and the mechanism of brittle fracture in compression.     

基于频率和模态保证准则的结构内部多缺陷反演

静响应(位移、应变等)在实际问题的反演分析中很难由安装在结构上的一组传感器记录得到,而结构的动力特性(频率、振型)和 动力响应(加速度、速度、动位移)在实际问题中较易通过传感器采集得到. 文中基于频率残差和模态保证准则构建了反演分析模型的目标函数,并结合频域内动力扩展有限元法和人工蜂群智能优化算法 的优点,扩展有限元法通过引入非连续位移模式在不重新划分网格的情况下通过改变水平集函数反映缺陷的数量、位置及大小, 避免了反演分析每次迭代过程中的网格重剖分,人工蜂群智能优化算法在每次迭代中都采用全局和局部搜索,找到最优解的概 率大幅增大并可很好地避免局部最优,同时,通过引入拓扑变量,将缺陷的数量纳入到反演分析过程中,迭代过程中可智能反演出缺陷的数目,建立了结构内部多缺陷(孔洞、裂纹)的反演分析模型. 通过若干算例的分析表明:建立的反演分析模型能够较为准确地探测出结构内部圆形、椭圆形以及裂纹状缺陷的数量、位置及大小,且算法具有较好的鲁棒性.      

缺陷识别反问题的研究状况与若干进展

简要回顾了缺陷识别反问题的发展状况,评述了几类典型识别方法:基于势函数理论的电学法,静态ＢＥＭ优化迭代法,射线法,Ｔ矩阵法,Ｂｏｒｎ近似法,边界积分方程及边界元法．介绍了作者建立的裂纹及夹杂识别的迭代优化法．指出了缺陷识别反问题需要研究的主要问题．      

An experimental and numerical study of fracture coalescence in pre-cracked specimens under uniaxial compression

This study presents crack initiation, propagation and coalescence at or near pre-existing open cracks or flaws in a specimen under uniaxial compression. The flaw geometry in the specimen was a combination of a horizontal flaw and an inclined flaw underneath. This flaw geometry is different from those reported in the previous studies, where a pair of parallel flaws was used. Three materials were used, PMMA (Poly Methyl MethAcrylate), Diastone (types of molded gypsum), and Hwangdeung granite. Crack initiation and propagation showed similar and different patterns depending on the material. In PMMA, tensile cracks initiated at the flaw tips and propagated to the tip of the other flaw in the bridge area. The cracks then coalesced at a point of the inclined flaw, which is affected by the flaw inclination angle. For Diastone and Hwangdeung granite, tensile cracks were observed followed by the initiation of shear cracks. Coalescence occurred mainly through the tensile cracks or tensile and shear cracks. Crack coalescence was classified according to the crack coalescence types of parallel flaws for overlapping flaw geometry in the past works. In addition, crack initiation and coalescence stresses in the double-flawed specimens were analyzed and compared with those in the single-flawed specimen. Numerical simulations using PFC^2D (Particle Flow Code in two dimensions) based on the DEM (Discrete Element Method) were carried out and showed a good agreement with the experimental results in the coalescence characteristics in Hwangdeung granite. These experimental and numerical results are expected to improve the understanding of the characteristics of cracking and crack coalescence and can be used to analyze the stability of rock and rock structures, such as the excavated underground openings or slopes, tunneling construction, where pre-existing cracks or fractures play a crucial role in the overall integrity of such structures.     

The far-field scattering response of a side drilled hole in single/layered anisotropic media in ultrasonic pulse-echo setup

Ultrasonic testing for defects in anisotropic material is one of the difficult problems in non-destructive testing (NDT) with elastic waves. Even though a series of studies have been performed on the waves interacting with flaws, however, only a small portion was on anisotropic materials. In this paper, an analytical solution for the far-field scattering response of a side drilled hole (SDH) in anisotropic media in an ultrasonic pulse-echo setup with its incident wave normal to the axis of cylindrical hole is presented. The solution is based on the Kirchhoff approximation, and validated upon several numerical examples, yielding satisfactory results in the comparison to the results achieved by different methods. Also, an attempt is made to extend the use of this solution from homogeneous anisotropic media to weld, which is considered as the multi-layer anisotropic media.     

Modeling dynamic brittle behavior of materials with circular flaws or pores

Compressive failure of brittle materials is driven primarily by crack growth from pre-existing flaws in the material. These flaws, such as grain boundaries, pores, preexisting cracks, inclusions and missing grains, are randomly spaced and have a range of possible shapes and sizes. The current work proposes a micromechanics-based model for compressive dynamic failure of brittle materials with circular pore flaws, which incorporates both the number density and the size distribution of flaws. Results show that the distribution of flaw sizes is very important, particularly at moderate strain rate, since analyses based solely on the mean flaw size overpredict strength. Therefore, in order to increase dynamic strength at low to moderate strain rates, it is most effective to control the presence of large flaws. At very high strain rates, however, crack growth is activated even in small flaws and therefore controlling the total number density rather than the size of the flaws is effective for increasing dynamic strength. Finally, the model shows that neglecting very small flaws in the pore population may not have significant effects on the results in many cases, suggesting that the model is a useful tool for identifying a minimum resolution required for experimental characterization of microstructure.     

Finite Element study of fracture initiation in flaws subject to internal fluid pressure and vertical stress

Hydraulic fracturing is a method used routinely in oil and gas exploitation and in engineered geothermal systems. While used frequently, there are many aspects of hydraulic fracturing, such as the direction of propagation of the newly-created fractures, which are not very well understood. Even though it is known that the local stress field plays a fundamental role in the orientation of the new fractures, there may be other factors, such as the geometry of the existing fractures and the magnitude of the hydraulic pressure applied, that may play a major role in the path that a new fracture follows when pressurized.The main goal of this study is to numerically analyze the effect of the ratio between a vertical load, or stress, and the hydraulic pressure applied in existing flaws on the stress field in the vicinity of the flaw tips. For that purpose, a double flaw geometry 2a-30-30 was modeled in the Finite Element code ABAQUS, and different vertical loads and internal flaw pressures were applied to the model. The variation of the maximum principal stresses and maximum shear stresses around the flaw tips were analyzed and related to fracture initiation.The study showed that the ratio between the water pressure applied in the flaws and the vertical load/stress (WP/VL) plays a crucial role in the magnitude and shape of the stress field around a flaw tip, and therefore in the location of tensile and shear fracture initiation. As WP/VL increases, the location of initiation of new tensile fractures shifts from the upper face of the studied flaw towards the region right ahead of the flaw tip; simultaneously, the location of initiation of new shear fractures shifts from the region ahead of the flaw tip to the upper face of the analyzed tip.     

Correlation of elastic wave attenuation and scattering with volumetric grain size distribution for polycrystals of statistically equiaxed grains

This study establishes an explicit relation between spatial two-point correlation function (TPCF) and volumetric (or three-dimensional) grain size distribution for aggregates of statistically equiaxed grains by extending a prior study (Sha, JASA, 2018). This relation is further validated by applying it to available TPCF and volumetric grain size distribution in the literature. Based on this relation, analytical attenuation coefficients for longitudinal and transverse waves, accounting for volumetric grain size distribution, are derived under Born approximation for macroscopically isotropic polycrystals of equiaxed triclinic grains. These attenuation models are applicable for whole frequency range except geometric region. Moreover, scattering coefficients for a polycrystal of equiaxed triclinic grains with a volumetric grain size distribution are obtained. Finally, the analytical attenuation model for the longitudinal wave is verified by comparison with existing 3D finite element simulation results in the literature. This theoretic study has practical applications to the inverse determination of volumetric grain size distribution from ultrasonic measurements.     

Generalized Born scattering in anisotropic media

The Born scattering approximation has been widely used in seismology to study scattered waves, and to linearize the propagation problem for inversion. The standard Born theory requires the model be separated into a smooth, reference model and a perturbation. Scattering occurs from the pertubation. In the distorted Born approximation, when the reference model is inhomogeneous, the reference Green's functions are normally not known exactly, but the error in these Green's functions is rarely quantified. In this paper, we generalize Born scattering theory to include the errors in the Green's functions explicitly, and obtain scattering integrals from these errors. For forward modelling, there is no need to separate the model into a reference and perturbation part - approximate Green's functions in the true model can be used to calculate the scattered signals.

The theory is developed for inhomogeneous, anisotropic media. Asymptotic ray theory results are suitable approximate Green's functions for the generalized Born scattering theory. The error terms are simple, easily calculated and included in the scattering integrals. Various applications of generalized Born scattering theory have already appeared in the literature, e.g. quasi-shear ray coupling, and this paper is restricted to an improved and more complete theoretical development. Further applications will appear elsewhere.     

The scattering of SH waves by numerous inhomogeneities in an anisotropic body

The fundamental solution of antiplane strain motion in an anisotropic infinite medium is derived. On the basis of this, an integral equation for the scattered displacement field associated with many inhomogeneities of arbitrary shapes is proposed with the help of an equivalent body force and two-dimensional Heaviside functions. By using the Born approximation theory the scattered far-field is discussed when only two flaws (or voids) are considered. At the same time the differential cross line is defined and deduced. In the end, numerical examples are given.     

Effects of interfacial friction on flaw tolerant adhesion between two dissimilar elastic solids

Flaw tolerance refers to a state in which a pre-existing crack-like flaw does not propagate even as the material is stretched to failure near its theoretical strength. Such an optimal scenario can be achieved when the characteristic length scale is reduced to below a critical value. So far, the critical conditions to achieve flaw tolerance have been discussed mostly for homogeneous materials or for two dissimilar materials in frictionless or perfectly bonded adhesion. In this paper, we consider the role of friction in flaw tolerant adhesion between two dissimilar elastic solids. We adopt a frictional contact model in which slip is allowed wherever the shear stress along the interface reaches a threshold value defined as the friction strength. The critical length scale for flaw tolerance is derived analytically for a penny-shaped crack and for an external circular crack. Compared to the cases of frictionless contact, we find that interfacial friction can reduce the critical length scales for flaw tolerance by up to 12.5%.     

CHARACTERISTICS OF FATIGUE SURFACE MICROCRACK GROWTH IN VICINAL INCLUSION FOR POWDER METALLURGY ALLOYS

Inclusion flaw is one of the worst flaws of powder metallurgy. The inclusion flaw plays an important role in the failure of high temperature turbine materials in aircraft components and automotive parts, especially fatigue failure. In this paper, an experimental investigation of fatigue microcrack propagation in the vicinal inclusion were carried out by the servo-hydraulic fatigue test system with scanning electron microscope (SEM). It has been found from the SEM images that the fatigue surface microcrack occurs in the matrix and inclusion. According to the SEM images, the characteristics of fatigue crack initiation and growth in vicinal inclusion for powder metallurgy alloys are analyzed in detail. The effect of the geometrical shape and material type of surface inclusions on the cracking is also discussed with the finite element method (FEM).     

Correction of the near threshold behavior of electron collisional excitation cross-sections in the plane-wave Born approximation

The modeling of NLTE plasmas requires the solution of population rate equations to determine the populations of the various atomic levels relevant to a particular problem. The equations require many cross sections for excitation, de-excitation, ionization and recombination. A simple and computational fast way to calculate electron collisional excitation cross-sections for ions is by using the plane-wave Born approximation. This is essentially a high-energy approximation and the cross section suffers from the unphysical problem of going to zero near threshold. Various remedies for this problem have been employed with varying degrees of success. We present a correction procedure for the Born cross-sections that employs the Elwert–Sommerfeld factor to correct for the use of plane waves instead of Coulomb waves in an attempt to produce a cross-section similar to that from using the more time consuming Coulomb Born approximation. We compare this new approximation with other, often employed correction procedures. We also look at some further modifications to our Born Elwert procedure and its combination with Y.K. Kim's correction of the Coulomb Born approximation for singly charged ions that more accurately approximate convergent close coupling calculations.     

A method of interface inversion in inhomogeneous media

First, an approximate solution of time domain interface scattering field is derived by extending the classical Born approximation in the problem of interface scattering. In accordance with the solution form, a projection density compensation (PDC) inversion method is developed according to the projection slice theorem, which is valid for the cases of inhomogeneous media and wave mode transformation. Finally, in the model of layered media, the calculation algorithm and the simulation inversion comparison results of point defect, crack, and crack on an interface, as well as the experiment method and results in the condition of acoustic wave, are given. The project supported by the National Natural Science Foundation of China (No.19232031) and Chinese Education Commission Science Foundation     

Diagrams of critical equilibrium for brittle bodies with sharp flaws

Certain forms of the stress-intensity factors close to the tips of sharp flaws (plane problem) are used as the basis of a method for plotting critical equilibrium diagrams for brittle bodies with flaws in the form of pointed cavity-cracks [5]. Concrete examples are discussed, mainly in the context of such diagrams, for a brittle body weakened by a circular cavity flaw with a crack leaving the edge of the flaw. Determination of the stress-intensity factors for this problem is based on approximate solution of an integral equation by the method of collocations. Plots of some familiar diagrams are also analyzed.Translated from Prikladnoi Mekhaniki i Tekhnicheskoi Fiziki, Vol. 11, No. 3, pp. 98–104, May–June, 1970.     

预制缺陷对花岗岩层裂破坏的影响

利用50 mm杆径的霍普金森压杆装置对完整和预制缺陷花岗岩试样进行层裂破坏实验,并采用高速摄像仪记录了试件层裂破坏的全过程。通过理论分析,计算了半正弦波加载情况下完整杆可能的初始层裂位置。高速摄影结果显示,预制缺陷对初始层裂位置具有一定影响,层裂一般发生在预制缺陷处。结合PFC2D（particle flow code in two dimensions）数值模拟进一步发现,初始层裂位置受到预制缺陷和反射拉伸波上升沿的影响,反射拉伸波上升沿越长,初始层裂越可能发生在预制缺陷处,反射拉伸波上升沿越短,初始层裂位置发生在预制缺陷处的可能性则相对越小。     

Global interpolating meshless shape function based on generalized moving least-square for structural dynamic analysis

A global interpolating meshless shape function based on the generalized moving least-square (GMLS) is formulated by the transformation technique. Both the shape function and its derivatives meet the Kronecker delta function property. With the interpolating GMLS (IGMLS) shape function, an improved element-free Galerkin (EFG) method is proposed for the structural dynamic analysis. Compared with the conventional EFG method, the obvious advantage of the proposed method is that the essential boundary conditions including both displacements and derivatives can be imposed by the straightforward way. Meanwhile, it can greatly improve the ill-condition feature of the standard GMLS approximation, and provide good accuracy at low cost. The dynamic analyses of the Euler beam and Kirchhoff plate are performed to demonstrate the feasibility and effectiveness of the improved method. The comparison between the numerical results of the conventional method and the improved method shows that the proposed method has better stability, higher accuracy, and less time consumption.     

Is Weibull distribution the correct model for predicting probability of failure initiated by non-interacting flaws?

The utility of the Weibull distribution has been traditionally justified with the belief that it is the mathematical expression of the weakest-link concept in the case of flaws locally initiating failure in a stressed volume. This paper challenges the Weibull distribution as a mathematical formulation of the weakest-link concept and its suitability for predicting probability of failure locally initiated by flaws. The paper shows that the Weibull distribution predicts correctly the probability of failure locally initiated by flaws if and only if the probability that a flaw will be critical is a power law or can be approximated by a power law of the applied stress.Contrary to the common belief, on the basis of a theoretical analysis and Monte Carlo simulations we show that in general, for non-interacting flaws randomly located in a stressed volume, the distribution of the minimum failure stress is not necessarily a Weibull distribution. For the simple cases of a single group of identical flaws or two flaw size groups each of which contains identical flaws, for example, the Weibull distribution fails to predict correctly the probability of failure. Furthermore, if in a particular load range, no new critical flaws are created by increasing the applied stress, the Weibull distribution also fails to predict correctly the probability of failure of the component. In all these cases however, the probability of failure is correctly predicted by the suggested alternative equation. This equation is the correct mathematical formulation of the weakest-link concept related to random flaws in a stressed volume. The equation does not require any assumption concerning the physical nature of the flaws and the physical mechanism of failure and can be applied in cases of locally initiated failure by non-interacting entities.