Calibration of Weibull Stress Models Using Fracture Toughness Data

Robert H. Dodds, Jr.

Department of Civil Engineering University of Illinois

July 1998
July 1998 1

Need for Models

Assessment of Sub-Size Fracture Specimens

Constraint Loss Ductile Tearing as Precursor to Cleavage Effects of Aspect Ratio, SGs Become More Critical Make Toughness Values Usable in To Determinations Shallow Surface Cracks Tension Loaded (Uni & Biaxial), Impact Better Quantify Conservatism in Defect Assessments

Transferability of Toughness (To) to Structure

July 1998

Engineering Models: Cleavage

Transgranular Cleavage in DBT Range Initiation, Propagation, Arrest Events Primarily Stress Controlled Strong Sensitivity to Constraint Strong Volume Sampling Effects
Microcrack Propagation
Carbide Microcrack

Fracture of Carbide

July 1998

Weakest Link Model

Simple Chain
F F

Crack Front

Single Flaw Global Fracture

    = 
 

July 1998

Each Volume Uniformly Stressed and Independent

Need Integral Over Volumes Since Each Has Different Stress

PFP: Weibull Stress

Limiting Distribution for Fracture Stress:     = 
   
Weibull Stress: 

  =  

 

   

Distribution of Weibull Stress:     = 
 

 =  
 


July 1998

a0

Weibull Stress Model



SSY
Increasing Constraint & m

PCVN
JPCVN JSSY

SSY Reference Model Is Plane-Strain

July 1998 6

Weibull Stress, n =10

3.0

2.5

m = 20  
= 

SSY (T = 0) SE(B)

 

2.0

b W a W = B, a/W = 0.5, Plane-Sided

1.5

1.0

0.01

0.02

   

0.03

0.04

0.05

July 1998

Constraint Correction

  

1 1

Based on Calibrated m

PCVN
Distribution of JSSY Values

  
July 1998 8

Calibration Schemes
 



    = 
 
Microscopic Model
July 1998


 = 
 Macroscopic Model
9

Problems With Calibration

Experimental Sets of Jc Values Often Have Limited Numbers of Specimens (6-10) MLE Values for Have Low Confidence MLE Values for Have Much Better Confidence Calibrated m Has Low Confidence (e.g., m = 20, +- 8) 


 = 


July 1998

10

Ruggieri-Dodds Proposal (1997)

Obtain Jc Values Under SSY Conditions (test a/W > 0.4 SEBs with M > 50) Get MLE Value for  Assume =  (Theoretical Value for SSY) Build Large Jc Set of Values Using Monte-Carlo Simulation of Theoretical Distribution Use Iterative MLE Method to Fit  
 Values Are Non-Unique: Many  
 Pairs Provide Equally Good Micro-Macro Fit !

July 1998

11

Implications of SSY Jc Values

Deep Notch SE(B)s Have     (for M > 50) SE(B) Crack Front Stress Field Governed By J Alone, i.e., a 1 Parameter Field Weibull Stress Model Has 2 Parameters

 = 



    = 
 




=

1 Parameter

2 Parameters

July 1998

12

Example of Non-Uniqueness

SSY, T = 0, Plane-Strain, B = 25 mm  =     =  = 

= 80, 120, 160 KJ/m2

Finite Strain Solution Show That Many  
 Pairs Make This Relationship Hold 
=

 

July 1998

13

 !   
 

100 80

=     
   



60

SSY
40 20 0

10

15

20

25

=     
July 1998 14

Non-Uniqueness of Parameters
( 
)
(
)


=  

 = 
= 
 =  
= "
 = 
= "

5 4 3 2 1 0

( 
)
(
)

=   
 = 
= #
 =  
= "$
 = 
= "

0.5

1.0

1.5

2.0 0

0.5

1.0

1.5

2.0

July 1998

15

New Proposal for Calibration

July 1998

16

Gao, Ruggieri, Dodds (1998)

Test to Get 2 Jc Sets w/ Different Stress Fields, i.e., Constraint SE(B)s, a/W = 0.5 (A) and 0.1 (B) (no tearing) Gao, Ruggieri, Dodds (1998)

(A)
   = 

 = {} Essentially SSY

(B)
   =  
 = {}
Constraint Loss

July 1998

17

Gao, Ruggieri, Dodds (1998)

Constraint Correct Both Sets to SSY Using a Trial Value of Weibull Modulus, m
  Compute  and  Using MLE With Weibull Exponent =    Iterate on m Until  = 


1
   

(A)
   = 
m increasing

(B)

   = 

Trial m


18

July 1998

Robustness of Calibration

Analyze PCVN and SSY

PCVN: 3-D, Finite Strain, Fine Mesh SSY: Plane Strain, Finite Strain Identical Near Front Meshes, Root Radius

  =    =  ' 

Assume  Known, %& =   Let Denote %& Corrected to SSY

Error of Calibration:   =   Want to Find m Such that R(m) = 0!

July 1998

19

3-D Model for PCVN

B/2

Symmetry Plane
W

22,710 Nodes 19,838 Elements (8-node)

2W

B = W = 10 mm a/W = 0.5

July 1998

20

SSY & PCVN Response

 
5 4 3 2 1 0 0 0.02 0.04 0.06 0.08

0.05 0.04

 (  )
  =   ='
1 1

SSY (T = 0) PCVN
 = '   =    = 

0.03 0.02 0.01 0 0 0.02

m = 12, 16, 20, 24

0.04 0.06 0.08 0.10

 (  )

 (  )

July 1998

21

Residuals for m

0.6 0.4 0.2

  =     = 



0.0 -0.2 -0.4 -0.6 5 10 15

 =   =      = '  = $     =   = #   

20

25

July 1998

22

Modified Weibull Distribution

Standard 2 Parameter Model:  


Unconditional Cleavage Probability Overestimates Actual Scatter Poor Match at Low Probabilities (no threshold)

New Proposal

Prompted by Anderson-Steinstra Work Macroscopic Form Adopted in E-1921

E-1921: Proposal:

  "   
 = 


Kmin = 20             = 


      =   
=   
23

July 1998

Calibration for A36 Steel

Testing Program by Sorem et al. (U. Kansas) A36 Steel Plate (Structural) L. Strength, H. Hardening (  = 290 MPa, n = 4-5) Extensive J, CTOD Testing to Obtain Full Transition

a/W = 0.5, B x B (B = 31.8 mm) a/W = 0.15, B x B (B = 31.8 mm) Large Constraint Loss in a/W = 0.15 Specimens No Tearing in Either Configuration @ - 43oC 8-9 Toughness Values for Each Configuration @ - 43oC

   =   
July 1998 24

A36 Steel Plate: Toughness

Jc (kJ/m2)
700 600 500 400 300 200 100 0 -120 700

Jc (kJ/m2)
600 500

a/W = 0.5

Brittle Ductile Tearing

B = W = 31.8 mm Data Used in Calibration

400 300 200 100 0 -120

Data Used in Calibration

a/W = 0.15
-100 -80 -60 -40 -20 0 20

-100

-80

-60

-40

-20

20

Temperature (oC)

Temperature (oC)

July 1998

25

Calibration: A36 Steel

( 
n = 4-5
A36 Steel @ -43oC  = # (

800 600 400 200 0

0.6 0.4 0.2 0.0 -0.2


A36 Steel @ -43oC

m = 7.8
0 5 10 15 20

0.05 0.10 0.15 0.20 0.25 0.30

-0.4

)

July 1998

26

Fit to Test Data (A36, Sorem)

1.0 0.8 0.6 0.4 0.2 0 0 50 100


a/W = 0.5 a/W = 0.15
Tests

1.0 0.8 0.6 0.4 0.2 0


a/W = 0.5

 = $'
=       =  

2 Para. Model 3 Para. Model 0 50

  

150

200

250 300

  
!   + "

100

150

200

Median Rank Probabilities for Data: ! =

July 1998

27

Work In Progress

Add 3rd Geometry to Process for Checking Calibrate m Using SE(B)s with a/W = 0.15, 0.5 Predict Pf for Surface Cracked Plates Loaded in Tension Link & Joyce Tests (ASTM STP1321)

A515, L-S 7 Identical Specimens, Pin Loaded @ -40oC, No Tearing 7 Identical Specimens, Bolt Loaded @ -7oC, No Tearing a/t = 0.25, 2c/a = 6, t = 25 mm New SE(B) Tests from Tregoning (NSWC)

July 1998

28

Weibull Models: Issues

Complexity of Cleavage Mechanism
Only 2, 3 Model Parameters  
    

Temperature Dependence? Tearing as Precursor to Cleavage - History Effects? Gradients of Stress-Strain Fields? Loading Rate Effects?

Calibration Philosophy

Notched Round Bars vs. Fracture Specimens Uniqueness of Calibrated  
 Threshold Stress, Toughness:  "      Applicability Range of Parameters

July 1998

29

2.0

1.5

1.0

SSY
0.5

0.0 0.0

0.5

1.0

1.5

2.0

July 1998

30

0.030 0.025 0.020 0.015 0.010 0.005 0.000

10

15

20

25

30

July 1998

31

5 4 3 2 1 0 0.0 0.5 1.0 1.5 2.0

5 4 3 2 1 0 0.0 0.5 1.0 1.5 2.0

July 1998

32