4102 - Chap 12 - Fracture Control PDF

MAAE 4102
Engineering Materials
Strength & Fracture Analysis
Chapter 12
Fracture Control & Design Codes
Professor R. Bell
Department of Mechanical & Aerospace Engineering
Carleton University
2013
Chapter 12 - Fracture Control &
Codes
Department of Mechanical &

Aerospace Engineering
Fatigue
g Design
g Approaches
pp
Infinite Life
Unlimited safety design stresses below fatigue limit
Safe Life
Finite life safety factor = 20 x design life
Fail Safe
Cracks will exist inspection and repair
Damage Tolerant
Refinement of fail-safe philosophy
Use of FM to predict crack growth
Codes

Fatigue
g Life Improvement
p
Options
p
I
Lower design Stress
II Smaller Initial flaw size

III Small improvement in
toughness
IV Large improvement in
toughness

Codes

Fracture Control Plans

Purpose:
To design a structure that will perform
the operating function.
Efficiently
Safely
Economically
To Achieve These Goals Engineers
Predict Service Loads and Conditions
Calculate Stresses
Specify
S
if Materials
M t i l
Size Components and Members
Consider Possible Failure Modes
Codes

Possible Failure Modes

General Yielding or Excessive Plastic Deformation
Buckling or General
G
Instability (elastic
(
or plastic))
Sub-Critical Crack Growth
Fatigue
Stress-Corrosion
Corrosion Fatigue
(leads to unstable crack growth)
Unstable Crack Extension
Ductile or Brittle
Other
Oth
Corrosion
Creep
Codes

Design Philosophy
To Design Against Brittle Fracture and Fatigue
Engineers will:
Select materials with good fracture toughness

Eliminate or minimize stress raisers
Control welding procedures
Proper inspection
A Fracture Control Plan is jjust a formalization of basic

requirements into a set of guidelines for a specific structure.

Codes

Fracture Control Plan

Identification
of factors that mayy contribute to failure. Description
p
of service loading
g and
conditions.
Establishment
of relative contribution of each of these factors to a possible failure.
Determination
D t
i ti
of relative efficiency and trade-offs of various design methods to minimize
possibility of failure.
Recommendation
of specific design considerations to ensure the safety and reliability of the
structure.
material selection
design
d i stress
t
llevels
l
fabrication
inspection

Codes

3 Primary Factors
Notch Toughness
at particular service temperature loading rate plate
thickness
Size of Crack
at possible fracture initiation sites
Tensile Stress Level
including residual stress
Fracture mechanics has shown that all three factors can be
interrelated to predict the susceptibility of a structure to brittle failure.

Codes

Historical Background
General guidelines from experience
Reduce design stress levels
Eliminate
a e sstress
ess co
concentration
ce a o
Improve notch toughness of materials
Fracture Mechanics has made these general guidelines

a quantitative procedure.

Codes

Service Conditions and Loading

Fracture Toughness
KIC
slow loading
KIC(t)
loading rate
KID
impact loading
Loads measured
wind - waves calculation
codes
earthquake (experience)
Static or Fatigue loading
Fatigue
Constant
C
t t Amplitude
A lit d - rotating
t ti machinery
hi
Variable Amplitude - bridges aircraft

Codes
10

Service Conditions and Loading

Chemical or Environment
corrosion
stress corrosion
cavitation
corrosion fatigue
Establishment of minimum service temp
Quality of Fabrication - control initial defect size
Notch Toughness
Judgement

Codes
11

Establish Relative Contribution of Each Factor

to Possible Fracture
1. Tensile Stress Level
2. Material Toughness
3. Crack Size

Codes
12

Effect
ect o
of Plane
a e St
Stress
ess Plane
a e St
Strain
a Co
Conditions
dto s

Codes
13

Effect of Toughness
g
on Critical Crack Size

Codes
14

Trade-Offs Decrease Design

g Stress

Codes
15

Trade-Offs Improve
p
Fabrication

Codes
16

The effect of the 3 Factors on Total Life

TENSILE STRESS (large effect on life)
FCG is decrease when F is decreased. Design stress
range (max - min) primary factor to control.
FLAW SIZE (large effect on life)

rate of FCG is low for small flaws. Quality of inspection is
primary factor to control.
MATERIAL TOUGHNESS
large effect on life when moving from plane-strain
behaviour to elastic p
plastic behaviour.
small effect on life when moving from elastic-plastic
behaviour to plastic behaviour

Codes
17

Elements of A Fracture Control Plan
Design
Stress Distribution Information

Flaw Tolerance in region of high stress
Estimates of stable cack growth for typical periods of service
Recommendation for sae operating periods between inspections
Materials
Strength and fracture properties
Recommended Heat and Material treatments
Recommended welding
elding proced
procedures
res
Fabrication
Inspections
Control of Residual Stresses
Protection of required Strength and Fracture properties
Maintain fabrication and materials records
Codes
18

Elements of A Fracture Control Plan

Inspection
p
Fabrication Inspections
NDT Inspections
Proof Testing
Estimates of largest defect sizes
Operations
Control of Stress levels and stress fluctuations in service
Corrosion Protection
Periodic In-service inspections
Decommissioning
Codes
19

Fracture Control Options

p

Codes
20

Fracture Control Options

PERIODIC INSPECTION:
repair upon crack detection
FAIL SAFE DESIGN:
repair upon occurrence of partial failure
DURABILITY DESIGN:
replacement or retirement after time H.
PERIODIC PROOF TESTING: repair after failure in proof test

STRIPPING
periodic removal of crack

p

Codes
21

Periodic Inspection
INSPECTION METHODS
Visual
Penetrant
P
t t
Magnetic Particles
Materials
X-Ray
Ultrasonic
Eddy Current
Acoustic Emission
Naked Eye Accessibility

C l
Coloured
d Li
Liquid
id -Accessibility
A
ibilit
UV Light
Magnetic
Small surface flaws difficult
Cheap
Interpretation difficult

Codes
22

Periodic Inspection

Codes
23

Failsafe Design
Cracks or failed members must be detected
and repaired.
The
Th structure
t t
is
i designed
d i
d ffor ttolerance
l
off
large damage.
Crack arresters
Multiple Load Paths
Leak
L kb
before
f
b
break.
k

Codes
24

Durability
y Design
g
CRACK ai assumed to exist
Time
Ti
H iis d
determined
t
i d ffor a smallll crack
k tto
grow from ai to ap
Structure retired or replaced at H/2.
This may be wasteful.

Codes
25

Proof Testing
If toughness low apermissible < adetectable

at time t component subjected to proof
Fracture occurs if crack aproof exists
If no fracture occurs, therefore a safe operational life from aproof
to apermissible is ensured
pipelines and pressure vessels - hydro-tests

Codes
26

Proof Testing

Codes
27
Stripping

This is an option with small

undetectable cracks if apermissible
Exists.
Machine surface layer so that
as a p
depth
p of surface layer
y
After stripping it would take H hours
for crack to grow from as to ap again
- safe operation
operation. After H hours ap
would exist, therefore stripping
would be repeated every H hours.

Codes
28

Costs of Fracture Control

Damage Tolerance Analysis
20,000 - 50,000 man hours for an aircraft
Coupon Tests and Verification
Inspections
Repairs and Periodic replacement
Codes
29

Potential Costs of Fracture

Loss of Human Lives
Impact on environment
Litigation expenses
Replacement of Structure
Damage to buildings and surrounding structures
Down time - loss of production
Loss of sales and contracts

Codes
30

Regimes of LEFM, EPFM and Collapse

Codes
31

Failure Analysis Diagram FAD
Fractures from brittle to fully plastic can be represented on a FAD
Normalized FAD

Codes
32

Fitness for Purpose Procedures

Codes
33
R6 - Procedure
Kr
K
K mat
; Lr

P
PL ( y )
Depending on the available data

data, there
are a number of options within R6 which
may be used to evaluate the function
f, which defines the shape of the failure
assessment curve. The simplest choice
f f is
for
i the
th option
ti 1 curve:
F ( Lr ) (1 0.1 L2r )(0.3 0.7 exp(0.65L6r ))

Plastics Collapse given by :
1 u
Lr Lmax
1
r
2 y
The basic
Th
b i R6 approach
h requires
i
only
l material
t i l properties
ti (tensile
(t
il and
d ffracture
t
toughness) and simple calculations of K and PL. Stress intensity factors, K, and
limit loads, PL, are available for many components in compendia or may
calculated using FEM

Codes
34

BS 7910 (PD 6493) Procedure
BS 7910 is a revision of PD6493:1991

Codes
35


BS 7910 is a revision of PD6493:1991.
In PD 6493 there are 3 levels of assessment were
given.
i
Level 1, termed the `Preliminary Assessment'
method,
This level includes a limit of 0.7 on Kr and 0.8 on Sr.
These two limits result in a safety factor of 2 on flaw
size.
Al restricting
Also
t i ti Sr to
t 0.8
0 8 lilimits
it nom to
t b
be less
l
th
than th
the
yield stress
i.e flow 1.2 yield
These safety factors allow Level 1 to be used as a
rapid
id assessmentt off safety
f t off an existing
i ti structure.
t t
The fracture behaviour in Level 1 can also be
established in term of CTOD

Codes
I
C
where
K 2I
I the driving force
YS E
C the resistance force
36


PD 6493 - Level 2, the `Normal Assessment' method was
similar to the 1980 edition (Rev. 2) of the R6 method.
This is
Thi
i the
th preferred
f
d assessmentt level
l
l ffor the
th majority
j it off
structural application and it is based on the Dugdale strip
yield model
8

K r , r S r 2 ln sec S r
2
Kr
K
K mat
Sr
F
FL
Level 3, the `Advanced Assessment' method was based on

revision 3 of R6 and allowed the user to take account
of the resistance to ductile crack extension
extension. At all these
levels, the fracture toughness could be expressed in terms of
CTOD or Kmat.

Codes
37

Fracture - FAD
Fatigue
g
Codes
38

Engineering Treatment Model - CDF

Crack Driving Force CDF
GKSS Germany
The ETM is based on a mechanical model
model,
which for the fully plastic range, utilises the
material's stress-strain behaviour
represented by a piece-wise power law to
estimate the quantities 5, J-integral, and the
deformation of a cracked body
End-of-life failure conditions can be assessed
in terms of
crack size
size, a;
applied load expressed as force, F,
moment, M, internal pressure, p, stress, ;
applied strain, a.

Codes
39

Engineering Treatment Model - CDF

Crack Driving Force CDF
GKSS Germany
Point Value of Fracture

Toughness given
Determination of Critical Conditions

Failure conditions are given by the
intersection of the ETM curve with the
Fracture resistance of the material
material,
represented by Jmat or 5Ymat,
R-Curve Analysis

Codes
40
SINTAP Procedure

The SINTAP procedure offers both a FAD and a CDF route.

They are complementary and yield identical results.
The underlying principles of the SINTAP method are:
a hierarchical structure based on quality of available data inputs;
decreasing conservatism with increasing data quality;
detailed guidance on determination of characteristic
input values such as fracture toughness;
the choice of representation of results in terms of a FAD or CDF;
specifc methods for allowing for the effect of weld strength mismatch;
guidance on dealing with situations of low constraint and, for
components containing pressurised fluids, leak before break analysis;
compendia of solutions for stress intensity factors, limit load solutions
and weld residual stress profiles.

Codes
41
SINTAP Procedure

FAD Approach
Failure Assessment Line
K r f ( Lr )
Kr
Lr Lmax
r
K
K mat
Lr
define the plastic collapse limit of the structure

Codes
42
SINTAP Procedure

CDF Approach
Failure Assessment Line
K r f ( Lr )
Kr
Lr Lmax
r
K
K mat
Lr
define the plastic collapse limit of the structure

Codes
43
References

PD6493:1991: Guidance on methods for assessing the acceptability of Flaws in
Fusion welded structures. British Standards Institution, London, 1991.

BS 7910:1999: (incorporating Amendment No.1) Guide on methods for assessing
the acceptability of Flaws in metallic structures. British Standards Institution,
London, 2000.
U. Zerbsta,*, R.A. Ainsworthb, K.-H. Schwalbea
Basic principles of analytical Flaw assessment methods,International Journal of Pressure
Vessels and Piping 77 (2000) 855-867
C.S. Wiesnera, S.J. Maddox, W. Xua, G.A. Webster, F.M. Burdekin,
R.M. Andrews, J.D. Harrison
Engineering critical analyses to BS 7910 the UK guide on methods for assessing the
acceptability of Flaws in metallic structures
International Journal of Pressure Vessels and Piping 77 (2000) 883-893
P.J. Budden, J.K. Sharples, A.R. Dowling
The R6 procedure: recent developments and comparison with alternative approaches
Ted L. Anderson, David A. Osage
API 579: a comprehensive Fitness-for-service guide
International Journal of Pressure Vessels and Piping 77 (2000) 953
953-963
963
Codes
44
References

R.A. Ainsworth, A.C. Bannister, U. Zerbst

An overview of the European aw assessment procedure SINTAP and its validation
Broek, D., The Practical Use of Fracture Mechanics , Kluwer Academic Publishers,
1988
Barsom, J., and Rolfe, S.T., Fracture and Fatigue Control in Structures, 2nd Ed.,
Prentice-Hall, 1987

Codes
45

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MAAE 4102

Department of Mechanical &

Department of Mechanical &

Lower design Stress

II Smaller Initial flaw size

Chapter 12 - Fracture Control &

Department of Mechanical &

Fracture Control Plans

Department of Mechanical &

Possible Failure Modes

Department of Mechanical &

Select materials with good fracture toughness

A Fracture Control Plan is jjust a formalization of basic

Chapter 12 - Fracture Control &

Department of Mechanical &

Fracture Control Plan

Chapter 12 - Fracture Control &

Department of Mechanical &

Chapter 12 - Fracture Control &

Department of Mechanical &

Fracture Mechanics has made these general guidelines

Chapter 12 - Fracture Control &

Department of Mechanical &

Service Conditions and Loading

Chapter 12 - Fracture Control &

Department of Mechanical &

Service Conditions and Loading

Chapter 12 - Fracture Control &

Department of Mechanical &

Establish Relative Contribution of Each Factor

Chapter 12 - Fracture Control &

Department of Mechanical &

Chapter 12 - Fracture Control &

Department of Mechanical &

Chapter 12 - Fracture Control &

Department of Mechanical &

Trade-Offs Decrease Design

Chapter 12 - Fracture Control &

Department of Mechanical &

Chapter 12 - Fracture Control &

Department of Mechanical &

The effect of the 3 Factors on Total Life

FLAW SIZE (large effect on life)

Chapter 12 - Fracture Control &

Department of Mechanical &

Elements of A Fracture Control Plan

Stress Distribution Information

Department of Mechanical &

Elements of A Fracture Control Plan

Department of Mechanical &

Fracture Control Options

Chapter 12 - Fracture Control &

Department of Mechanical &

Fracture Control Options

repair upon crack detection

FAIL SAFE DESIGN:

repair upon occurrence of partial failure

replacement or retirement after time H.

PERIODIC PROOF TESTING: repair after failure in proof test

periodic removal of crack

Chapter 12 - Fracture Control &

Department of Mechanical &