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Structural
Safety factors in structural integrity
integrity assessment of assessment
components with defects
457
Yury Matvienko
Mechanical Engineering Research Institute of the Russian Received 18 September 2012
Academy of Sciences, Strength, Survivability and Safety, Revised 20 November 2012
Moscow, Russian Federation Accepted 19 December 2012
Abstract
Purpose – The purpose of this paper is to develop basic principles of deterministic structural
integrity assessment of a component with a crack- or notch-like defect by including safety factors
against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.
Design/methodology/approach – The safety factors against fracture are calculated by demanding
that the applied critical stress should not be less than the yield stress of the material for a component
with a crack or a notch of the acceptable size. Structural integrity assessment of the engineering
components damaged by crack- or notch-like defects is discussed from view point of the failure
assessment diagram (FAD). The methodology of the FAD has been employed for the structural
integrity analysis and assessment of acceptable sizes of throw-thickness notch in a plate under tension
and surface longitudinal notch-like defects in a pressure vessel.
Findings – Basic equations have been presented to calculate the safety factor against fracture for critical
values of the stress intensity factor, crack tip opening displacement (CTOD), the J-integral and the FAD as
well as to estimate an acceptable (safe) region for an engineering component with a crack- or notch-like
defect of the acceptable size. It was shown that safety factors against fracture depend on both the safety
factor against plastic collapse and employed fracture mechanics criterion. The effect of crack/notch tip
constraint is incorporated into criteria equations for the calculation of safety factors against fracture.
Originality/value – The deterministic method of fracture mechanics is recommended for structural
integrity assessment of a component with a crack- or notch-like defect by including safety factors
against fracture and plastic collapse in criteria equations of linear and nonlinear fracture mechanics.
Keywords Biaxial loading, Constraint, Crack- and notch-like defects, Fracture mechanics criteria,
Safety factors, Structural integrity assessment
Paper type Research paper
1. Introduction
Structural integrity assessment methods play an important role in the industrial
realization of fracture mechanics applications. If the engineering component is
defect-free, the applied stresses are compared with a limit stress such as the yield stress
of the material. As long as the yield stress exceeds the applied stress, the component is
regarded as safe. If the component contains a crack- or notch-like defect, fracture
mechanics approach has to be employed. Therefore, the comparison between the
applied crack driving force and the fracture toughness of the material has to be carried
out on the basis of fracture mechanics parameters such as the stress intensity factor, International Journal of Structural
Integrity
Vol. 4 No. 4, 2013
The author acknowledges the support of the Russian Foundation of Basic Research (Grant pp. 457-476
q Emerald Group Publishing Limited
No. 10-08-00393-a). Furthermore, the author appreciates the kind help from the reviewers, who 1757-9864
provided beneficial suggestions for improving the final version of the manuscript. DOI 10.1108/IJSI-09-2012-0022
IJSI the J-integral, the crack tip opening displacement (CTOD) or, etc. Two types of
structural integrity assessment are made: a probabilistic assessment or a deterministic
4,4 assessment. It is obvious that the following parameters must be known when the
structure reliability is analyzed: load, crack length, the component geometry, fracture
toughness and yield stress of materials. The principles of establishing a probabilistic
approach have been considered in details by Wang et al. (1999), Tronskar et al. (2003),
458 Bullough et al. (2001) and Citarella and Apicella (2006). But, it should be noted that the
reliability analysis is more complex and costly compared with a deterministic analysis,
and is not convenient for common engineers to utilize it. Moreover, probabilistic
fracture mechanics is relatively new in the area of structural integrity and there are
often few data to have sufficient confidence in the results of the calculations to rely on
them for decisions on permission for engineering structures to operate. That is why the
deterministic method is assumed to be the basis of structural integrity assessment.
Therefore, in engineering, most assessment of component reliability are made
deterministically so that failure is avoided by including safety factors on each of the
different equation inputs. In this case, safety factors against fracture and plastic
collapse have been considered (Matvienko and Makhutov, 1999; Brickstad et al., 2000;
Matvienko, 2009). The safety factors are set to unity for the evaluation of critical
conditions.
The purpose of this paper is to develop basic principles of deterministic structural
integrity assessment of a component with a crack- or notch-like defect by including
safety factors against fracture and plastic collapse in basic equations of linear and
nonlinear fracture mechanics.
460 40
30
20
Figure 1.
The effect of the 10
strain hardening exponent
on the safety factor
0
against fracture in terms 1.5 1.6 1.7 1.8 1.9 2.0
of the J-integral
Safety Factor Against Plastic Collapse, SFY
It should be also noted that the proposed approach can be spread to structural integrity
assessment of the engineering component with notch-like defects considering a large
variability of the notch acuity 4 # a=r # 400 and employing the basic equation for the
J-integral (Berto et al., 2007).
where a and W are the crack size and width of a component, respectively. Values of
b(a/W) can be considered as a normalized measure of the crack tip constraint and have
been tabulated for various geometries by Sham (1991), Leevers and Radon (1982) and
Sherry et al. (1995).
The local strength within the fracture process zone ahead of the defect tip can be
also rewritten from equations (1), (10) and (11) as follows:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
s0 b 1 b 2 ð1 þ n 2 2 nÞðb=SF Y Þ2 2 1
¼2 þ 2 ð13Þ
sY 2SF Y 4 SF Y ð1 2 2nÞ2
ln secðp=2ÞðsY =s0 Þ
SF d ¼ : ð15Þ
ln secðp=2ÞðsY =ððSF Y Þs0 ÞÞ
The safety factor against fracture SFd depends on both the safety factor against plastic
collapse SFY and the biaxiality ratio b(a/W) (equations (13) and (14)) which
characterizes the crack tip constraint.
IJSI 3. Structural integrity assessment based on the failure assessment diagram
4,4 Structural integrity assessment of the component with a crack- or notch-like defect in a
frame of deterministic fracture mechanics is also illustrated by the failure assessment
diagram (FAD). The basic failure curve of the FAD is described by the following
equation Kr ¼ f(Lr), where Kr ¼ K/Kmat is the ratio of the applied stress intensity factor
K to the fracture toughness Kmat and Lr is equal to the ratio of applied load P to plastic
462 collapse load PY. In our case, the FAD is based on the criterion of the average stress
ahead of the crack/notch tip and considered in terms of K/Kmat and sC/sY, where sC is
the applied failure stress and sY is the yield stress. To determine an acceptable (safe)
region, it should be reasonable to introduce safety factors (Matvienko and Makhutov,
1999; Brickstad et al., 2000; Matvienko, 2009) in the failure criterion describing the FAD.
Consideration of a crack as a special case of a notch (Kt ! 1) changes the notch FAD
(equation (16)) into the FAD for the component with the crack:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2
sC
K ¼ K mat 1 2 ; ð18Þ
s0
and the notch fracture toughness K cNmat (equation (17)) leads to the
constraint-dependent fracture toughness for the crack:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2
c sC
K mat ¼ K mat 1 2 : ð19Þ
s0
30
465
20 AA2014-T6, Plane Stress
Equation (19), Kmat = 50.4 MPam1/2
10
SINTAP, Kmat = 48.3 MPam1/2
Experimental Results
0
0.0 0.2 0.4 0.6 0.8 1.0
Normalized Failure Stress, σC/ σY
(a)
600
500 +5%
–5%
σc- analysis, MPa
400
300
200
Test Figure 2.
Comparison of predicted
100 and experimental
100 200 300 400 500 600
(Christopher et al., 2005)
σc- test, MPa results of fracture analysis
(b) for AA2014-T6 aluminium
Notes: The constraint-dependent fracture toughness (a); the alloy centre-cracked
tensile specimens at 20 K
failure stress (b)
The safety factor SFFAD can be calculated by making an assumption that the applied
acceptable stress should be not less than the yield stress sY (equation (1)) of material
for an engineering component with a notch-like defect of the acceptable size
(Matvienko and Makhutov, 1999). In this case, the failure criterion for a notch-like
defect of the acceptable size on the boundary of fracture and plastic collapse can be
given by:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi"
2 2 #21=2
1 pffiffiffiffiffiffi sY s0 1
prsY K t ¼ K mat 1 2 12 ; ð23Þ
2 s0 sY K 2t
where r is the notch tip radius. Here, the stress intensity factor at the notch-like defect
tip is assumed to be as given by the relationship:
1 pffiffiffiffiffiffi
K notch ¼ prsK t : ð24Þ
2
The safety factor SFY against plastic collapse corresponding to equation (1) is
introduced in the failure criterion (22) to determine the acceptable defect as:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi"
2 #21=2
1 pffiffiffiffiffiffi sY K mat sY =SF Y 2 s0 1
pr Kt ¼ 12 12 : ð25Þ
2 SF Y SF FAD s0 sY =SF Y K 2t
Combining equations (23) and (25), the safety factor SFFAD against fracture can be
presented as:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiqffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1 2 ððsY =SF Y Þ=s0 Þ2 1 2 ðs0 =sY Þ2 1=K 2t
SF FAD ¼ SF Y qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiqffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi : ð26Þ
1 2 ðsY =s0 Þ2 1 2 ðs0 =ðsY =SF Y ÞÞ2 1=K 2t
Thus, the right-hand side of equation (22) defines the acceptable region in the notch
FAD. If the assessment point falls within this region, the component with a notch-like
Structural
D16T-1, σY = 372 MPa integrity
Crack Growth Initiation Stress, MPa
300
W = 100 mm assessment
270 W = 200 mm
240 467
210
180
150
0 10 20 30 40 50 60
Crack Length, mm
(a)
320
W = 100 mm
W = 200 mm
280
240
200
Figure 3.
160
Experimental results
(Drozdovsky et al., 1969)
120 for D16T-1 (a) and V-95
0 10 20 30 40 50 60 70 (b) tensile plates having
Crack Length, mm through thickness cracks
2a at 293 K
(b)
defect is acceptable, i.e. it fulfils the required safety demands. For the special case of a
crack (Kt ! 1) the notch FADs are transferred to the FAD for component with a sharp
crack (Matvienko, 2003, 2005, 2009, 2011), and the safety factor (26) becomes the safety
factor against fracture of cracked component:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1 2 ððsY =SF Y Þ=s0 Þ2
SF FAD ¼ SF Y qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi : ð27Þ
1 2 ð sY = s 0 Þ 2
3.3.2 The effect of biaxial loading on the safety factor against fracture. It can be seen
from equation (26), taking into account equations (13) and (14), that the safety factor
IJSI
4,4 40
30
Kcmat, MPam1/2
468
20
0
0.0 0.2 0.4 0.6 0.8 1.0
Normalized Crack Growth Initiation Stress, σC/ σY
(a)
50
40
Kcmat, MPam1/2
30
20
D16T-1, W = 200 mm, Plane Stress
against fracture for a component with a notch-like defect is a function of the safety
factor against plastic collapse as well as the elastic stress concentration factor and the
biaxiality ratio b(a/W).
The following result is an illustration of the estimation of SFFAD versus the elastic
stress concentration factor for the through-thickness center-notched plate under
uniaxial and biaxial remote loading (with the stress biaxial parameter k ¼ s1 1
xx =syy ).
Generally, the biaxiality ratio b(a/W) is also a function of crack size for certain
geometry. Therefore, to apply equations (13) and (14) for calculation of the normalized
local strength in the case of finite geometries, it is necessary to provide dependency of
Structural
50
integrity
assessment
40
Kcmat, MPam1/2
30 469
20
V-95, W = 100 mm, Plane Stress
Equation (19), Kmat = 43 MPam1/2
0
0.0 0.2 0.4 0.6 0.8 1.0
Normalized Crack Growth Initiation Stress, σC/ σY
(a)
50
40
Kcmat, MPam1/2
30
20
V-95, W = 200 mm, Plane Stress
1/2
Equation (19), Kmat = 40 MPam Figure 5.
10 SINTAP, Kmat = 38.8 MPam 1/2
Comparison of predicted
Experimental Results and experimental
(Drozdovsky et al., 1969)
0 constraint-dependent
0.0 0.2 0.4 0.6 0.8 1.0
fracture toughness of V-95
Normalized Crack Growth Initiation Stress, σC/ σY aluminium alloy
(b) centre-cracked tensile
specimens at 20 K
Notes: W = 100 mm (a) and W = 200 mm (b)
the biaxiality ratio on crack size for specific crack configurations and loading modes.
It was shown by Leevers and Radon (1982) that finite-width effects do not drastically
modify the value of b(a/W) for uniaxially loaded plate (k ¼ 0), which remains about 2 1
over the whole domain of crack lengths a/W. However, for high values of k, crack tip
conditions are by no means constant during crack extension. For example, for k ¼ 0.5
the value of b(a/W) varies from 20.5 to 2 0.75 for crack lengths a/W from 0 to
0.7 (Leevers and Radon, 1982). For a conservative estimation of trends in the safety
factor against fracture for biaxially loaded plate, the biaxiality ratio b is assumed to
be 20.5 for the value of k ¼ 0.5 independently on a/W.
IJSI Calculation of the safety factor against fracture (equation (26)) as a function of the
elastic stress concentration factor leads to the following dependence for plane strain and
4,4 plane stress (Figure 7).The safety factor against fracture SFFAD is, in general, dependent
on the elastic stress concentration factor and the biaxiality ratio as well as out-of-plane
conditions (plane strain or plane stress), as shown in Figure 7. It should be pointed out,
however, that the effect of out-of-plane conditions on the value of SFFAD is significant,
470 while the safety factor against fracture SFFAD is only weakly dependent on the biaxiality
ratio (k ¼ 0 and 0.5) for plane stress. It can be also seen that the value of SFFAD shows no
significant differentiation among the two biaxiality ratios for plane strain.
A crack-like defect is transferred in a sharp crack at Kt ! / . In this case, the
safety factor against fracture tends to its minimum value (equation (27)), i.e. typical
value for a sharp crack.
1.2
1.0
K1/Kmat, Kcmat/Kmat
0.8
Figure 6. 0.6
Comparison of predicted Equation (19) SINTAP
and experimental 0.4 Experimental Results, plane stress
(Drozdovsky et al., 1969) D16T-1 at 293 K, W = 100 mm, Kmat = 38.3 MPam1/2
results of the FAD at crack D16T-1 at 293 K, W = 200 mm, Kmat = 47.4 MPam1/2
growth initiation for 0.2 AKCH-1 at 293 K, W = 200 mm, Kmat = 50.9 MPam1/2
V-95 at 293 K, W = 100 mm, Kmat = 43 MPam1/2
D16T, AKCH-1 and V-95
V-95 at 293 K, W = 200 mm, Kmat = 40 MPam1/2
aluminium alloy
0.0
centre-cracked tensile 0.0 0.2 0.4 0.6 0.8 1.0
specimens at 293 K Normalized Crack Growth Initiation Stress, σC/ σY
Structural
Safety Factor Against Fracture, SFFAD
4.0
Plane Strain (Notch), k = 0 integrity
3.6 Plane Strain (Notch), k = 0.5
Plane Strain (Crack), k = 0
assessment
3.2 Plane Strain (Crack), k = 0.5
2.8
471
2.4
2.0
1.6
1.2
2 4 6 8 10 12 14 16 18
Elastic Stress Concentration Factor, Kt
(a)
Safety Factor Against Fracture, SFFAD
3.2
2.8
2.4
2.0 Figure 7.
2 4 6 8 10 12 14 16 18 The effect of biaxial
Elastic Stress Concentration Factor, Kt loading on the safety
(b) factor against fracture
(SFY ¼ 1.5, v ¼ 0.3)
An acceptable (safe) region for an engineering component with a notch-like defect of the
acceptable size can be represented from equation (22) by Figure 9. It can be seen that the
safe region trends to infinite for low values of the applied stress. It means that failure of
the notched component (characterized by the certain elastic stress concentration factor)
cannot occur under low applied stresses. This general result is consistent with the
results predicted by Smith (1999).
3.4.2 Acceptable notch-like defect in a pressure vessel. An assessment of the acceptable
surface longitudinal notch-like defects in a pressure vessel is based on the notch FAD
described by equation (25). Substituting equation (26) into equation (25), the acceptable
elastic stress concentration factor [Kt] can be written as follows:
IJSI 34
4,4 Notch-like defect
32
Acceptable Length, mm
Crack
30
472
28
26
Figure 8.
Acceptable defect length 24
in an infinite plate as a
function of the elastic 6 8 10 12 14 16 18 20
stress concentration factor
Elastic Stress Concentration Factor, Kt
FAD
2.5 FAD including safety factors
2.0
Critical Region
Knotch/Kmat
1.5
1.0
Acceptable Region
0.5
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
"
u
u 4 K2 2 # 2
sY s0
½K t ¼ t mat
12 þ : ð29Þ
pr s2Y s0 sY
Thus, acceptable state of the damaged pressure vessel has been presented by the following
criterion:
K t # ½K t ; ð30Þ
where Kt is the elastic stress concentration factor for the surface notch-like defect under
consideration.
The pressure vessel geometry is described by the wall thickness t, vessel outer
diameter D, longitudinal surface defect depth l, and defect tip radius r. In the analysis
presented below a wall thickness of 30 mm and a diameter of 1,200 mm are applied. Structural
The notch-like defect length is assumed to be an infinite value. To determine the elastic integrity
stress concentration factor for the surface external defect, the 2D finite element
simulations of steel pressure vessels were carried out using the ANSYS code assessment
(Figure 10).
473
(a)
Figure 10.
Geometrical model of
pressure vessel with the
surface external
longitudinal notch (a) and
a fragment of finite
element model in the
vicinity of the notch tip (b)
(b)
IJSI It was shown (Matvienko, 2009) that the elastic stress concentration factor can be given
4,4 by the following equation (Figure 11):
sffiffiffi
l l
Kt ¼ 2 Y ; ð31Þ
r t
474 where Y(l/t) is a geometrical correction factor for the stress intensity factor in the case
of the SENT specimen.
The following mechanical properties of the steel and the safety factor against plastic
pffiffiffiffi
collapse for plane strain were used: K mat ¼ 100 MPa m, sY ¼ 285 MPa, v ¼ 0.3,
SFY ¼ 1.5. For a conservative estimation of the normalized local strength, the
biaxiality ratio b is assumed to be 2 0.5. In this case, the acceptable depth of a surface
notch-like defect with acceptable defect tip radius [r ] ¼ 0.4 mm in the pressure vessel
amounts to 10.23 mm.
4. Conclusions
The deterministic method of structural integrity assessment is recommended to be
based on including safety factors against fracture and plastic collapse in criteria
equations of linear and nonlinear fracture mechanics. Structural integrity assessment
of the engineering components damaged by crack- or notch-like defects is discussed
from view point of the FAD.
The safety factors against fracture are calculated by demanding that the applied
critical stress should not be less than the yield stress of material for a component with a
crack or a notch of the acceptable size. Basic equations have been presented to calculate
the safety factor against fracture for critical values of the stress intensity factor, CTOD,
the J-integral and the notch FAD as well as to estimate an acceptable (safe) region for
an engineering component with a crack- or notch-like defect of the acceptable size.
It was shown that safety factors against fracture depends on both the safety factor
against plastic collapse and employed fracture mechanics criterion. For notch-like
90
80
70
60
50
Kt
40
l = 3.5 mm, 0.025 < ρ < 3 (mm)
30 l = 7.5 mm, 0.025 < ρ < 3 (mm)
Figure 11. l = 10.5 mm, 0.025 < ρ < 3 (mm)
The results of calculation 20 l = 3.5 mm, ρ = 0.035 mm)
of the elastic stress l = 7.5 mm, ρ = 0.075 mm)
concentration factor for 10 l = 10.5 mm, ρ = 0.105 mm)
surface longitudinal
notch-like defects by the 0
0 50 100 150 200 250 300 350 400
FEM and equation (31)
l/ρ
defects, the safety factor becomes a function of the elastic stress concentration factor. Structural
Moreover, the effect of crack/notch tip constraint has been expressed by biaxiality ratio integrity
and it is incorporated into criteria equations for the calculation of safety factors against
fracture. assessment
The methodology of the FAD has been employed for the structural integrity
analysis and assessment of acceptable sizes of through-thickness notch in a plate under
tension and surface longitudinal notch-like defects in a pressure vessel. 475
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Corresponding author
Yury Matvienko can be contacted at: ygmatvienko@gmail.com