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NASA Technical Memorandum 100174

Fracture Mechanics Concepts in Reliability

Analysis of Monolithic Ceramics

Jane M. Manderscheid and John P. Gyekenyesi

Lewis Research Center
Cleveland, Ohio

Prepared for
Testing High Performance Ceramics
cosponsored by the American Ceramic Society and
the American Society for Nondestructive Testing
Boston, Massachusetts, August 25-27, 1987
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(6851-TR-100174) FRACTURE BECBAIICS

CCBCBETS III P E L I A E X L I T Y BLALPSIS O P
WCIOLITEIXC CE6AhlICS
( I A S B ) 16 p
Avail:
b ! U S BC A02/BF
A01
CSCL 20K

Y87-27269

63/39

Unclas
0092896

FRACTURE MECHANICS CONCEPTS I N RELIABILITY ANALYSIS OF MONOLITHIC CERAMICS

Jane M. Manderscheid and John P. Gyekenyesi
N a t i o n a l A e r o n a u t i c s and Space A d m i n i s t r a t i o n
Lewis Research Center
Cleveland, Ohio 44135
ABSTRACT

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B a s i c d e s i g n concepts f o r high-performance, m o n o l i t h i c cerami-c s t r u c t u r a l

components a r e addressed. The design o f b r i t t l e ceramics d i f f e r s from t h a t
o f d u c t i l e m e t a l s because o f the i n a b i l i t y of ceramic m a t e r i a l s t o r e d i s t r i b u t e h i g h l o c a l s t r e s s e s caused by i n h e r e n t f l a w s . Random f l a w s i z e and
o r i e n t a t i o n r e q u i r e s t h a t a p r o b a b i l i s t i c a n a l y s i s be performed in o r d e r t o
determine component r e l i a b i l i t y . The c u r r e n t t r e n d i n p r o b a b i l i s t i c analys i s i s t o combine l i n e a r e l a s t i c f r a c t u r e mechanics concepts w i t h the two
parameter W e i b u l l d i s t r i b u t i o n f u n c t i o n t o p r e d i c t component r e l i a b i l i t y
under mu1 t i a x i a l s t r e s s s t a t e s . N o n d e s t r u c t i v e e v a l u a t i o n supports t h i s
a n a l y t i c a l e f f o r t by s u p p l y i n g d a t a d u r i n g v e r i f i c a t i o n t e s t i n g . I t can
a l s o h e l p t o determine s t a t i s t i c a l parameters which d e s c r i b e the m a t e r i a l
s t r e n g t h v a r i a t i o n , i n p a r t i c u l a r the m a t e r i a l t h r e s h o l d s t r e n g t h ( t h e
t h i r d W e i b u l l parameter), which i n the p a s t has o f t e n been t a k e n as z e r o for
simp1 i c i t y .
INTRODUCTION
Ceramic m a t e r i a l s are c u r r e n t l y under c o n s i d e r a t i o n f o r s t r u c t u r a l components i n advanced h e a t engines f o r several reasons. The p r i m a r y m o t i v a t i o n
i s t h e i r h i g h s t r e n g t h under s i g n i f i c a n t l y i n c r e a s e d o p e r a t i n g temperatures.
The use o f these h i g h temperature m a t e r i a l s w i l l p e r m i t b e t t e r f u e l e f f i c i e n c y and reduce c o o l i n g s y s t e m requirements. I n a d d i t i o n t o h i g h temperat u r e s t r e n g t h , t h e low d e n s i t y o f ceramics a l s o makes them a t t r a c t i v e ,
e s p e c i a l l y f o r r o t a t i n g components. Other e n t i c i n g p h y s i c a l p r o p e r t i e s
i n c l u d e good o x i d a t i o n and c o r r o s i o n r e s i s t a n c e , low f r i c t i o n and wear chara c t e r i s t i c s , and the f a c t t h a t ceramics a r e manufactured from abundant, nons t r a t e g i c raw m a t e r i a l s .
U n f o r t u n a t e l y , several u n d e s i r a b l e c h a r a c t e r i s t i c s a r e a l s o p r e s e n t i n
ceramics because o f t h e i r l a c k o f d u c t i l i t y and t h e i r random f l a w d i s t r i b u t i o n . Due t o t h e i r atomic s t r u c t u r e , ceramics i n t r i n s i c a l l y e x h i b i t low
s t r a i n t o l e r a n c e and low f r a c t u r e toughness. Low toughness, when combined
w i t h d e s i r e d t e n s i l e s t r e s s s t a t e s , u s u a l l y r e s u l t s i n a v e r y small c r i t i c a l f l a w s i z e . Furthermore, a l a r g e d i s p e r s i o n i n f r a c t u r e s t r e n g t h e x i s t s .

The f r a c t u r e s t r e n g t h v a r i e s n o t o n l y i n n o m i n a l l y i d e n t i c a l t e s t s , b u t t h e
mean s t r e n g t h i s also dependent upon t h e method o f t e s t i n g and t h e volume
of t e s t e d m a t e r i a l . L i m i t e d design e x p e r i e n c e e x i s t s f o r m a t e r i a l s h a v i n g
such p r o p e r t i e s , w i t h much of t h e e a r l y b r i t t l e m a t e r i a l s d e s i g n e x p e r i e n c e
gained from work w i t h g r a p h i t e (Refs. 1 and 2) or g l a s s ( R e f . 3 ) .
There i s a w e l l - e s t a b l i s h e d l i n k between l i n e a r e l a s t i c f r a c t u r e mechanics
(LEFM) and n o n d e s t r u c t i v e e v a l u a t i o n (NDE) i n t h e f l a w - t o l e r a n t d e s i g n method f o r metal 1 i c components, However, s e v e r a l f a c t o r s c u r r e n t l y p r e v e n t a
s i m i l a r s i t u a t i o n for ceramics. F i r s t , a v a s t number o f f l a w s t y p i c a l l y
e x i s t i n a v a r y i n g m u l t i a x i a l s t r e s s f i e l d w i t h i n a ceramic component. Second, t h e p r o b a b i l i s t i c n a t u r e o f advanced NDE methods must be t a k e n i n t o
account, e s p e c i a l l y for t h e small c r i t i c a l f l a w s i z e s encountered i n such
a p p l i c a t i o n s . T h i r d , t h e a b i l i t y o f t h e NDE method t o determine t h e f l a w
t y p e , shape, and o r i e n t a t i o n must be considered. F o u r t h , t h e r e l a t i o n s h i p
between t h e f l a w and t h e f r a c t u r e s t r e n g t h must be e s t a b l i s h e d . There a r e
many t y p e s o f p o s s i b l e s t r e n g t h - c o n t r o l l i n g f l a w s : machining damage,
c r a c k s , pores, agglomerates, i n c l u s i o n s , l a r g e g r a i n s , g r a i n boundaries,
and o t h e r m i c r o s t r u c t u r a l i r r e g u l a r i t i e s . A c c o r d i n g t o a r e c e n t r e v i e w b y
Singh (Ref. 4 ) on t h e e f f e c t o f f l a w s on t h e f r a c t u r e s t r e n g t h o f ceramics,
t h e f l a w s i z e - s t r e n g t h r e l a t i o n s h i p i s n o t yet determined f o r a l l f l a w
types i n a l l m a t e r i a l s . However, e x p e r i m e n t a l d a t a shows t h a t most d e f e c t s
e x h i b i t c r a c k - l i k e b e h a v i o r and can be modeled b y LEFM even though t h e y a r e
n o t t r u e cracks i n e v e r y sense, i . e . , t h e y a r e n o t f l a t planes o f geometric
d i s c o n t i n u i t y . T h i s i s done by i n t r o d u c i n g an e f f e c t i v e c r a c k which is r e l a t e d , a l t h o u g h n o t e x a c t l y equal, t o t h e a c t u a l f l a w shape and s i z e . Due
t o t h e above c o n s i d e r a t i o n s , an a p r i o r i a n a l y t i c a l d e t e r m i n a t i o n o f t h e
c r i t i c a l f l a w i n a component i s p r e s e n t l y i n t r a c t a b l e . Hence, i t i s gene r a l l y i m p r a c t i c a l t o use t r a d i t i o n a l d e t e r m i n i s t i c f r a c t u r e mechanics and
s i n g l e c r a c k NDE t o p r e d i c t t h e s t r e n g t h o f a g i v e n ceramic component.
T h e r e f o r e , t h e c u r r e n t t r e n d i n m o n o l i t h i c ceramics s t r u c t u r a l a n a l y s i s i s
t o couple LEFM w i t h s t a t i s t i c a l weakest l i n k concepts t o p r e d i c t t h e
s t r e n g t h v a r i a t i o n and f a i l u r e b e h a v i o r o f ceramic components. I n t h i s
method, a f r a c t u r e s t r e n g t h d i s t r i b u t i o n i s f i r s t determined from s i m p l e
u n i a x i a l l y loaded ( f l e x u r a l or t e n s i l e ) t e s t specimens. Then, u s i n g t h i s
d a t a , t h e r e l i a b i l i t y f o r a g i v e n component geometry and l o a d i n g can be c a l c u l a t e d . A d i r e c t c o r r e l a t i o n between f l a w t y p e l s i z e and f r a c t u r e s t r e n g t h
i s n o t necessary. A c c o r d i n g l y , p r e - e x i s t e n t f l a w s do n o t need t o be e x p l i c i t l y detected.
However, t h i s does n o t i m p l y t h a t NDE cannot p l a y a r o l e i n t h e r e l i a b i l i t y
a n a l y s i s . The o b j e c t i v e o f t h i s paper i s t o d i s c u s s two o f N D E s r o l e s i n
t h e a n a l y t i c a l p r e d i c t i o n o f f a s t - f r a c t u r e r e 1 i a b i 1 it y o f s t r u c t u r a l cerami c s , along w i t h a basic d e s c r i p t i o n o f the r e l i a b i l i t y analysis i t s e l f .
Accurate experimental v e r i f i c a t i o n o f t h e r e l i a b i l i t y models demands NDE
c h a r a c t e r i z a t i o n o f t h e t e s t specimens. A second r o l e would be t o c o r r e l a t e
NDE measurements w i t h t h e s t a t i s t i c a l parameters r e q u i r e d for r e l i a b i 1 it y
a n a l y s i s , thus e l i m i n a t i n g c o s t l y t e s t i n g . Furthermore, i n t h e low f a i l u r e
p r o b a b i l i t y regimes o f i n t e r e s t i n design, NDE p r o v i d e s increased a n a l y s i s
capabi 1 it y b y e x p e r i m e n t a l l y d e t e r m i n i n g a t h i r d s t a t i s t i c a l parameter t o be

used i n t h e a n a l y s i s . The f i r s t r o l e , experimental v e r i f i c a t i o n , i s

c u r r e n t l y i n progress a t NASA Lewis Research Center and w i l l be b r i e f l y summ a r i z e d i n a l a t e r s e c t i o n of t h i s paper. The l a t t e r r o l e , parameter d e t e r m i n a t i o n , i s p r o b l e m a t i c a l a t t h i s time, and i s consequently seldom used,
b u t i t s p o t e n t i a l a p p l i c a t i o n w i l l be described. I n f o r m a t i o n about r e l i a b i l i t y a n a l y s i s w i l l be presented t o a i d i n t h e understanding o f NDE's
r o l e s i n t h i s r e s e a r c h area.
RELIABILITY ANALYSIS
Fundamentals of t h e Weakest L i n k Fracture Theory
The f r a c t u r e s t r e n g t h of ceramics i s c o n t r o l l e d by one o f t h e l a r g e r f l a w s
i n t h e m a t e r i a l and hence can be described by a form o f extreme v a l u e s t a t i s t i c s . Most mathematical d e s c r i p t i o n s of f a i l u r e p r o b a b i l i t y are based on
t h e weakest l i n k t h e o r y (WLT). The WLT assumes t h a t complete f a i l u r e w i l l
o c c u r when t h e weakest l i n k of a number of independent and m u t u a l l y e x c l u s i v e l i n k s f a i l s . Consequently, if two a p p a r e n t l y i d e n t i c a l m a t e r i a l s o f
d i f f e r e n t volumes a r e s u b j e c t e d t o the same s t r e s s s t a t e , t h e l a r g e r volume
o f m a t e r i a l w i l l be more l i k e l y t o f a i l because i t c o n t a i n s more l i n k s , some
o f which a r e l i k e l y t o be weaker than those found i n t h e s m a l l e r specimen.
WLT i s o b v i o u s l y a more conservative f a i l u r e t h e o r y t h a n t h e p a r a l l e l or
bundle model which a l l o w s r e d i s t r i b u t i o n o f loads t o t h e surrounding mater i a l when one l i n k f a i l s . Because of t h e b r i t t l e n a t u r e o f m o n o l i t h i c
ceramics, i t has been observed t h a t they behave i n a weakest l i n k or s e r i e s
manner. For comparison, i t i s b e l i e v e d t h a t composite ceramics c o u l d be
d e s c r i b e d by some combination of p a r a l l e l and s e r i e s concepts, meaning f a i l u r e of one element o f m a t e r i a l w i l l n o t n e c e s s a r i l y cause c a t a s t r o p h i c
fracture.
i

The weakest l i n k concept was f i r s t proposed by M i d g l e y and P i e r c e (Ref. 5)

who noted t h a t as t h e l e n g t h o f a piece o f y a r n increased, t h e s t r e n g t h d i s t r i b u t i o n became n e g a t i v e l y skewed, i . e . , t h e r e was a g r e a t e r tendency t o
f r a c t u r e a t a lower s t r e n g t h . Weibull a p p l i e d t h e same concept t o t h e
s t r e n g t h of a s o l i d volume o f m a t e r i a l , b u t i n a d d i t i o n he assumed a unique
d i s t r i b u t i o n f u n c t i o n which i s now known as t h e Weibull d i s t r i b u t i o n .
A general form o f t h e Weibull d i s t r i b u t i o n f o r v o l u m e t r i c f l a w s i s

where t h e p r o b a b i l i t y o f f a i l u r e , Pf, due t o a u n i a x i a l s t r e s s , U, i s

dependent upon t h r e e s t a t i s t i c a l m a t e r i a l parameters--the Weibull modulus
(shape parameter) m, t h e t h r e s h o l d s t r e n g t h ( l o c a t i o n parameter) uU, and
t h e n o r m a l i z i n g s t r e s s ( s c a l e parameter) u0. The Weibull modulus i s i n d i c a t i v e o f s t r e n g t h v a r i a b i l i t y , w i t h s m a l l e r values r e p r e s e n t i n g a l a r g e r vari a t i o n . Ceramics t y p i c a l l y have a modulus between 5 and 15 whereas t h e

shape parameter o f most d u c t i l e m e t a l s i s g r e a t e r t h a n 40. G e n e r a l l y , t h e

s t r e n g t h d i s p e r s i o n i n m e t a l s i s small enough t h a t t h e mean s t r e n g t h v a l u e
i s s u f f i c i e n t f o r most d e s i g n purposes and a p r o b a b i l i s t i c a n a l y s i s i s n o t
necessary. The n o r m a l i z i n g s t r e s s i s r e l a t e d t o t h e mean s t r e n g t h . Note
t h a t for dimensionless Pf, t h e u n i t s of 00 a r e s t r e s s x (volume)l/m, n o t
s t r e s s . The t h r e s h o l d s t r e n g t h i s t h e maximum a l l o w a b l e s t r e s s for which
t h e r e i s no p o s s i b i l i t y o f f a i l u r e . By assuming t h a t t h e t h r e s h o l d s t r e n g t h
i s z e r o , t h e two parameter W e i b u l l model i s o b t a i n e d . Since t h i s form i s
adequate t o describe most s t r e n g t h d a t a and i t i s m a t h e m a t i c a l l y simple,
t h e two parameter form o f t h e W e i b u l l e q u a t i o n i s o f t e n used f o r s t r u c t u r a l
ceramics. Consequences o f t h i s assumption w i l l be discussed i n a l a t e r
sect i o n .
The W e i b u l l equation shows an i m p o r t a n t d i f f e r e n c e between d e s i g n based on
p r o b a b i l i s t i c s t r e n g t h d i s t r i b u t i o n and a d e t e r m i n i s t i c design; i n t h e
former approach t h e s t r e s s d i s t r i b u t i o n o v e r t h e e n t i r e volume o f t h e component i s necessary. The d e s i g n i s n o t n e c e s s a r i l y governed by t h e t h e most
h i g h l y s t r e s s e d l o c a t i o n or t h e c r i t i c a l p o i n t , b u t by t h e e n t i r e s t r e s s
field.
A s i m i l a r form o f t h e W e i b u l l d i s t r i b u t i o n c o u l d be w r i t t e n f o r s u r f a c e f l a w
induced f r a c t u r e , w i t h corresponding s u r f a c e m a t e r i a l parameters. For simp l i c i t y , t h i s paper w i l l deal o n l y w i t h t h e e q u a t i o n s f o r t h e volume f l a w
p o p u l a t i o n . Although n o t discussed h e r e i n , i n s i g h t i n t o t h e i n t e r a c t i o n
between m u l t i p l e f l a w p o p u l a t i o n s may be o b t a i n e d from Johnson (Ref. 6).

Multiaxial R e l i a b i l i t y Predictions
The W e i b u l l f u n c t i o n i s u s u a l l y used t o c h a r a c t e r i z e t h e s t r e n g t h d i s t r i b u t i o n i n a u n i a x i a l s t r e s s s t a t e . I t may a l s o be used f o r a m u l t i a x i a l
s t r e s s f i e l d , provided t h a t t h e n o r m a l i z i n g s t r e s s i s p r o p e r l y a d j u s t e d .
However, t h i s approach r e q u i r e s t e s t i n g i n each s t r e s s s t a t e f o r which r e l i a b i l i t y d a t a i s d e s i r e d . Due t o the c o s t i n v o l v e d i n f a b r i c a t i n g and
t e s t i n g complicated components, i t i s o b v i o u s t h a t an a l t e r n a t e method i s
necessary. The o b j e c t i v e i s then t o develop a n a l y s i s methods so t h a t t h e
r e l i a b i l i t y i n any s t r e s s s t a t e can be c a l c u l a t e d u s i n g o n l y u n i a x i a l t e s t
data. Several approaches t o t h e problem have been proposed.
The f i r s t o f these suggestions was W e i b u l l ' s a r b i t r a r y assumption t h a t t h e
u n i a x i a l t h e o r y c o u l d be extended by o b t a i n i n g an e f f e c t i v e s t r e s s t h r o u g h
a v e r a g i n g t h e t e n s i l e normal s t r e s s a t a g i v e n l o c a t i o n b e f o r e p e r f o r m i n g
t h e volume i n t e g r a t i o n . T h i s method i n v o l v e s t h e i n t e g r a t i o n , o v e r a spheri c a l s u r f a c e area w i t h u n i t r a d i u s , o f t h e s t r e s s ( r a i s e d t o t h e power m)
normal t o a tangent p l a n e of t h e u n i t sphere. Thus, t h e normal s t r e s s i n
every p o s s i b l e d i r e c t i o n a t t h e p o i n t i s i n c l u d e d . Except f o r s i m p l e loadi n g c o n d i t i o n s such as u n i a x i a l s t r e s s s t a t e s , numerical i n t e g r a t i o n i s necessary. Under a g e n e r a l l o a d i n g c o n d i t i o n , compressive normal s t r e s s e s a r e
excluded from the a v e r a g i n g process. T h i s method i g n o r e s t h e e f f e c t o f
shear s t r e s s e s , or, i n LEFM t e r m i n o l o g y , o n l y mode I f r a c t u r e i s presumed
t o c o n t r i b u t e t o t h e f a i l u r e p r o b a b i l i t y . I n s p i t e o f i t s l i m i t a t i o n s and
i t s numerical requirements, t h e normal s t r e s s a v e r a g i n g method has been
used e x t e n s i v e l y ( R e f s . 7 t o 1 4 ) .

A s i m p l e r method c a l l e d t h e p r i n c i p l e o f independent a c t i o n ( P I A ) was proposed t o a v o i d t h e i n t e g r a t i o n r e q u i r e d for t h e a v e r a g i n g process. T h i s

model assumes t h a t each t e n s i l e p r i n c i p a l s t r e s s (01, 0 2 , and 03) a c t s independently of the others t o give a t o t a l f a i l u r e p r o b a b i l i t y o f

i n t h e case where O i > 0 (i=1,2,3).

T h i s model i s t h e s t a t i s t i c a l equival e n t o f t h e maximum p r i n c i p a l s t r e s s t h e o r y . I t has o f t e n been used f o r
s t r u c t u r a l ceramic d e s i g n ( R e f s . 15 t o 22). However, i t y i e l d s unconservat i v e r e s u l t s because i t i g n o r e s b o t h t h e shear s t r e s s e s and t h e i n t e r a c t i o n
between p r i n c i p a l s t r e s s e s .
R e c e n t l y , several t h e o r i e s have been proposed which model t h e b e h a v i o r of
b r i t t l e m a t e r i a l s i n a m e c h a n i s t i c r a t h e r than phenomenological manner.
These t h e o r i e s e x p l i c i t l y assume t h a t cracks a r e p r e s e n t i n t h e m a t e r i a l
and assume l i n e a r e l a s t i c f r a c t u r e mechanics and weakest l i n k t y p e behavi o r . The model t h a t w i l l be discussed i n d e t a i l h e r e was i n i t i a l l y proposed b y B a t d o r f and Crose ( R e f . 1 ) and was l a t e r extended t o account f o r
shear s t r e s s e s by B a t d o r f and H e i n i s c h (Ref. 23).
Before d i s c u s s i n g B a t d o r f ' s assumptions, t h e concepts o f c r i t i c a l s t r e s s
and e f f e c t i v e s t r e s s , o c r and Oe r e s p e c t i v e l y , w i l l be developed. A
c r i t i c a l s t r e s s i s defined as t h e remote s t r e s s which w i l l cause f r a c t u r e
when a p p l i e d normal t o a g i v e n crack. Hence, from LEFM, t h e c r i t i c a l
s t r e s s i s dependent upon t h e c r a c k l e n g t h and shape, t h e m a t e r i a l mode I
f r a c t u r e toughness, and t h e geometrical c o n s t r a i n t s s u r r o u n d i n g t h e c r a c k .
Cracks a r e g e n e r a l l y small enough and f a r enough a p a r t t h a t t h e geometry
can be assumed t o be a s i n g l e c r a c k i n an i n f i n i t e body. The e f f e c t i v e
s t r e s s a c t i n g on a c r a c k i s dependent upon t h e s e l e c t i o n o f a mixed-mode
f r a c t u r e c r i t e r i o n . The t h e o r i e s which p r e d i c t i n i t i a t i o n o f c r a c k propagat i o n under combined normal and shear loads can be c a t e g o r i z e d as c o p l a n a r
and o u t - o f - p l a n e c r a c k e x t e n s i o n t h e o r i e s . Coplanar t h e o r i e s i n c l u d e those
t h a t a r e based on c r i t i c a l values of normal s t r e s s , maximum t e n s i l e s t r e s s ,
and t o t a l s t r a i n energy r e l e a s e r a t e . Out-of-plane c r a c k e x t e n s i o n c r i t e r i a a r e b e l i e v e d t o more a c c u r a t e l y r e f l e c t r e a l i t y and t h e y i n c l u d e t h e
maximum s t r a i n energy r e l e a s e r a t e , t h e minimum s t r a i n energy d e n s i t y , and
t h e maximum t a n g e n t i a l s t r e s s . However, these t h e o r i e s l e a d t o more comp l e x e q u a t i o n s f o r e f f e c t i v e s t r e s s and, t h e r e f o r e , a r e o f t e n r e p l a c e d b y
s i m p l e approximations (Ref. 24).
The d e r i v a t i o n o f a simple e f f e c t i v e s t r e s s e q u a t i o n w i l l be shown t o i l l u s t r a t e t h e b a s i c p r i n c i p l e s . Assume t h a t mixed-mode f r a c t u r e t a k e s p l a c e
when t h e c r a c k e x t e n s i o n f o r c e o r s t r a i n energy r e l e a s e r a t e , G, reaches a
c r i t i c a l value, Gc. The t o t a l s t r a i n energy r e l e a s e r a t e i s r e l a t e d t o t h e
and KII
for opening, s l i d i n g , and t e a r s t r e s s i n t e n s i t y f a c t o r s , KI, KI,
i n g modes r e s p e c t i v e l y by (Ref. 2 5 )

G under
sons
2a i n
shear

(3)

p l a n e s t r a i n c o n d i t i o n s , where E i s Youngs modulus and u i s P o i s r a t i o . The s t r e s s i n t e n s i t y f a c t o r s for a G r i f f i t h c r a c k o f l e n g t h

an i n f i n i t e p l a t e s u b j e c t e d t o a normal t e n s i l e s t r e s s an and a
s t r e s s I: p a r a l l e l t o t h e l e n g t h of t h e c r a c k a r e (Ref. 25)
KI = u n @,

KII

(4)

I:@

where on and I: a r e determined from t h e p r i n c i p a l s t r e s s e s b y s t r e s s

transformation equations.
The e f f e c t i v e s t r e s s i s o b t a i n e d by e q u a t i n g t h e v a l u e o f G f o r mode I
f r a c t u r e ( G I ~ ) t o i t s e q u i v a l e n t v a l u e a t f r a c t u r e under mixed i n - p l a n e
loading conditions, t h a t i s
2
1-u2 2
1 - u
u
f i a = E
E
cr

(ui n a +

I:

na)

(5)

or
and, n o t i n g t h a t t h e c r i t i c a l s t r e s s i s t h e e f f e c t i v e s t r e s s i n a mode I
t e s t , we o b t a i n

I f t h e shear i s i n s t e a d assumed t o be i n t h e d i r e c t i o n o f mode I11 cracki n g , p o s s i b l e o n l y f o r volume f l a w s , then u s i n g Eq. ( 3 ) and KIII
=
we o b t a i n

I:P

=p
n

+ -1

1
- u

for

on

>

We have assumed t h a t t h e m a t e r i a l flaws causing f r a c t u r e upon t e n s i l e loadi n g a r e adequately and c o n s i s t e n t l y modeled by G r i f f i t h cracks t h r o u g h o u t
t h e m a t e r i a l volume. The G r i f f i t h c r a c k , however, i s n o t t h e b e s t model
f o r e i t h e r s u r f a c e or volume f l a w s because i t i s a two-dimensional, throught h e - t h i c k n e s s c r a c k . I t i s for t h i s reason t h a t o n l y Eq. (6a) has.been p r e v i o u s l y used i n c o n n e c t i o n w i t h t h i s c r a c k geometry. More a p p r o p r i a t e
three-dimensional c r a c k models e x i s t (penny-shaped or e l l i p t i c a l f o r v o ume
f l a w s and G r i f f i t h n o t c h or s e m i - e l l i p t i c a l f o r s u r f a c e f l a w s ) , b u t t h e
e q u a t i o n s were d e r i v e d h e r e i n f o r a G r i f f i t h c r a c k f o r s i m p l i c i t y and h St o r i c a l considerations.
With these d e f i n i t i o n s i n mind, t h e B a t d o r f t h e o r y w i l l be o u t l i n e d n e x t .
F u r t h e r d e t a i l s a r e a v a i l a b l e i n t h e r e f e r e n c e s ( R e f s . 1, 23, 26 t o 29).
The f a i l u r e p r o b a b i l i t y o f a small u n i f o r m l y s t r e s s e d volume of m a t e r i a l ,
AV, i s t h e p r o d u c t o f two independent p r o b a b i l i t i e s , P i and P2. P i i s

t h e p r o b a b i l i t y t h a t a c r a c k e x i s t s w i t h i n t h a t volume which has a c r i t i c a l

s t r e s s between UCr and o c r t dacr. The mathematical form o f P i i s
dN( uCr)
P1 = AV

ducr

dacr

(7)

where N(ocr) i s t h e B a t d r o f c r a c k d e n s i t y f u n c t i o n which i s a m a t e r i a l

p r o p e r t y u s u a l l y determined from simple u n i a x i a l t e s t s . I t i s u s u a l l y
assumed t h a t i t can be expressed i n t h e form o f a Weibull d i s t r i b u t i o n
which under c e r t a i n c o n d i t i o n s can be w r i t t e n as a power f u n c t i o n

where

kB

i s the Batdorf crack density c o e f f i c i e n t .

F r a c t u r e depends n o t o n l y on t h e e x i s t e n c e o f t h e c r a c k w i t h a c e r t a i n c r i t i c a l s t r e n g t h , b u t a l s o on t h e c r a c k o r i e n t a t i o n w i t h r e s p e c t t o t h e a p p l i e d
s t r e s s e s , t h e magnitude o f those s t r e s s e s , t h e shape o f t h e c r a c k , and a
f r a c t u r e c r i t e r i o n . I n o t h e r words, f r a c t u r e depends on t h e e f f e c t i v e
s t r e s s and i s p o s s i b l e o n l y when the e f f e c t i v e s t r e s s i s g r e a t e r t h a n t h e
c r i t i c a l s t r e s s . Since t h e e f f e c t i v e s t r e s s depends on t h e c r a c k o r i e n t a t i o n and s i n c e t h e c r a c k s a r e assumed t o be randomly d i s t r i b u t e d , a second
p r o b a b i l i t y f u n c t i o n , P2, i s i n t r o d u c e d . S p e c i f i c a l l y , P2 i s t h e r a t i o
of t h e a n g u l a r range of c r a c k o r i e n t a t i o n s f o r which oe 2 o c r t o t h e t o t a l
range o f p o s s i b l e c r a c k o r i e n t a t i o n s . Having d e f i n e d b o t h P1 and P2, t h e
f a i l u r e p r o b a b i l i t y for t h e e n t i r e component can now be w r i t t e n as

A computer program ( S t r u c t u r a l Ceramics A n a l y s i s and R e l i a b i l i t y E v a l u a t i o n

or SCARE) i s under development a t NASA Lewis t o p r e d i c t t h e f a s t f r a c t u r e
r e l i a b i l i t y o f m o n o l i t h i c ceramics. The program i s based on t h e B a t d o r f
t h e o r y as p r e v i o u s l y described. The program a l s o i n c l u d e s t h e P I A t h e o r y
because o f i t s h i s t o r i c a l s i g n i f i c a n c e and f o r t h e sake o f comparison.
D e t a i l s of t h e program a r e contained i n t h e r e f e r e n c e s (Refs. 26 t o 2 8 ) .
NDE'S ROLE I N RELIABILITY TESTING

Background
S t r i n g e n t t e s t i n g i s needed t o v e r i f y t h e Batdorf t h e o r y (Ref. 30). An
e x p e r i m e n t a l v e r i f i c a t i o n program which i n v o l v e s m a t e r i a l s c h a r a c t e r i z a t i o n ,
a n a l y s i s , f r a c t u r e t e s t i n g , and NDE has been i n i t i a t e d a t NASA Lewis. The
program w i l l be b r i e f l y d e s c r i b e d w i t h an emphasis on t h e importance o f NDE
t o assure v a l i d r e s u l t s . I n t h i s a p p l i c a t i o n , NDE i s u t i l i z e d t o remove
p h y s i c a l u n c e r t a i n t y about t h e m a t e r i a l b e i n g t e s t e d .
An i m p o r t a n t f a c t o r i n e v a l u a t i n g the B a t d o r f t h e o r y i s t h e u n i f o r m i t y o f
t h e t e s t m a t e r i a l . The d e n s i t y of ceramic d i s k s o r modulus o f r u p t u r e

(MOR) b a r s i s u s u a l l y lower a t t h e c o r e of t h e specimen t h a n a t t h e p e r i p h e r y ( R e f . 31). Nonuniform d e n s i t y causes a nonuniform f r a c t u r e toughness,

thermal expansion c o e f f i c i e n t and c o n d u c t i v i t y , e l a s t i c modulus (Refs. 32
and 331, and Poisson's r a t i o (Ref. 33). T h i s w i l l a f f e c t t h e accuracy o f
t h e e l a s t o s t a t i c a n a l y s i s upon which r e l i a b i l i t y c a l c u l a t i o n s a r e based.
Furthermore, the c r a c k d e n s i t y f u n c t i o n N(oc,) w i l l v a r y . I n a r i g o r o u s
t e s t i n g program these v a r i a t i o n s can be m i n i m i z e d by c h a r a c t e r i z a t i o n o f
t e s t specimens by NDE as d e s c r i b e d below.

Approach
One hundred commercially a v a i l a b l e s i n t e r e d a l p h a s i l i c o n c a r b i d e d i s k s
have been examined w i t h c o n v e n t i o n a l and m i c r o f o c u s r a d i o g r a p h y . The t h i c k ness o f these d i s k s v a r i e d between 1.27 mm (0.050 i n . ) and 3.81 mm (0.150
From these d i s k s ,
i n . ) and t h e i r o u t s i d e diameter was 50.80 mm (2.00 i n . ) .
t h e 45 w i t h t h e most u n i f o r m r a d i o g r a p h s ( i n d i c a t i v e o f near u n i f o r m dens i t y and m i c r o s t r u c t u r e ) were s e l e c t e d f o r f u r t h e r s u r f a c e p r e p a r a t i o n and
subsequent t e s t i n g . E l a b o r a t e machining procedures were performed on these
d i s k s t o minimize g r i n d i n g damage and t o o b t a i n an i s o t r o p i c s u r f a c e f i n i s h . I n a d d i t i o n t h e y were c a r e f u l l y lapped and p o l i s h e d t o an e x t r e m e l y
f i n e mirror surface f in i sh.
A f t e r s u r f a c e p r e p a r a t i o n i s complete, t h e d i s k s w i l l be s u b j e c t e d t o f u r t h e r s c r u t i n y . Proposed methods i n c l u d e a c o u s t i c microscopy, u l t r a s o n i c
v e l o c i t y and a t t e n u a t i o n mappings, and computerized tomography. A c o u s t i c
microscopy can p r o v i d e i n f o r m a t i o n about gross m a n u f a c t u r i n g f l a w s . Furthermore, u l t r a s o n i c v e l o c i t y imaging i s more s e n s i t i v e t o m i c r o s t r u c t u r a l
i r r e g u l a r i t i e s such as d e n s i t y v a r i a t i o n s t h a n r a d i o g r a p h y ( R e f . 3 4 ) .
Because o f t h e l o n g t i m e r e q u i r e d f o r imaging, i t has a l s o been decided
t h a t computerized tomography be s e l e c t i v e l y performed t o p r o v i d e more
t i m e l y r e s u l t s . I n any event, i t i s e s s e n t i a l t h a t t h e MOR b a r c h a r a c t e r i z a t i o n of t h e material f l a w population a c c u r a t e l y represents the m a t e r i a l
i m p e r f e c t i o n s , and t h a t f a i l u r e i n t h e d i s k s as w e l l as t h e MOR specimens
be caused by s t a t i s t i c a l l y i d e n t i c a l phenomena.

A f t e r t h e c a r e f u l s u r f a c e p r e p a r a t i o n and e x t e n s i v e NDE c h a r a c t e r i z a t i o n ,
s e v e r a l d i s k s w i l l be c u t i n t o f o u r p o i n t loaded MOR b a r s f o r u n i a x i a l f r a c t u r e t e s t s . S e l e c t i o n o f t h e d i s k s for MOR b a r t e s t i n g and t h e p a t t e r n f o r
c u t t i n g t h e bars w i l l depend on t h e observed d e n s i t y v a r i a t i o n s and t h e des i r e t o check i s o t r o p i c surface b e h a v i o r . From t h e MOR b a r f r a c t u r e
s t r e n g t h s t h e Weibull parameters and t h e B a t d o r f c r a c k d e n s i t y c o e f f i c i e n t
can be c a l c u l a t e d . I t should be noted t h a t when MOR b a r t e s t s a r e employed
t o c a l c u l a t e these parameters f o r d e s i g n purposes, these t e s t s should be
conducted w i t h g r e a t c a r e t o a v o i d p o t e n t i a l e x p e r i m e n t a l e r r o r s as d i s cussed by B a r a t t a (Ref. 3 0 ) . The t e s t i n g f i x t u r e s f o r t h i s program were
designed based on t h e proposed m i l i t a r y standard (Ref. 35). The r e m a i n i n g
d i s k s w i l l be f r a c t u r e d under p r e s s u r e loads which produce a b i a x i a l s t r e s s
s t a t e . Then the f a i l u r e p r o b a b i l i t y under t h e b i a x i a l s t r e s s s t a t e can be
c a l c u l a t e d and compared t o t h e e x p e r i m e n t a l o b s e r v a t i o n s . Fractography i s
necessary for a l l t h e t e s t s t o separate t h e c r i t i c a l f l a w s i n t o volume and
s u r f a c e f l a w p o p u l a t i o n s . S i m i l a r room temperature t e s t s w i 11 be performed
l a t e r on s i l i c o n n i t r i d e specimens.

NDE'S ROLE I N DETERMINING THE STATISTICAL PARAMETERS

Two-Parameter D i s t r i b u t i o n
A r e s e a r c h area which has n o t y e t been discussed i n t h e l i t e r a t u r e i s t h e
p o s s i b l e c o r r e l a t i o n o f t h e Weibull parameters and t h e B a t d o r f c r a c k dens i t y c o e f f i c i e n t w i t h NDE measurements. Presumably, t h i s c o u l d be accomp l i s h e d by c h a r a c t e r i z i n g o n l y one t e s t specimen, r a t h e r than t h e t h i r t y or
more r e q u i r e d f o r t y p i c a l d e s t r u c t i v e t e s t i n g . This i s t r u e because NDE
can look a t t h e v a r i a t i o n w i t h i n one r e p r e s e n t a t i v e specimen by t a k i n g measurements a t v a r i o u s l o c a t i o n s . I n c o n t r a s t , mechanical t e s t i n g i s l i m i t e d
t o f i n d i n g t h e s i n g l e worst f l a w under a p p r o p r i a t e t e s t c o n d i t i o n s . However, t h e c r a c k d e n s i t y f u n c t i o n s f o r b o t h s u r f a c e and volume f l a w s must be
determined, t h a t i s , an NDE method which i s s e n s i t i v e t o i m p e r f e c t i o n s o n l y
w i t h i n the volume must be found as we1 1 as one which measures s u r f a c e f l a w
d e n s i t y . I f t h i s c o u l d be accomplished, the c o s t o f specimens and o f t h e i r
s u r f a c e p r e p a r a t i o n would be g r e a t l y reduced. However, i t should be noted
t h a t t h e c r a c k d e n s i t y f u n c t i o n i s n o t s i m p l y t h e number o f c r a c k s p e r u n i t
volume ( o r s u r f a c e a r e a ) , b u t i t i n v o l v e s t h e number o f c r a c k s w i t h a c r i t i c a l s t r e n g t h l e s s than or equal t o g i v e n c r i t i c a l s t r e s s .

S i g n i f i c a n c e o f t h e T h i r d Parameter
The two parameter W e i b u l l d i s t r i b u t i o n i s v e r y p o p u l a r f o r c h a r a c t e r i z i n g
t h e s t r e n g t h v a r i a t i o n o f b r i t t l e m a t e r i a l s because i t y i e l d s a s t r a i g h t
l i n e on a I n I n - I n p l o t of inverse s u r v i v a l p r o b a b i l i t y versus s t r e n g t h .
However, t h i s d i s t r i b u t i o n i m p l i e s t h a t t h e r e i s always a nonzero f a i l u r e
p r o b a b i l i t y no m a t t e r how small the a p p l i e d s t r e s s .
When v e r y h i g h r e l i a b i l i t y i s d e s i r e d (Pf << 0.01), t h i s c o n s e r v a t i v e assumption may l e a d t o
i n e f f i c i e n t and u n a f f o r d a b l e designs.
Shih ( R e f . 16) has shown t h a t i f data from 20 t o 30 t e s t specimens can be
r e p r e s e n t e d by a two parameter Weibull d i s t r i b u t i o n t h e n i t can a l s o be reasonably r e p r e s e n t e d by s e v e r a l three parameter W e i b u l l d i s t r i b u t i o n s . I f
t h e d e s i r e d r e l i a b i l i t y i s w i t h i n t h e d a t a range (0.05 < Pf < 0.951, any
one o f these curves w i l l g i v e the same r e s u l t . However, a t low f a i l u r e
p r o b a b i l i t i e s , t h e a l l o w a b l e s t r e s s f o r each d i s t r i b u t i o n i s q u i t e d i f f e r e n t . The s e l e c t i o n o f one f u n c t i o n r a t h e r t h a n another i s an a r b i t r a r y
e x t r a p o l a t i o n o f the a v a i l a b l e data. The customary c h o i c e o f uu = 0 w i l l
g e n e r a l l y l e a d t o c o n s e r v a t i v e designs a t low f a i l u r e p r o b a b i l i t i e s .
S h i h ' s a n a l y s i s i s concerned only w i t h f a i l u r e p r o b a b i l i t i e s f o r a s i n g l e
s t r e s s s t a t e , u s u a l l y t h e u n i a x i a l case. When u s i n g t h e t h i r d parameter,
t h e t h e o r i e s f o r m u l t i a x i a l r e l i a b i l i t y p r e d i c t i o n s become more c o m p l i cated, even f o r a simple u n i a x i a l s t r e s s s t a t e . Vardar and F i n n i e ( R e f , 12)
have shown t h a t i f u n i a x i a l d a t a i s used t o determine a three-parameter Weib u l l d i s t r i b u t i o n and then a u n i a x i a l s t r e s s s t a t e i s analyzed by u s i n g t h e
W e i b u l l normal s t r e s s a v e r a g i n g technique w i t h 02 = 03 = 0, t h e r e s u l t does
n o t agree w i t h o r i g i n a l data. This d i s c r e p a n c y o c c u r s because t h e o r i g i n a l
W e i b u l l f u n c t i o n does n o t assume any d i r e c t i o n a l dependency whereas t h e normal s t r e s s a v e r a g i n g method presumes a d i r e c t i o n a l v a r i a t i o n i n the f l a w
popul a t i o n .

Evans ( R e f . 36) has suggested t h a t t h e t h r e e parameter f u n c t i o n should be

v a l i d o n l y i n an e q u i t r i a x i a l t e n s i l e s t r e s s s t a t e ( f o r volume f l a w s ) .
T h i s i s a reasonable assumption s i n c e o n l y e q u i t r i a x i a l s t r e s s w i l l cause a
f l a w t o be s u b j e c t t o t h e same s t r e s s s t a t e (no shear s t r e s s ) r e g a r d l e s s o f
i t s o r i e n t a t i o n t o t h e p r i n c i p a l s t r e s s axes. Matsuo ( R e f . 37) extended
t h i s assumption u s i n g B a t d o r f ' s t h e o r y . He showed t h a t t h e number o f
c r a c k s p e r u n i t volume ( c r a c k d e n s i t y f u n c t i o n ) s h o u l d be a f u n c t i o n o f
( o c r - uU) i f the t h r e e parameter d i s t r i b u t i o n i s v a l i d f o r e q u i t r i a x i a l
t e n s i o n . The a n a l y s i s a l s o shows t h a t t h e s t r e n g t h d i s t r i b u t i o n under u n i a x i a l or e q u i b i a x i a l loads i s no l o n g e r d e s c r i b e d by t h e three-parameter
W e i b u l l d i s t r i b u t i o n . I n a d d i t i o n , Matsuo p l o t t e d t h e r a t i o o f u n i a x i a l t o
e q u i b i a x i a l f a i l u r e p r o b a b i l i t i e s ( f o r small p r o b a b i l i t i e s ) as a f u n c t i o n
o f uu and m. As t h e t h r e s h o l d s t r e s s i n c r e a s e s , t h e r e i s a l a r g e r d i f f e r e n c e between u n i a x i a l and e q u i b i a x i a l f r a c t u r e probabi 1 i t i e s .
Methods t o Determine t h e T h i r d Parameter
There a r e several methods f o r d e t e r m i n i n g t h e t h r e s h o l d s t r e s s . Among
these, NDE holds s p e c i a l promise. However, v e r i f i c a t i o n o f t h e e f f e c t o f
t h e t h i r d parameter i n t h e low f a i l u r e p r o b a b i l i t y r e g i o n has n o t y e t been
undertaken because of t h e hundreds of necessary t e s t s .
Several a n a l y t i c a l methods for d e t e r m i n i n g uU have been discussed by Gregory and S p r u i l l (Ref. 38). A simple method i s t o modify t h e I n - l n versus
I n p l o t o f i n v e r s e s u r v i v a l p r o b a b i l i t y versus s t r e n g t h so t h a t t h e t h r e s h o l d s t r e n g t h i s i n c l u d e d on t h e a b s c i s s a (U - uU), where uU i s chosen
i t e r a t i v e l y . Then t h e v a l u e o f oU which g i v e s t h e b e s t s t r a i g h t l i n e f i t
t o t h e d a t a i s picked. However, f o r small sample s i z e s , c o n s i d e r a b l e judgment i s r e q u i r e d t o p i c k t h e b e s t v a l u e o f uU. A second method i s t o use
a l e a s t mean squares a p p r o x i m a t i o n . I n t h i s method, values f o r uU a r e
i t e r a t i v e l y s e l e c t e d u n t i l t h e l e a s t mean squares d i f f e r e n c e between t h e
d i s t r i b u t i o n and t h e s t a t i s t i c a l sample i s s u f f i c i e n t l y reduced. McClint o c k ' s method o f moments has a l s o been used t o c a l c u l a t e uU. T h i s
i n v o l v e s c a l c u l a t i n g t h e skewness of t h e d i s t r i b u t i o n . I t has been shown
t h a t f o r accurate r e p r e s e n t a t i o n b o t h M c C l i n t o c k ' s method and t h e l e a s t
mean squares method r e q u i r e a t l e a s t 100 samples (Ref. 38).
I t has o f t e n been suggested t h a t a component be p r o o f - t e s t e d t o determine
i t s t h r e s h o l d s t r e n g t h l e v e l so t h a t performance c o u l d be guaranteed. The
p r o o f t e s t r e f l e c t s t h e v a r y i n g s t r e s s s t a t e a c t u a l l y p r e s e n t i n t h e compon e n t , r a t h e r than a c o n s t a n t e q u i t r i a x i a l s t a t e , where t h e l o c a t i o n and
o r i e n t a t i o n o f t h e c r a c k would n o t m a t t e r . Thus, t h e major d i f f i c u l t y w i t h
t h i s method i s t h a t t h e o b t a i n e d t h r e s h o l d s t r e n g t h i s i n d i c a t i v e o f a lowe r s t r e n g t h l i m i t o n l y i n t h e s t r e s s s t a t e encountered i n t h e p r o o f t e s t ,
j u s t as t h e Weibull n o r m a l i z i n g s t r e s s i s v a l i d o n l y for t h e s t r e s s s t a t e
t e s t e d . Although t h e d e t e r m i n a t i o n of t h i s t h r e s h o l d i s u l t i m a t e l y d e s i r e d ,
i t i s t h e m a t e r i a l t h r e s h o l d s t r e n g t h r a t h e r t h a n t h e component t h r e s h o l d
s t r e s s which i s necessary for a n a l y s i s . I n a d d i t i o n , i t i s d i f f i c u l t t o
e c o n o m i c a l l y reproduce i n a p r o o f t e s t t h e s t r e s s s t a t e encountered i n
s e r v i c e , e s p e c i a l l y when thermal s t r e s s e s a r e i n v o l v e d . I t c o u l d a l s o be
expensive, e s p e c i a l l y i f many component f a i l u r e s occur i n t h e t e s t s . The
p o t e n t i a l o f s u b c r i t i c a l c r a c k growth must a l s o be remembered and c a r e
s h o u l d be taken t o a v o i d t h i s f o r m of a d d i t i o n a l t i m e dependent m a t e r i a l
damage.
10

An a l t e r n a t e method, w i t h o u t the drawbacks n o t e d above, i s t h e use of NDE.

NDE can screen o u t Components w i t h l a r g e flaws.
Assuming t h a t NDE methods
can v i r t u a l l y always d e t e c t defects l a r g e r t h a n a g i v e n s i t e then, b y taki n g t h e weakest p o s s i b l e f l a w type and a l o c a l l y low f r a c t u r e toughness, a
t h r e s h o l d s t r e n g t h can be c a l c u l a t e d for a component u s i n g LEFM p r i n c i p l e s . For t h i s a p p l i c a t i o n , NDE m u s t have a very h i g h p r o b a b i l i t y of detect i o n and s i z e d e t e r m i n a t i o n f o r r e l a t i v e l y l a r g e f l a w s on the surface of
and w i t h i n g e o m e t r i c a l l y complex components, r a t h e r than h a v i n g a lower
When making m a t e r i a l c h a r a c t e r i z a p r o b a b i 1 it y o f f i n d i n g a s m a l l e r flaw.
t i o n t e s t w i t h l e s s complicated geometry MOR b a r s , s m a l l e r f l a w s i z e s may
be r e l i a b l y measured and a c o r r e s p o n d i n g l y h i g h e r t h r e s h o l d s t r e n g t h would
be computed. A t l e a s t two methods of c a l c u l a t i n g t h e m a t e r i a l parameters
a r e p o s s i b l e . The f i r s t approach i s t o use t h e h i g h e r t h r e s h o l d s t r e n g t h
a v a i l a b l e from the MOR bar and i n t e r p r e t t h e o t h e r m a t e r i a l parameters, a0
and m, from t h e corresponding specimen f r a c t u r e data. I t should be noted,
however, t h a t t h e presence of uU a f f e c t s t h e subsequent c a l c u l a t i o n o f
t h e o t h e r two parameters. The second method would assume t h a t t h e t h r e s h o l d s t r e n g t h i s l i m i t e d by what can be found i n t h e a c t u a l component and
t h a t t h e m a t e r i a l parameters must be c a l c u l a t e d as b e f o r e b u t w i t h a d i f f e r e n t v a l u e of uu. These NDE a p p l i c a t i o n s w i l l a s s u r e d l y m i n i m i z e some o f
t h e i n t r i n s i c s t a t i s t i c a l u n c e r t a i n t i e s a s s o c i a t e d w i t h r e l i a b i l i t y studies, but w i l l require additional investigations.
CONCLUSIONS

A b a s i c r e v i e w of s t a t i s t i c a l r e l i a b i l i t y a n a l y s i s has been presented. The

importance of NDE i n a s s u r i n g v a l i d e x p e r i m e n t a l r e s u l t s by several methods
o f c h a r a c t e r i z i n g t e s t specimens has been addressed. Furthermore, t h e r o l e
o f t h e three-parameter W e i b u l l d i s t r i b u t i o n i n t h e p r e d i c t i o n o f low f a i l u r e p r o b a b i l i t i e s has been discussed a l o n g w i t h t h e p o t e n t i a l use o f NDE
methods t o o b t a i n b o t h the t h r e s h o l d s t r e n g t h s and t h e c r a c k d e n s i t y f u n c t i o n parameters. F u r t h e r s t u d i e s a r e needed, e s p e c i a l l y i n the a r e a o f
material properties determination.
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14

National AeronaUIICS and

1. Report No.

Report Documentation Page

2. Government Accession No.

3. Recipient's Catalog No.

NASA TM-100174
5. ReDOrt Date

6. Performing Organization Code

8. Performing Organization Report No.

7. Author@)

E-3143

Jane M. Manderscheid and John P. Gyekenyesi

10. Work Unit No.

5 3 3 -0 5 -01
9. Performing Organization Name and Address

N a t i o n a l Aeronautics and Space A d m i n i s t r a t i o n

Lewis Research Center
Cleveland, Ohio 44135-3191

11. Contract or Grant No.

13. Type of Report and Period Covered

12. Sponsoring Agency Name and Address

T e c h n i c a l Memorandum

N a t i o n a l Aeronautics and Space A d m i n i s t r a t i o n

20546-0001
Washington, D.C.

14. Sponsoring Agency Code

15. SuDDlementary Notes

Prepared f o r T e s t i n g High Performance Ceramics cosponsored by t h e American

Ceramic S o c i e t y and t h e American S o c i e t y f o r N o n d e s t r u c t i v e T e s t i n g , Boston,
Massachusetts, August 25-27, 1987.

16. Abstract

Basic design concepts f o r high-performance, m o n o l i t h i c ceramic s t r u c t u r a l components a r e addressed. The design o f b r i t t l e ceramics d i f f e r s f r o m t h a t o f
d u c t i l e m e t a l s because o f t h e i n a b i l i t y o f ceramic m a t e r i a l s t o r e d i s t r i b u t e
h i g h l o c a l s t r e s s e s caused by i n h e r e n t f l a w s . Random f l a w s i z e and o r i e n t a t i o n
r e q u i r e s t h a t a p r o b a b i l i s t i c a n a l y s i s be performed i n o r d e r t o determine component r e l i a b i l i t y . The c u r r e n t t r e n d i n p r o b a b i l i s t i c a n a l y s i s i s t o combine
l i n e a r e l a s t i c f r a c t u r e mechanics concepts w i t h t h e two parameter W e i b u l l d i s t r i b u t i o n f u n c t i o n t o p r e d i c t component r e l i a b i l i t y under m u l t i a x i a l s t r e s s
s t a t e s . N o n d e s t r u c t i v e e v a l u a t i o n supports t h i s a n a l y t i c a l e f f o r t by s u p p l y i n g
d a t a d u r i n g v e r i f i c a t i o n t e s t i n g . I t can a l s o h e l p t o determine s t a t i s t i c a l
parameters which d e s c r i b e t h e m a t e r i a l s t r e n g t h v a r i a t i o n , i n p a r t i c u l a r t h e
m a t e r i a l t h r e s h o l d s t r e n g t h ( t h e t h i r d W e i b u l l parameter), which i n t h e p a s t
has o f t e n been taken as zero f o r s i m p l i c i t y .

17. Key Words (Suggested by Author($)

18. Distribution Statement

Unclassified - Unlimited
S u b j e c t Category 39

Ceramics; F r a c t u r e mechanics; Nondestructive evaluation; S t a t i s t i c s ;

Wei b u l l ; B a t d o r f ; Re1 i a b i 1it y
19. Security Classif (of this report)

Unclassified

20 Security Classif (of this page)

Unclassified

21 No of pages

15

22 Price'

A02