Advanced proof testing for structural ceramics

Abstract Proof testing is used to remove weak ceramic components from a manufactured batch in turn truncating the lower end of the strength‐failure probability distribution. With proof testing, components are subjected to stresses comparable to those observed during service load histories resulting in the remaining ones having assured minimum reliabilities. The degree to which the reliability of the remaining parts is assured depends on the proof test protocol, which includes multiple variables such as stress level, realistic sampling of flaws, complex geometries, multiaxial stresses, transient loading histories, time‐dependent damage due to slow crack growth and/or fatigue, and change in material behavior due to temperature and/or environmental conditions. This paper advances the early work done on proof test theory, which was limited to simple stress states, to include general stress and material states. The theory introduced in this paper takes into account practical conditions often encountered in industrial applications. This advanced proof test theory was coded into the CARES/Life code (Ceramics Analysis and Reliability Evaluation of Structures/Life). Examples are provided to demonstrate the theory.